How can an existing shopfloor be realistically digitized to virtually test layouts and workplace concepts?
This was the challenge faced by Schmitz Cargobull when existing assembly areas needed to be efficiently redesigned – with high variant diversity and increasing pressure for adaptation.
Using Halocline Professional and the Point Cloud Add-On, they successfully used scans of the shopfloors to virtually recreate the current state, create layout variants and review changes realistically already in the early planning phases.
Schmitz Cargobull operates large factories for its semi-trailer assembly lines. New assembly lines and workplace concepts were to be integrated into these shopfloors. The existing area was complex, with machines, material and work platforms. Conventional methods, such as 2D plans and static drawings, were no longer sufficient to gain an accurate picture or to plan variants. It was clear: the current state had to be transferred as precisely as possible into the planning tool to ensure that later layout decisions could be made on a reliable basis.
Procedure
Step 1: Create a Point Cloud
Before an accurate virtual reconstruction can take place, the current state was documented using a point cloud. This capture serves as the foundation for all subsequent planning steps in Halocline.
Schmitz Cargobull used an iPhone with a LiDAR scanner to scan the shopfloor in multiple sections. Each area was prepared beforehand (free of people, well-lit).
These steps resulted in a point cloud that fully represents the real hall area and serves as a digital planning basis.
→ More in the workflow: Creating Point Clouds with iPhone & iPad
Step 2: Import and Place the Point Cloud in Halocline Layout
In the next step, the point cloud was imported into Halocline. This allowed the team to visualize the real environment directly in the software and make all planning decisions within the spatial context.
- The prepared point cloud was imported in the Layout tab using the Import button as a .pts file. Care was taken to ensure that the point cloud was not too large (divided into several sections if necessary) to avoid performance issues.
- After import, the team began desktop layout planning. They selected 3D Templates from the menu and placed the point clouds.
- Position and alignment were precisely adjusted using the Adjust tool and Gizmos. The Angle Grid (e.g., 1°) was also used to ensure exact orientations.
- The measuring tool was used to verify dimensions.
As a result, the real hall area was visible 1:1 in Halocline, creating a precise and transparent foundation for subsequent layout planning.
→ More in the workflow: Point Clouds as 3D Templates
Step 3: Rebuild and Create Layout Variants
The imported point cloud then served as a visual and geometric reference for digitally reconstructing the current state. This allowed equipment and tools to be aligned precisely to the reference.
- Based on the point cloud, existing objects such as machines or shelves were recreated using objects from the library. These standard objects were inserted and aligned with the geometries of the point cloud using the Adjust tool.
- For custom or irregular shapes, the Box Creation Tool was used to replicate the objects. Supplementary photos or notes supported further detailed planning.
- Various layout variants were then developed – new arrangements of workstations, platforms and material areas that could be directly compared with the point cloud baseline.
This allowed Schmitz Cargobull to assess during the conceptual phase how new configurations would perform within the existing hall space.
→ More in the workflow: Layout Planning – Designing Efficient Workflows
Step 4: Review in VR, Detailing and Comparison
Finally, the virtual shopfloor was reviewed in VR. This allowed all stakeholders to experience the layout realistically and immediately identify where adjustments were needed.
- VR was used to walk through the different layout variants and check clearances, accessibility and sightlines.
- Stakeholders from industrial engineering, production and management were actively involved to provide direct feedback in VR. This ensured that practical experience informed the planning process.
- Variants were then refined: objects were moved, paths widened and equipment repositioned – always in reference to the real point cloud.
This achieved a close integration of virtual and practical planning – without media disruptions and with high precision.
→ More in the workflow: Layout Planning – Designing Efficient Workflows
Results & Added Value for Schmitz Cargobull
By using the Point Cloud Add-On together with Halocline Professional, Schmitz Cargobull was able to:
- Realistically reproduce the current state, based on actual scans instead of estimates
- Compare layout variants without prototypes
- Gain planning confidence, since changes are visible within context
- Save time, as evaluations and variants can be tested virtually early on
- Actively involve employees and immediately implement their feedback
Conclusion
The Schmitz Cargobull use case demonstrates how Halocline Professional with the Point Cloud Add-On enables the transition to digital, realistic factory planning and workplace design.
Scans become the real foundation: layout decisions are made in the context of the actual environment, variants are validated early and planning becomes faster, safer and more transparent – a decisive step toward digital factory planning.