Intelligent Engineering
Our Intelligent Engineering solutions across products, plant and networks, combine our engineering expertise with advanced technologies to enable digital engineering & operations, develop autonomous products & platforms, and build sustainable energy and infrastructure
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Introduction
In an era where digital transformation is reshaping industries, the railway sector stands at a critical juncture. For decades, rail infrastructure planning and maintenance have been constrained by traditional 2D drawings, limiting the design efficiency, visualization accuracy, and asset management. Cyient is addressing this challenge with a groundbreaking solution. By leveraging AI, computer vision, and Gen AI we’ve developed an innovative system that automatically converts 2D railway track drawings into detailed 3D Building Information Modeling (BIM) models. This leap from static schematics to dynamic, data-rich 3D models revolutionizes planning, construction, and maintenance - delivering greater efficiency, reduced costs, and smarter decision-making throughout the rail infrastructure lifecycle.
High-Level Solution
This solution automates the conversion of large-scale 2D railway track diagrams into detailed 3D BIMs. By harnessing advanced technologies like computer vision and generative AI, it extracts and organizes critical information from 2D drawings, transforming them into accurate 3D representations essential for modern rail infrastructure management. This automated process boosts efficiency, minimizes human error, and enhances asset management, design coordination, and lifecycle planning, making it a vital tool for rail infrastructure modernization.
Solution Details
Key Steps in the Solution:
High level Diagram
Technology Comparison
AI-driven automation and BIM modeling offer a significant advantage over traditional manual methods in terms of speed, accuracy, and scalability. Manual CAD-based drafting, for example, lacks the ability to automatically extract data, enable real-time collaboration, and integrate comprehensive asset information within the model. In contrast, this automated solution harnesses AI to eliminate manual errors, detect design conflicts early, and improve asset management through a unified, data- driven platform —ultimately enhancing project efficiency and decision-making.
Benefits
In manual operations, this process typically takes approximately 2 hours per 20Km of track, according to experimental data. However, an automation experiment showcased the remarkable potential of computer vision and generative AI to drastically reduce both time and costs. the automated solution delivered a 40% cost reduction per 20Km of track and while cutting the time spent by more than 60%. This highlights the transformative efficiency that AI- driven automation brings to railway infrastructure management.
Enhanced Visualization
BIM offers precise 3D visualizations, minimizing design errors.
Improved Collaboration
It facilitates seamless coordination among stakeholders.
Lifecycle Management
BIM supports asset management throughout the infrastructure lifecycle.
Regulatory Compliance
Ensures that all designs adhere to industry regulations and standards.
Sustainability
Assists in planning environmentally sustainable and resilient infrastructure.
Stakeholder Communication
Enhances communication through data rich, visually engaging models.
Future Adaptability
BIM models can be easily updated to accommodate future modifications.
Conclusion
The transition from 2D drawings to 3D Building Information Modeling (BIM) marks a crucial advancement in addressing critical challenges in railway infrastructure management. Cyient’s innovative solution, powered by AI, computer vision, and generative AI, creates a seamless, automated process that vastly enhances accuracy, efficiency, and collaboration. Unlike traditional methods, which face issues such as data loss, complex geometry, and time- intensive manual interventions, this AI-driven approach significantly minimizes those challenges. Compared to outdated CAD- based drafting, which lacks the precision and adaptability of modern BIM systems, AI- powered automation streamlines the workflows, allowing rail networks to be managed and visualized more effectively.
Supporting Technologies & Industry Impact:
Industry experts emphasize that BIM adoption can reduce infrastructure project costs, thanks to improved planning, minimized rework, and early detection of design clashes. Cyient’s solution goes even further, offering a 30-40% reduction in costs and saving over 60% time, showcasing the tangible benefits of integrating AI into BIM workflows.
Addressing the Competition:
Traditional tools and manual 2D-to-3D conversion methods are no longer scalable in today’s fast-moving, regulation-heavy environment. Competing technologies require more time, effort, and prone to human errors during asset extraction and placement. In contrast, AI-driven automation not only enhances accuracy but also offers flexibility to adapt to future needs. Cyient’s automated system, equipped with human-in-the-loop verification, ensures high-confidence, data- rich BIM models are delivered with greater speed and reliability than traditional methods.
Solution Designs from Solumina
Solumina MES provides various solution designs specifically tailored for the diverse requirements of complex manufacturing sectors such as aerospace, defence, electronics, and medical devices. Here are some of the key solution designs:
Evolution of Solumina MES: A Look at Version Histories
Recent Developments (2020s)
- Continuous enhancements in user experience and analytics.
- Introduction of AI-based predictive quality solutions.
- Emphasizes digital thread and digital twin concepts for improved lifecycle integration across design, manufacturing, and maintenance processes.
These major versions reflect the system's growth from basic shop-floor control to a modern, cloud- enabled MES designed for Industry 4.0 needs.
