Enhancing Pre-Engineering Efficiency: Addressing Challenges and Implementing Solutions

Introduction

The pre-engineering phase is a critical component in the lifecycle of engineering projects, laying the groundwork for successful execution. However, this phase is often fraught with challenges that can impede progress and inflate costs. This article delves into the primary obstacles encountered during pre-engineering, explores their implications, and discusses potential strategies to enhance efficiency. A dedicated section will also highlight insights from industry experts Flo and Seb on innovative solutions to these challenges.​ (Check the article here: Epicflow)

Challenges in the Pre-Engineering Phase

1. Complex Data Gathering

Effective pre-engineering depends on collecting and analyzing factory data from various sources. Engineers must interpret information coming from:

• Measurement data within the factory, which is frequently stored across multiple, disconnected systems.

• Drawings, which are often not digitized or regularly updated, making them difficult to access or verify.

• Employee knowledge, which is sometimes undocumented or only exists informally in the minds of workers.

These sources are almost never structured and read to collect. This makes the pre-engineering process challenging, time consuming and may lead to gaps in understanding or ineffective decision-making.

2. Time-Consuming Scenario Analysis

Developing and evaluating multiple design scenarios is essential for identifying the most viable decarbonization strategies, particularly when integrating industrial-scale heat pumps. However, companies across sectors such as food & beverage, manufacturing, and pharmaceuticals often rely on traditional engineering workflows that require extensive manual calculations and fragmented data sources. This slows down project development and limits the ability to compare scenarios based on dynamic energy pricing, process heat demand variability, or existing infrastructure compatibility. For industrial clients seeking to electrify their thermal processes, this inefficiency can lead to missed incentives, delayed ROI projections, and a general reluctance to initiate the transition.

3. Limited Execution of Pre-Engineering Studies

Up to 50% of engineering capacity is often spent on pre-engineering. This limits engineering firms from unlocking the next phase in a project. In many industrial organizations, pre-engineering studies for heat pump integration are skipped due to limited internal capacity, unclear stakeholder alignment, or the complexity of gathering cross-disciplinary inputs (thermal demand, process requirements, grid impact, etc.). This is particularly true for mid-sized manufacturing firms or district energy players exploring electrification for the first time. The absence of data-driven feasibility assessments often results in oversized or underperforming systems, budget overruns, or late-stage design revisions. Industrial decarbonization demands a shift toward streamlined, yet thorough, early-stage analysis to reduce uncertainty and build strong business cases for electrification.

4. Integration of Multidisciplinary Inputs

Pre-engineering requires the collaboration of various disciplines, each contributing unique expertise. Coordinating these inputs to develop a cohesive design can be challenging, often leading to miscommunications and design inconsistencies. (For more info, check the article here: https://www.researchgate.net/publication/2462377_Challenges_in_Requirements_Engineering)

Consequences of Pre-Engineering Challenges

The hurdles faced during pre-engineering have far-reaching implications:​

• Reduced Project Initiation: The daunting nature of pre-engineering can deter organizations from pursuing new projects, limiting innovation and growth.​

• Increased Risk of Project Failure: Inadequate pre-engineering can lead to design flaws, budget overruns, and scheduling conflicts, jeopardizing project success.​

• Resource Drain: Prolonged pre-engineering phases consume valuable resources, diverting them from other critical organizational activities.​

  
  
  
  

  

  Pre-engineering discussions in the energy sector: a team of experts collaboratively evaluates heat pump system designs, tackling early-stage challenges such as integration feasibility, system efficiency, and infrastructure compatibility—key hurdles in the pre-engineering phase of clean energy deployment.

Strategies for Enhancing Pre-Engineering Efficiency

Addressing these challenges necessitates the adoption of innovative approaches and technologies (for more details, check this successful example by JOA Air: https://joaairsolutions.com/blog/pre-engineering-study-better-extraction-systems/):​

1. Leveraging Advanced Data Analytics and Automating Design Processes

Implementing data fusion techniques can streamline the aggregation and analysis of information from multiple sources, enhancing data accuracy and expediting the decision-making process. Data fusion involves integrating data from various sensors and sources to produce more consistent and comprehensive information, which is crucial in complex engineering projects. (For more info check the article here: ​nap.nationalacademies.org)

Additionally, utilizing parametric modeling software can significantly reduce the time required for scenario analysis.Parametric modeling allows engineers to create detailed 3D models where geometry is defined by parameters, facilitating rapid exploration of design alternatives and enabling the identification of optimal solutions efficiently. (For more info check the article here: ​MDPI+3Autodesk+3Bk Engineering+3Bk Engineering)

By integrating these two strategies, organizations can create a more cohesive and efficient pre-engineering phase, ultimately improving overall project outcomes.​

2. Adopting Concurrent Engineering Practices and Integrated Software Solutions

Embracing concurrent engineering methodologies promotes the simultaneous development of different project components, fostering collaboration among multidisciplinary teams. This approach reduces development time and enhances design integration, ensuring that various aspects of the project are harmoniously aligned. Concurrent engineering allows for real-time feedback and adjustments, which can significantly mitigate risks and improve project reliability. ​

Additionally, implementing integrated software solutions can further streamline the pre-engineering process.Comprehensive software platforms support multiple facets of pre-engineering, including data management, simulation, and visualization. By using these tools, organizations can improve workflow efficiency, enhance communication among team members, and facilitate better decision-making. ​

Deploying these strategies collectively can create a more cohesive and efficient pre-engineering phase. By leveraging advanced data analytics, automating design processes, adopting concurrent engineering practices, and implementing integrated software solutions, organizations are better equipped to navigate the complexities of pre-engineering. This holistic approach not only optimizes resource utilization but also ensures superior project outcomes.​

Expert Insights:

Pre-engineering should be the easiest phase of any project, but today it’s slow and repetitive because of outdated methods, fragmented data, and manual workflows. At Entropic, we’re fixing that.

We tackle three core problems:

1. Data Disparity – We fuse all relevant data sources into one streamlined platform.

2. Manual Scenario Simulations – Our engine can run thousands of simulations in minutes.

3. Manual Business Case Development – Our AI-powered generator uses real-time pricing and legislative data to pinpoint the best plan.

   
   

With Entropic, you reduce overhead, eliminate guesswork, and move projects forward faster.

Plan a meeting to see how we can streamline your pre-engineering process.