Improved Production and Layout

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New-Layout

How we improved the layout in Hackefors with Viscando 3D&AI and Gazpacho

Improving efficiency and competitiveness in production environments is no longer just about machines and materials, it’s about creating smooth workflows, reducing waste, and enhancing the working environment. To achieve this, it is crucial to understand how people, materials, and equipment move through production. At Virtual Manufacturing’s factory in Hackefors, we tested how the combination of Viscando 3D&AI and Gazpacho Analytics can generate these insights quickly and reliably, resulting in clear improvements to the production process.

Background: The Need for Data-Driven Decisions

Traditionally, layout improvements and material placement have been based on experience, observations, and educated guesses. Without objective data, it can be difficult to see where time and resources are truly being lost. The goal of the Hackefors pilot project was to collect movement data from operators during assembly and analyze how walking paths, work tasks, and material flows could be optimized.

Method: Tracking with Viscando 3D&AI

In an area of approximately 30×15 meters, Viscando 3D&AI sensors were installed. Using visual markers (AprilTags) on hard hats and T-shirts, the system tracked the operators’ movements. The solution does not require battery-powered devices on the tracked objects, and the sensors provide high-precision coverage over large areas.

The movement data was then imported into Gazpacho Analytics, where it was visualized in several ways:

  • Spaghetti diagrams to show exact walking paths
  • Heatmaps to highlight the most used areas
  • Geofencing and zone analysis to measure time spent in critical work areas

Measurable Results

During the three-hour data collection period, two operators walked nearly three kilometers combined, spending more than 65% of their time outside their designated work zones. These numbers provided a clear picture of how much unnecessary movement affected daily work. By analyzing walking paths, time in zones, and flow patterns, we were able to quantify bottlenecks, identify time-wasters, and create a concrete basis for improvements.

Results: Insights That Drive Change

The analysis clearly showed where operators spent most of their time, often at fastener and kitting areas, and how much time was lost to unnecessary movement. With these insights, we were able to:

  • Identify bottlenecks in the workflow
  • Measure walking distances and time spent in work zones
  • Plan an improved layout with shorter distances to critical materials and smoother flows
  • Optimize kitting and picking systems based on data

The new layout can now be tested and validated through continued data collection, making it possible to measure the impact of changes directly in Gazpacho Analytics.

Gazpacho Analytics – More Than Visualization

Gazpacho Analytics is not just a visualization tool. The platform can be combined with any tracking system and enables analysis of historical and real-time data simultaneously. It transforms movement patterns into measurable KPIs, such as time in motion, total walking distance, and utilization of critical zones.

With Analytics, teams can:

  • Compare before-and-after data from layout changes
  • Identify deviations from standardized workflows
  • Measure the effects of improvements and adjust processes proactively

The result is a fact-based decision-making foundation that delivers real impact on productivity, material flows, and the working environment. By combining Viscando 3D&AI with Gazpacho Analytics, companies can take the next step toward lean and data-driven production, where every movement is measured, understood, and optimized.

 

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