Poor facility design - a ticking time bomb
According to the Swedish Work Environment Authority, 44 fatal accidents occurred in Swedish workplaces in 2021, an increase from the previous year. Many of these accidents occur in industry and can be linked to inadequate construction and poor maintenance of production facilities. The importance of systematic and long-term safety work is required to eliminate accident risks. It is also obvious that the more machines in motion, the greater the risk of incidents, as the laws of mechanics always apply. Moreover, with increasing electrification and connectivity, breakdowns can also be due to electrical faults or Wi-Fi coming and going. There are many aspects to consider, each important in its own way.
So reviewing plant design from a safety perspective is not just about optimizing production - it's about saving lives.
"By identifying weak points early on in the design phase, we can eliminate many of the risks that could otherwise lead to catastrophic consequences. We know what needs to be done, and we have the resources to make it happen, so it's completely unreasonable that some people go to work and never come home," says Robert Velén, plant design specialist at Plantvision.
A well thought-out facility design saves lives
When plant design is not well thought out, problems can arise that affect the whole production chain. These can include poorly positioned machinery, inaccessible maintenance areas or a lack of redundancy in systems critical to operations. Such shortcomings not only lead to production disruptions, but can also create dangerous working environments where accidents become more likely.
Optimizing plant design means integrating safety into the entire process - from planning and construction to operation and maintenance. By implementing robust safety solutions, companies can both reduce the risk of breakdowns and increase their overall productivity. And here, Robert says, it's important not to be dumb and chase dollars and cents, but rather be smart.
"Being cheap can be an expensive lesson. The most expensive solutions are not always the best, but the absolute cheapest are rarely well thought out. An undersized structure, inadequate safety solutions or limited maintenance space can have disastrous consequences. Thinking cost-consciously, but smartly, is the way to go."
Unplanned downtime - an economic nightmare
A single unplanned downtime can cost companies millions of dollars. According to a Siemens report, "The True Cost of Downtime 2024", unplanned downtime can cost industry up to $50 billion annually globally2. Production stops, resources have to be reallocated and, in the worst case, the entire supply chain can be affected.
Having a well-planned plant design significantly reduces the risk of these losses.
"A well thought-out and optimized system not only provides a safer working environment, it also contributes to a more stable and cost-effective production. Small changes in design can make a big difference to both safety and uptime," says Velén.
Digital tools revolutionize plant design
Modern digital tools such as 3D CAD solutions and digital twins make it possible to identify potential problems even before a plant is built.
- 3D CAD solutions enable detailed and interactive drawings where all aspects of a plant can be closely examined. By simulating operations, companies can avoid design errors that could otherwise lead to inefficiencies or safety risks.
- Digital twins create an exact digital replica of the plant, making it possible to test different scenarios in real time, predict downtime and optimize maintenance actions.
These technologies help companies make better decisions at the planning stage, both reducing the risk of accidents and making the production environment more efficient.
How to create a robust and sustainable facility
To minimize the risks of breakdowns and accidents, companies need to think proactively already in the design phase. Here are some key aspects to take into account:
- Redundancy in critical systems - Having back-up solutions on Location allows production to continue even if one system fails.
- Ergonomic and safe access to machinery - Maintenance and servicing should be carried out without exposing staff to unnecessary risks.
- Automated safety systems - Sensors and AI-based analytical tools can identify potential problems before they lead to downtime or accidents.
- Risk analysis and simulations - Careful pre-construction analysis can identify and address weaknesses at the design stage.
The future of industry requires smart solutions
Technological advances in automation, IoT and AI have provided industry with powerful tools to optimize their production facilities. The future of plant design is about integrating these solutions to create safe, cost-effective and sustainable production.
"We are facing a time when industry needs to adapt faster than ever before. The companies that invest in smart solutions today will be the winners of tomorrow"
He continues:
"Take a step back and look a little bigger than just what needs to be solved. The holistic perspective is super important to have. When working on this type of assignment, it's always best to run the project as a cohesive team, rather than working in separate silos, and we always emphasize the importance of using resources that can see the big picture and have incentives to collaborate, rather than chasing pennies in the context," Velén concludes.
What does your facility design look like? Is it built to minimize risk and maximize efficiency, or are you sitting on a ticking time bomb?
Everyone deserves to come home after work.
