Enabling a Reduction in Alarm Response Times of 75% - Zero Evacuations in 3 Years

Alarm Response
Business Continuity
Transforming ERT Operations of Pharma Production Facility

Location: Leinster, Ireland
Facility Type:
Pharmaceutical Production
Assets Mapped:
8,716 Across 1,560 Rooms
Deployment Date:
September 2021
Return on Investment:
Business Continuity - Zero unnecessary evacuations sense deployment. (Down from 2/3 per month)
Project Date: September 2021

PlantQuest's innovative solution reduced alarm response times by up to 73% and eliminated unnecessary evacuations at a major pharmaceutical facility in Leinster, Ireland. By integrating fire system and EHS asset data into a Google Maps-like platform, the solution enhanced emergency response, minimized operational disruptions, and significantly improved financial performance.

The Challenge Faced

At one of Europe’s largest solid-dose pharmaceutical manufacturing facilities, established in 1992, operational complexity posed significant challenges for emergency response teams (ERT). Spanning over 133,000 square meters across 12 buildings and 4 levels, this facility houses over 800 employees and operates 24/7. Key challenges included:

  • Efficiently locating and responding to alarms across 1,500 rooms to support uninterrupted operations.
  • Reducing emergency response times to prevent costly downtime, estimated at $20,000 per minute.
  • Mitigating unnecessary evacuations, which disrupted production and strained resources.
  • Streamlining workflows related to 5,500 fire detection devices and 2,000 EHS assets.
  • Developing a robust solution that functions seamlessly in areas with limited Wi-Fi and GPS connectivity.
  • Ensuring no disruptions to ongoing operations during implementation in a 33-year-old brownfield facility.

The Solution

PlantQuest delivered a transformative solution that exceeded client expectations by introducing a Google Maps-like platform for emergency response. The system included:

  • Comprehensive Mapping: Over 300 fire layout drawings were digitized, enabling instant access to the location of alarms, fire devices, and EHS assets across the facility.
  • Interactive Navigation: Emergency responders could locate and navigate to any alarm or asset within the facility in 50% to 75% less time. The platform’s tablet functionality ensured seamless operation even in areas with limited connectivity.
  • Minimal Disruption: Implementation and commissioning were completed with only two days on-site, causing zero interruptions to daily operations.

The Outcome

Since deploying the PlantQuest solution, the facility has achieved remarkable improvements in operational efficiency and emergency response:

  • Alarm Response Time: Reduced by up to 73%, with no alarm taking more than 12 minutes to locate and address.
  • Evacuation Prevention: Zero unnecessary evacuations since deployment, compared to 2-3 per month previously.
  • Operational Efficiency: Enhanced first responder training and confidence, resulting in smoother and quicker alarm handling.
  • EHS Asset Management: Instant access to the location of 2,000 EHS assets, empowering teams to manage safety equipment effectively.
  • Contractor Navigation: Contractors utilized PlantQuest to locate assets and rooms efficiently, minimizing time spent on-site and ensuring safety.
  • Financial Impact: Prevented evacuation and downtime costs, significantly improving the facility’s financial performance.