Many industrial companies are facing changes while production must continue. Conversions, modernizations, or partial relocations cannot always be combined with a complete shutdown of the plant. This is exactly where disassembly during operation comes into play.
It enables the dismantling of machines or plant components while adjacent production areas remain active. This requires precise planning, clear responsibilities, and a high degree of technical and organizational experience.
Dismantling during ongoing operations describes the planned dismantling of machines, systems, or system components while other production areas continue to operate at the same time. In contrast to conventional dismantling, dismantling does not take place during a complete shutdown, but rather in close coordination with production, maintenance, and logistics.
While dismantling during shutdown involves taking the entire plant out of operation, dismantling often takes place during ongoing operation:
This approach is more demanding, but offers considerable economic advantages.
Disassembly during ongoing production is always advisable when a complete production shutdown is not possible for technical, economic, or organizational reasons.
This approach is often the only practical solution, especially in highly automated or cycle-time-bound production environments.
The biggest challenge lies not in the actual dismantling, but in the coordination of parallel processes.
Disassembly work often takes place in close proximity to running machines, forklift traffic, or automated systems. The risk of falling, falling parts, or unintentional restarting must be reliably ruled out.
Production, maintenance, external service providers, and logistics are all interlinked. Without clear responsibilities and communication channels, risks and delays can quickly arise.
Work often has to be carried out within tight time frames, such as between shifts, on weekends, or during planned production breaks on individual lines.
Disassembly without stopping production is not an improvisational project. It follows clear rules and structures.
Dismantling areas, restricted zones, traffic routes, and material storage areas are precisely defined in advance. This helps to avoid conflicts with ongoing production.
A structured work release or permit procedure ensures that:
Electrical, pneumatic, hydraulic, or media-carrying systems are specifically disconnected, drained, and secured against being switched back on, even if adjacent parts of the system remain in operation.
Regular coordination with shift supervisors and production managers is crucial in order to safely absorb short-term changes or disruptions.
Despite individual requirements, the process usually follows a proven structure.
First, the plant, surroundings, media, accessibility, and production processes are analyzed. This results in a dismantling concept with a time and space allocation.
An object-related risk assessment takes particular account of the interactions between dismantling and ongoing production.
Disassembly is carried out in stages, for example line by line or assembly by assembly, in coordination with production operations.
All dismantled components are labeled, documented, and prepared for reassembly, conversion, or disposal. Once this process is complete, the work areas are formally returned to the company.
Even small oversights can have major consequences.
Failure to assign responsibility quickly leads to uncertainty or delays.
Insufficiently separated work and production areas increase the risk of personal injury and property damage.
Without ongoing communication, planned work can conflict with production processes—with consequences for safety and scheduling.
Disassembly during operation requires more than just technical skill. The following factors are crucial:
Well-coordinated teams and experienced project management are clear success factors here.
Disassembly during ongoing operations is a challenging task, but it offers companies significant advantages. It enables conversions and modifications without completely interrupting production. This requires structured planning, clear safety concepts, and professional implementation.
Yes, if dismantling areas are clearly separated, media are safely isolated, and processes are precisely planned.
Among other things, risk assessments, barriers, work approvals, and clear coordination between all parties involved are required.
The duration depends on the scope of the system, the available time slots, and the complexity of the interfaces.
Only competent, trained personnel with experience in an industrial environment should undertake such work.
At A & P Industriemontage, we support companies worldwide in the assembly and commissioning of complex industrial plants. With our expertise and comprehensive services, we ensure efficient and safe production processes. Trust in our many years of experience and let us work together to successfully implement your projects.
