![[Boom-Gate-Design-Project-----Case-Study.webp]] **Client:** Pet Food Manufacturing Facility **Partner:** MNA Solutions **Service:** Engineering Design & Safety Layout Planning KEVOS®, in collaboration with MNA Solutions, undertook the design of a comprehensive boom gate and plant maintenance layout to enhance safety, access control, and operational efficiency within a busy pet food manufacturing facility. Although the project did not proceed to final approval, our approach demonstrated rigorous design thinking, stakeholder collaboration, and industry-aligned safety planning—exemplifying the quality of work we deliver across all industrial design projects. #### **Project Objectives** - **Improve Workplace Safety:** Introduce a controlled boom gate system to reduce vehicle–pedestrian conflicts. - **Optimise Facility Layout:** Integrate access control with a reworked maintenance layout to streamline movement across the site. - **Meet Compliance Requirements:** Align the design with relevant industrial safety standards and regulatory obligations. - **Future-Ready Solutions:** Develop scalable concepts that support future facility upgrades or operational changes. ### **Our Approach** **1. Site Analysis & Stakeholder Engagement** To understand the complexities of the site, we conducted a detailed operational study, focusing on: - On-site traffic assessments to identify congestion points and high-risk zones. - Consultations with plant managers, maintenance teams, and safety officers. - Close coordination with MNA Solutions to ensure strategic alignment with long-term operational goals. These insights formed the foundation of a design strategy tailored to real-world conditions. **2. Boom Gate System Design** The core of the project centred on a customised boom gate solution. Our design recommendations included: - **Automated boom gates** with integrated safety features—sensors, warning lights, and emergency override capability. - **Strategic positioning** to control traffic into critical areas such as loading docks and maintenance zones. - **Technology integration**, including RFID and keycard access, to streamline entry for authorised personnel and vehicles. Traffic simulation tools were used to validate optimal placement and reduce the potential for bottlenecks. **3. Plant Maintenance Layout Redesign** To complement the access control system, we delivered a refined maintenance layout featuring: - **Zoned pathways** separating forklifts, vehicles, pedestrians, and maintenance activities. - **Clear directional signage and floor markings** to support safe traffic flow. - **Dedicated maintenance access points** that avoid interference with production operations. This coordinated design created a safer, more efficient flow across the site. **4. Safety & Compliance Integration** Our design adhered to applicable safety standards and industrial facility guidelines. Key considerations included: - Compliance with OH&S requirements. - Inclusion of fail-safe mechanisms to minimise operational risk. - Recommendations for onboarding and staff training to support safe adoption of the proposed systems. #### **Project Challenges & Solutions** - **Complex Traffic Patterns:** High forklift and pedestrian activity required careful planning—addressed through modelling and scenario testing. - **Budget Constraints:** We proposed modular, phased implementation options to manage cost while retaining long-term scalability. - **Stakeholder Priorities:** Workshops and joint reviews ensured alignment between all parties, improving clarity and decision-making. #### **Outcomes** Although the project did not advance to implementation, it delivered several valuable outcomes for the client: - A **comprehensive, ready-to-implement design package** targeting safety, efficiency, and compliance. - Strengthened **stakeholder confidence** through collaborative planning and clear documentation. - Enhanced internal knowledge base for future industrial design and safety-focused initiatives. #### **Key Learnings** - Early stakeholder engagement ensures smoother alignment and faster decision cycles. - Modular design approaches enable flexibility where budgets or timelines are uncertain. - Data-driven analysis—traffic modelling, site data, and risk assessments—provides objective foundations for safer layouts. The Boom Gate Design Project highlights KEVOS® capability in tackling complex industrial safety and access-control challenges with precision and a people-first mindset. While not executed, the project reflects our commitment to quality, innovation, and safe design principles—values we bring to every client collaboration. > **Need Assistance With Your Industrial Design or Engineering Project?** If you’re exploring safety upgrades, access control solutions, or layout optimisation, our team is ready to help. Let’s bring clarity, compliance, and efficiency to your next project. **Contact us today to discuss your requirements.**