When a piece of equipment fails, the solution usually seems quite simple – order a replacement, install it, and resume operations. But what happens when a standard replacement isn’t possible?
Many industries rely on custom-built solutions tailored to their specific needs, which means that when they fail, off-the-shelf replacements aren’t always an option. Whether due to design flaws, compatibility issues, or the sheer cost and inconvenience of replacing an entire system, businesses often face challenges that need something more than just a standard fix.
This was exactly the challenge one of our clients faced. They had procured a critical piece of equipment, but when it failed, they realised an OEM replacement wasn’t a viable option. The original design was flawed, and the client had little confidence that a direct replacement would perform any better.
Without the in-house expertise needed to diagnose and repair the failure – and replacing the entire system being too disruptive and costly – a multidisciplinary engineering approach was required. This is where DOCAN stepped in.
In this blog, we’ll explore how we solved this particular problem for our client and how we can apply multidisciplinary engineering solutions to a range of applications.
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What is multidisciplinary engineering?
Multidisciplinary engineering is exactly what it sounds like – it’s an engineering field that combines multiple engineering disciplines to create a solution that solves complex problems.
It’s our speciality here at DOCAN as we have a strong team of engineers with different expertise, specialising in different fields. All of this knowledge and experience combined means we’re able to offer a range of advanced engineering solutions that work harmoniously together.
Whether we’re looking at an equipment failure, design flaw or operational challenge, we can combine key expertise such as FEA, CFD, stress analysis, FEED, Fitness for Service Assessments and more to tackle the problem head-on and devise the most effective solution.
In the case of this particular project we’re discussing, we combined various tools and skill sets such as reverse engineering and digital twin technology to develop a tailored solution that restored faulty equipment without requiring a full system replacement.
Why standard solutions can’t fix non-standard equipment problems
We were contracted by a UK-based company to investigate and fix a crucial piece of equipment that was failing. Their facility relies on highly specialised equipment designed to fit within a specific system, so this quickly became a non-standard problem.
For many businesses, when a piece of equipment fails, the first instinct is naturally to replace it. In some cases, a broken part can just be swapped out, but this wasn’t a standard issue that could be fixed with an off-the-shelf solution.
Key challenges:
- OEM replacement wasn’t viable: The original design had flaws, so a direct replacement risked repeating the same failure
- No in-house repair capabilities: The business didn’t have the technical expertise to resolve the issue without a full replacement
- Operational disruption: A completely new system would have been costly, disruptive, and unnecessary
- Customisation engineering required: This piece of equipment was unique, meaning a tailored engineering solution was the only way forward
With an equipment issue like this, we want to make sure the new solution enables the facility to operate in the same way and continue to produce the exact same quality of products.
What we wouldn’t want to do is replace the entire system just because one part was failing, and we also don’t have the option of a straightforward swap. So, a more strategic solution was needed. This is where custom engineering solutions come into play.
Why a multidisciplinary approach is critical to addressing these challenges
When we’re dealing with complex equipment failures like this, a single-discipline approach simply isn’t enough. The issue required a combination of expertise from multiple engineering fields.
DOCAN’s team of highly skilled engineers brought the in-house expertise needed to combine a range of disciplines encompassing inspection, testing, analysis and design, to develop a robust, tailored solution that ensures long-term reliability.
Step 1: Identifying the risks and issues
Our first challenge was to review the equipment and determine the current risks and issues, advise on any testing which should be completed, and determine which assessments were needed.
Pinpointing the exact cause of failure required a detailed inspection, which included the following:
- Reviewing the failed equipment – analysing what had gone wrong and identifying the key risks
- Assessing potential solutions – determining if the equipment could be salvaged or needed a full redesign
- Recommending further testing & analysis – defining what additional inspections were needed to make an informed decision
Step 2: Inspection & surveying
To move forward with a solution, we conducted a comprehensive inspection and survey using advanced engineering techniques:
- 3D laser scanning – capturing highly accurate measurements of the equipment
- Materials testing – evaluating material properties to ensure durability
- Dimensional survey work – mapping out the full geometry of the equipment to support the redesign
- Digital twin & reverse engineering – creating a virtual model of the equipment to simulate real-world conditions, analyse stress points, and optimise the design
By combining these high-precision assessment methods, we were able to gather the critical data we needed to engineer a more reliable, long-lasting solution.
Step 3: Engineering & redesign
Once we had a full understanding of the equipment’s failure points and structural weaknesses, we were able to move into the engineering phase. This is undoubtedly the most crucial point of the process requiring a multidisciplinary team to approach it in the right way, as it incorporates various high-skill techniques.
- The first step in this process was selecting the right materials to ensure durability and reliability in the finished product.
- To ensure the new design would withstand operational stresses, we conducted Finite Element Analysis (FEA) and stress testing, simulating real-world conditions to verify structural integrity.
- Additionally, we performed a load path assessment to confirm that forces were properly distributed, preventing future failures.
- Once the design was validated, we developed new tooling CAD models to support the manufacturing process, ensuring every component was precisely engineered for seamless integration.
- Detailed machining drawings were created to guide fabrication, providing manufacturers with exact specifications for production.
- Finally, we worked closely with the client to support the manufacturing and installation process, ensuring a smooth transition from concept to completion.
By integrating structural analysis, digital modelling, and hands-on manufacturing support, we delivered a solution that not only resolved the immediate failure but also improved the equipment’s overall reliability and performance.
How our tailored solution solved the problem
Instead of just replacing the failed equipment with another version of the same flawed design, we took a smarter approach. We dug into the root cause of the failure, using advanced testing and analysis techniques to understand the weaknesses, and designed a fully optimised solution that would last.
By combining our expertise in digital twin technology, stress testing and advanced engineering, we created a brand-new version of the equipment – one that was stronger, more reliable, and perfectly suited to the needs of the client. This meant no unnecessary downtime, no money wasted on an unreliable replacement, and complete confidence in the new design.
This isn’t anything new for us here at DOCAN as we always approach every challenge in the same way – combining our wide set of skills to create a solution that’s the most cost-effective, time-efficient and reliable for our clients. For our client, that meant that instead of a quick-fix short-term solution, they got a long-term solution that kept their business running smoothly without any costly disruptions.
How multidisciplinary engineering works for all businesses
This project is a great example of how multidisciplinary engineering can solve real-world problems, and it’s not just specific to one industry. Whether it’s industrial, commercial, or anything in between, businesses often run into situations where equipment breaks and standard solutions simply don’t work.
This type of approach applies to any type of critical equipment large or small where it’s not something that you can just purchase a direct replacement for, and there’s nobody on site with the capabilities to fix it without replacing the entire system. An engineering consultancy like ourselves can come in and fix the problem without stopping the business from functioning and not having huge implications in terms of costs or downtime.
To put it simply, if a critical piece of equipment breaks and there’s no easy replacement, you don’t have to start from scratch. For any business looking to extend the life of their equipment, avoid downtime, and improve efficiency, this approach isn’t just helpful – it’s essential. We have the expertise to turn a problem into an opportunity and come out with a stronger, more reliable solution than before.
DOCAN works with businesses across all industries to solve their most complex engineering challenges. No matter the sector you’re working in or the equipment issue you’re having, we can help. Get in touch with us today to find out how.