Many industrial plants are facing changes, yet production must continue. Renovations, upgrades, or partial relocations cannot always be carried out while the entire plant is shut down. This is exactly where dismantling during ongoing operations comes into play.
It allows for the dismantling of machines or plant components while adjacent production areas remain operational. This requires precise planning, clearly defined responsibilities, and a high level of technical and organizational expertise.
Dismantling during operation refers tothe planned dismantling of machines, systems, or system components while other production areas continue to operate simultaneously. Unlike traditional dismantling, this process does not take place during a complete shutdown, but rather in close coordination with production, maintenance, and logistics.
While dismantling during a shutdown involves taking the entire plant offline, dismantling during normal operation often takes place:
This approach is more challenging, but it offers significant economic benefits.
Dismantling while production is ongoing is always advisable when a complete production shutdown is not feasible for technical, economic, or organizational reasons.
Especially in highly automated or cycle-driven production environments, this approach is often the only practical solution.
The biggest challenge lies not in the actual dismantling, but in coordinating the parallel processes.
Dismantling work often takes place in close proximity to running machinery, forklift traffic, or automated systems. The risk of falls, falling parts, or unintentional restarting must be reliably eliminated.
Production, maintenance, external service providers, and logistics are all interconnected. Without clear responsibilities and communication channels, risks or delays can quickly arise.
Work often has to be done within tight time frames—for example, between shifts, on weekends, or during scheduled production breaks on individual lines.
Dismantling without interrupting production is not a project that can be improvised. It follows clear rules and structures.
Dismantling areas, restricted zones, traffic routes, and material staging areas are precisely defined in advance. This helps avoid conflicts with ongoing production.
A structured work authorization or permit process ensures that:
Electrical, pneumatic, hydraulic, or fluid-carrying systems are specifically isolated, drained, and secured against being switched back on, even when adjacent plant components remain in operation.
Regular coordination with shift supervisors and production managers is crucial for effectively handling last-minute changes or disruptions.
Despite individual requirements, the procedure usually follows a tried-and-true structure.
First, the facility, surroundings, media, accessibility, and production processes are analyzed. This results in a dismantling plan that includes a timeline and spatial layout.
An object-specific risk assessment takes into account, in particular, the interactions between disassembly and ongoing production.
Disassembly is carried out in stages—for example, line by line or by subassembly—in accordance with production operations.
All dismantled components are labeled, documented, and prepared for reassembly, modification, or disposal. Upon completion, the work areas are formally returned to the facility.
Even small oversights can have major consequences.
Failure to designate responsible parties can quickly lead to uncertainty or delays.
Work and production areas that are not adequately separated increase the risk of injury and property damage.
Without ongoing communication, scheduled work can conflict with production processes—with consequences for safety and the schedule.
Disassembly during operation requires more than just technical skill. The following factors are crucial:
Well-coordinated teams and experienced project management are clearly key factors for success here.
Dismantling equipment while it is still in operation is a challenging task, but it offers companies significant advantages. It allows for modifications and changes without completely interrupting production. This requires structured planning, clear safety protocols, and professional execution.
Yes, provided that the disassembly areas are clearly separated, media are securely isolated, and procedures are precisely planned.
Among other things, risk assessments, barriers, work permits, and clear coordination among 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 qualified, trained personnel with experience in an industrial setting should perform such work.
At A&P Industriemontage, we support companies worldwide in the installation and commissioning of complex industrial plants. With our expertise and comprehensive range of services, we ensure efficient and safe production processes. Trust in our many years of experience, and let’s work together to successfully implement your projects.