Main Features
3D Models:
Users can link parts from 3D designs to their tasks, making planning easier.
3D Work Instructions:
Workers get clear visual guides in 3D to help them do their jobs more accurately and efficiently.
Interactive Viewing:
The model lets users zoom in and rotate views to see details, providing useful information as they work.
Main Features available in the latest Solumina i-110 series
The Solumina i110 release introduces MBE Advanced, which includes the latest updates to Solumina’s leading model-based MES capabilities, crucial for a model-based enterprise (MBE). This release also brings various improvements aimed at enhancing quality, efficiency, and stability in process planning, shop floor operations, supplier management, backups, and upgrades.
Key Improvements in Solumina i110 Feature:
Model-Based MES: MBE Advanced offers the most sophisticated model-based MES features as follows:
Process planners can now use the Solumina WebUI to link components from the 3D model to specific operations or steps in a Process Plan. This feature offers a user-friendly visual interface for planners, ensuring that planners and technicians share a consistent view of the information.
When a component is selected on the 3D model, it is simultaneously highlighted in the Parts List and the "Need to Collect / Parts Collected" Panel, helping ensure accurate execution of each step.
Technicians receive guidance for each operation through clear visual cues that enhance efficiency and minimize errors.
3D components are allocated to steps and operations during the process authoring phase. Once a component is selected in the Part Data Collection Grid, it is highlighted on the 3D model.
Advantages of Cloud Hosted Solumina MES
About the Authors
Hitesh Palamada is a Practice Lead - Data Science & Data Engineering at Cyient, where he supports clients across industries such as aerospace, medical devices, mining, healthcare, telecom, and utilities in their digital transformation journey. With over 11 years of experience, Hitesh leverages his expertise in data engineering, AI, machine learning, and statistical techniques to drive innovative solutions for customers. His passion for harnessing data to unlock business value has been instrumental in helping organizations streamline operations and enhance decision-making. Hitesh holds a strong background in applying cutting-edge technologies to complex industry challenges and is based in India.
Shyla Kumar Thadikamala serves as the Head of Data Engineering, Analytics, and GenAI at Cyient, with over 24 years of extensive experience leading large-scale IT transformation projects across diverse industries, including Engineering, Industrial, Manufacturing, Banking, and Smart Cities. As a senior executive, Shyla excels in steering strategic initiatives, managing global teams, and overseeing multi-million-dollar transformation efforts. With deep expertise in artificial intelligence, machine learning, and cloud technologies, Shyla is committed to driving operational efficiency and integrating advanced technology solutions to deliver impactful business outcomes.
Business Benefits
Implementing Solumina MES (Manufacturing Execution System) brings numerous business benefits to manufacturers, especially in industries such as aerospace, defense, electronics, and medical devices.
Enhanced Operational Efficiency
- Solumina MES streamlines manufacturing processes, reducing waste and improving cycle times, leading to a 15-25% increase in productivity.
- By eliminating inefficiencies, the system minimizes downtime by 10- 15% and ensures optimal use of resources.
- Integrating quality management features helps manufacturers maintain high standards and comply with industry regulations, which can result in a 30-50% reduction in defects and rework, further reducing manufacturing costs by 10-20%.
Real-Time Decision-Making
- Solumina MES provides real-time insights into production processes, allowing faster decision-making and more effective problem-solving.
- This transparency helps identify bottlenecks, which contributes to a 20-30% improvement in lead time and on-time delivery, and significantly reduces inventory carrying costs by 20-30%.
Scalability and Flexibility
- Solumina’s adaptable architecture allows companies to scale their systems as they grow, incorporating new products or processes with minimal disruptions.
- The MES enhances the compliance process by up to 20-30% faster, ensuring timely adherence to evolving regulatory standards.
Enhanced Workforce Management
- Through performance tracking and training integration, Solumina MES enhances workforce efficiency, aligning employee skills with operational needs to achieve a 15- 25% boost in overall productivity.
- This approach also minimizes data entry errors by 50-70%, streamlining administrative processes.
Continuous Improvement and Cost Savings
- Solumina enables companies to foster a culture of continuous improvement, achieving a 5-15% annual improvement. Additionally, maintenance costs see a 10-20% reduction, enhancing operational sustainability and profitability.
Conclusion
In summary, MES Solumina, offers a transformative MES solution tailored for complex discrete manufacturing industries such as aerospace, defense, electronics, and medical devices. Its modular architecture, real-time data integration, and seamless compatibility with enterprise systems provide manufacturers with the tools essential to enhance operational efficiency and agility.
By focusing on quality management, workforce optimization, and advanced analytics, Solumina enables organizations to maintain compliance, improve product quality, and drive continuous improvement. Ultimately, Solumina empowers manufacturers to achieve operational excellence through informed decision-making, optimized processes, and maximized productivity.
