In collaboration with MNA Solutions, our team embarked on an ambitious project to enhance the operational safety and efficiency of a pet food manufacturing facility through the strategic design of a plant maintenance layout, incorporating a meticulously planned boom gate system. The Boom Gate Design Project aimed to create a safer work environment by optimizing access control and streamlining vehicle and personnel movement within the facility. Although the project did not proceed to final approval, our comprehensive approach and innovative design solutions demonstrated our commitment to delivering high-quality, safety-focused outcomes.

Project Objectives

The primary objectives of the Boom Gate Design Project were:

• Enhance Workplace Safety: Design a boom gate system to regulate vehicle access, reducing the risk of accidents in high-traffic areas.
• Optimize Plant Layout: Develop a maintenance layout that integrates seamlessly with the boom gate system to improve operational efficiency.
• Ensure Compliance: Align the design with industry safety standards and regulations to create a secure and compliant work environment.
• Future-Proof Design: Propose a scalable solution that could accommodate future expansions or modifications to the facility.

Our Role and Contributions

Our team, in partnership with MNA Solutions, took a hands-on approach to conceptualizing and developing the project plan. Key contributions included:

1. Site Analysis and Stakeholder Engagement

We conducted an in-depth analysis of the pet food manufacturing facility to understand its operational dynamics, traffic patterns, and safety challenges. This involved:

• On-site assessments to identify high-risk areas where vehicle and pedestrian interactions were frequent.
• Consultations with plant managers, maintenance staff, and safety officers to gather insights into operational needs and pain points.
• Collaboration with MNA Solutions to align our design proposals with the client’s long-term operational goals.

2. Boom Gate Design and Placement

The cornerstone of the project was the design and strategic placement of the boom gate system. Our approach included:

• Design Development: We proposed a robust, automated boom gate system equipped with safety features such as sensors, warning lights, and emergency overrides to ensure safe operation.
• Location Proposal: Using data from the site analysis, we identified optimal locations for boom gate installation to control access to critical zones, including loading docks and maintenance areas. The proposed locations minimized congestion while maintaining clear pathways for emergency access.
• Integration with Technology: We incorporated access control mechanisms, such as RFID tags and keycard systems, to streamline entry for authorized vehicles and personnel.

3. Plant Maintenance Layout

To complement the boom gate system, we redesigned the plant maintenance layout to enhance safety and efficiency. Key elements included:

• Zoning Strategy: Dividing the facility into distinct zones for vehicle traffic, pedestrian pathways, and maintenance activities to reduce the risk of collisions.
• Signage and Markings: Proposing clear signage and floor markings to guide traffic flow and reinforce safety protocols.
• Maintenance Access Points: Designing dedicated access points for maintenance crews to ensure they could perform their tasks without interfering with production or vehicle movements.

4. Safety and Compliance Focus

Safety was at the heart of our design process. We ensured that our proposals adhered to relevant occupational health and safety standards, including:

• Compliance with local regulations for industrial facility design.
• Integration of fail-safe mechanisms in the boom gate system to prevent accidents.
• Recommendations for staff training on the new system to ensure smooth adoption.

Challenges and Solutions

The project presented several challenges, which we addressed with creative and practical solutions:

• Safety Traffic Patterns: The facility’s high volume of forklift and pedestrian traffic required careful planning to avoid bottlenecks. We used simulation tools to model traffic flow and optimize boom gate placement.
• Budget Constraints: Limited funding necessitated cost-effective solutions. We prioritized modular designs that could be implemented in phases, allowing for future scalability.
• Stakeholder Alignment: Differing priorities among stakeholders required extensive collaboration. We facilitated workshops with MNA Solutions and the client to ensure consensus on the project scope and design.

Outcomes and Impact

Although the project did not receive final approval, our work laid a strong foundation for future safety enhancements at the facility. Key outcomes included:

• Comprehensive Design Proposal: A detailed plan that addressed safety, efficiency, and compliance, providing the client with a clear roadmap for implementation.
• Stakeholder Confidence: Our collaborative approach and thorough documentation strengthened the client’s trust in our ability to deliver innovative solutions.
• Knowledge Transfer: The project enhanced our team’s expertise in designing safety-focused systems for industrial environments, positioning us for future opportunities.

Lessons Learned

The Boom Gate Design Project offered valuable insights that will inform our future work:

• Importance of Early Stakeholder Engagement: Involving all stakeholders from the outset ensured that our design aligned with their needs and expectations.
• Flexibility in Design: Modular and scalable solutions are critical in projects with uncertain approval timelines or budget constraints.
• Data-Driven Decision Making: Using simulation tools and site data allowed us to create evidence-based designs that maximized safety and efficiency.

Conclusion

The Boom Gate Design Project for the pet food manufacturer, in partnership with MNA Solutions, showcased our ability to tackle complex industrial design challenges with creativity, precision, and a relentless focus on safety. While the project did not proceed to implementation, our comprehensive plan and collaborative approach demonstrated our commitment to delivering value to our clients. We are proud of the work accomplished and remain ready to apply these learnings to future projects, continuing to drive innovation and safety in industrial design.

Let’s Build Together

If you or your clients need expert engineering design and drafting support, we’re here to help. Our team is ready to provide the guidance and expertise you need to make your project a success. Contact us at info@kevos.com to explore how we can collaborate on your next venture!