How do you prepare for a crisis?

In the event of a major crisis – or, ultimately, war – much of society would feel the consequences, not least the manufacturing industry. Yet how does one prepare for a scenario that is, in many respects, uncertain? "The most important thing is to have thought it through," says Emma Mattisson, Project Manager at RISE.

The world is marked by unrest and uncertainty, and it’s becoming increasingly difficult to predict what lies ahead. In such times, it’s only natural to feel uncertain. Should we stay the course – or chart a path towards... well, what exactly?

To shed light on how authorities, industry, and research can work together to strengthen the resilience of society’s supply systems, the national initiative Prepare Sweden recently launched. The area itself is not new to RISE but has developed along several different tracks over many years. One of the people who has worked extensively with resilience and preparedness within the Swedish manufacturing industry is Emma Mattisson.

“Planning is often based on the expectation that a certain type of disruption or accident will occur – and then something entirely different happens instead. That’s the problem with building up large emergency stockpiles of ready components: You run the risk of ending up with a bunch of parts that are useless when the time comes. That said, the very act of preparing mentally by exploring various scenarios, and how to respond to them, is seldom in vain,” says Emma Mattisson.

There are several events that could affect production during a state of emergency. For instance, that a supplier becomes unavailable or the electricity supply is disrupted. To adopt a strategic and targeted approach in your preparedness work, Emma Mattisson recommends focusing on three key areas: material, manufacturing method and competence.

Are alternative materials an option?

Material selection typically takes place early in the manufacturing process. Once a material has been chosen, production is underway, and the components have been optimised according to factors such as profitability, competitiveness, manufacturing time, and sustainability, there is seldom a compelling reason to make a change. By considering alternative materials at an early stage and assessing how viable they are in practice, however, manufacturers can be better prepared to meet future needs.

“If you’re working with aluminium today, it might be possible to switch to plastic or steel if the situation calls for it. If you’re using plastics, perhaps wood could work just as well. If there’s an opportunity to start testing new materials now, that’s fantastic – but the most important thing is to have thought it through,” says Emma Mattisson.

Planning is often based on the expectation that a certain type of disruption or accident will occur – and then something entirely different happens instead.

Can things be done differently?

In the production process, many things can go wrong. The usual material may suddenly become unavailable, or spare parts for the production equipment might run short. The supply chain – from start to finish – is delicate, relying on numerous elements working seamlessly together. To build greater resilience against different kinds of disruption, it can be wise to look into alternative manufacturing methods.

“For cast metal components, there aren’t, unfortunately, many options – but critical components can still usually be machined. It’s also well worth taking a closer look at additive manufacturing, especially if you’re currently working with plastics or composites. Check what can be done, get to know the alternatives – even the ones that seem more expensive in peacetime. And find out how you can repair things,” says Emma Mattisson.

Can additive manufacturing save the day?

Additive manufacturing, commonly known as 3D printing, is increasingly promoted as a solution in resilience matters. Is it true? Definitely, at times, though with some reservations, notes Lenny Tönnäng, Research and Development Engineer in Additive Manufacturing at RISE.

Additive manufacturing is a process that has developed tremendously in recent years, enabling the production of complex components from a wide range of metals, polymers, and composite materials. The technology also allows for greater use of recycled materials, which is beneficial from both a resilience and sustainability perspective. Sweden is well positioned to take advantage of this technology. We lead the way in material development and the production of the metallic powders often required. Several major domestic companies are also driving innovation in bio-based polymers and recycled materials for use in additive manufacturing. In addition, Sweden hosts machine manufacturers specialising in both metallic and polymeric materials. So, where’s the catch?

“Primarily, it is about the individual company's access to all the equipment required, especially on the metal side. In addition, expertise within the organisation itself is needed, along with the right type of data. But from a resilience perspective, the technology offers many advantages. Perhaps one of the most significant is that you can have the material in a jar and from there create virtually any shape you want. It is possible to reproduce existing components, design entirely new geometries that result in lighter and more functional parts with less material usage, as well as to repair components, machine parts, or tools,” says Lenny Tönnäng.

Check what can be done, get to know the alternatives – even the ones that seem more expensive in peacetime.

Yet another advantage is that the additive manufacturing supply chain often is detached from the “traditional chain.” So, if there is a disruption anywhere along it, additive manufacturing can serve as an alternative, also allowing for greater localised production.

“If we look at a traditional manufacturing chain, it tends to have one or more weak links, regardless of whether you have chosen to build in some resilience by using multiple suppliers. For example, if the material comes from the same source, a disruption at one supplier will cause the same disruption for the others. Here, additive manufacturing offers an advantage, as its supply chain usually looks different,” says Lenny Tönnäng.

Both Lenny Tönnäng and Emma Mattisson stress, however, that being aware of the different options is what matters most. Knowledge can make all the difference in a crisis.

Where is the competence?

“In the event of a serious crisis, such as war, there’s a high chance you’ll lose a portion of your workforce, as they might be required to serve elsewhere. So, ask yourself the question: which personnel will remain in my manufacturing company during mobilisation? Having completed such an assessment, take the opportunity to talk to geographically or technically adjacent companies. Investigate where you might relocate parts of your production processes, should it be needed,” says Emma Mattisson.

It is also a good idea to make sure that multiple people hold the same knowledge, especially if it is critical to your operations. At RISE, your organisation can take part in or access a variety of projects and educational programmes aimed at building expertise and supporting production adjustments.

“RISE offers several initiatives to help your company increase preparedness and adaptability. The Application Center for Additive Manufacturing at RISE provides, among other things, introductory days, seminars, basic training courses, and feasibility studies in the field of additive manufacturing. In addition, the Production Leap is running multiple efforts, to name just a few,” says Emma Mattisson.

Is there anything tangible a manufacturing company can start with today, to initiate or strengthen its preparedness work?

“Obtain CAD models of all critical components and find a secure place to store them. They will come in handy, regardless of which material you have access to, which production process you are facing, or what expertise is available on site,” says Lenny Tönnäng.