Across the process industry, the task of digitizing an entire plant used to be complicated and slow. For years, reality capture required specialized experts and bulky equipment, leading many plant managers to assume scanning meant lengthy shutdowns and complex logistics.
But scanning today has evolved, dramatically.
With modern wearable scanners and intuitive real-time feedback, capturing precise spatial data now moves at the speed of a comfortable walk. Teams without extensive surveying backgrounds can easily collect comprehensive point clouds in a matter of hours. This empowers process plants to digitize quickly, safely, and independently.
Here’s exactly how that works.
From Walking to Scanning: The New Workflow
Dynamic laser scanning technology, such as NavVis VLX and NavVis MLX, relies on two key innovations: LiDAR sensors and simultaneous localization and mapping (SLAM). As the operator walks through the facility, LiDAR sensors rapidly emit and capture millions of laser points. Simultaneously, the SLAM algorithms track the scanner’s exact location in real-time, creating an accurate, detailed 3D snapshot of the plant.
Imagine Google Street View but for your entire facility.
You simply walk along planned paths, and the scanner captures the surroundings continuously. No stopping, no tripod setups every few meters. This means operators capture around 3,000 square meters per hour, roughly 10 times faster than traditional tripod-based scanning methods (enough to cover a large production unit in under an hour).
Scanning Fast, But Always Safe
Speed isn't the only benefit. It's also about safety.
Because dynamic laser scanners are hands-free and lightweight, operators can move safely through challenging environments, holding onto railings or ladders as needed. Shorter scanning sessions reduce the time spent in potentially hazardous or restricted spaces, aligning with safety standards and minimizing risk to personnel.
[ The enterprise mini-guide to Reality Capture: 3 practical steps for plant digitization ]
Additionally, the efficiency of dynamic laser scanning often means that teams can complete their capture during short maintenance windows or off-peak hours, entirely avoiding costly production interruptions.
Real-Time Confidence
One of the most significant advancements with devices like NavVis VLX and NavVis MLX is real-time feedback. As the team walks through the site, the scanner displays a live map that shows which areas are done and which still need a pass. This immediate visual confirmation ensures the operator covers every necessary corner and corridor. If there are gaps, the operator sees them instantly and can close them immediately, thereby avoiding surprises later.
This same real-time display also shows image quality. For example, if a particular corner of the plant has inadequate lighting, it will show clearly. Operators can solve this by bringing in site lights to support poor ambient light and improve data quality, but a tradeoff in efficiency must be made, as lights need to be frequently moved and kept plugged in or battery operated.
From Capture to Cloud in Hours, Not Days
After scanning, the captured data is processed automatically and rapidly. In many cases, data for significant sections of a plant can be processed in about half an hour, transforming it into a high-quality point cloud and panoramic imagery ready for use.
The output is immediately available through a browser-based platform, such as NavVis IVION. Unlike legacy solutions, there’s no special software or powerful workstation needed. Anyone authorized can log in via their browser to navigate, measure, and annotate the scan. Teams can add points of interest (POIs), link them to manuals, SAP part IDs, or instructional videos, and quickly use the model for daily operations.
Minimal Training, Immediate Value
Yet perhaps the biggest practical advantage of dynamic laser scanning for plants is how quickly teams can become proficient. Previously, surveying and scanning required weeks of training and constant external support.
Today, as Quadstege explains, the learning curve is short. "You can do everything with a mouse,” he explains. “Training is minimal."
As a result, plants are increasingly opting to train their in-house staff. Companies like Volkswagen Group Services and Schaeffler have successfully integrated internal scanning teams across their global networks, enabling frequent scans without relying on outsourced teams.
A Strategic Advantage for the Long Term
Because dynamic laser scanning is so quick and easy to learn, plants are no longer restricted to infrequent, large-scale digitization projects. Instead, they can conduct routine rescans whenever layouts change, machines are moved, or new lines are installed. Crucially, rescans can be limited to only the affected areas, meaning updates are swift and efficient.
Organizations like BMW have already leveraged this capability strategically, digitizing all their global production sites and granting around 15,000 employees remote access to this data. This transforms the way projects are planned, suppliers are onboarded, and remote audits are conducted, making digitization not just a nice-to-have, but a core part of their operational strategy.
Looking Ahead
Download the Enterprise Mini-Guide to Reality Capture and discover the full three-step path to plant digitization.
