Engineering
Clarity for Critical Asset Decisions
About the client
Sellafield Ltd is responsible for the safe and secure management of one of the world's most complex nuclear sites. As a mission-led organisation, it decommissions high-hazard facilities, manages nuclear materials, and delivers environmental remediation that protects people and the planet.
Operating on behalf of the Nuclear Decommissioning Authority (NDA), Sellafield plays a critical national role in addressing the UK’s nuclear legacy. The organisation delivers this mission through programme management, engineering oversight, stakeholder engagement, and supply chain coordination—supported by a long-term commitment to safety, value for money, and social impact.
📍 Sellafield, UK
💼 Nuclear
⚙️ P3 Management
We engaged Co-Lab to support integrating operational, engineering, and maintenance improvements for Sellafield’s Legacy Ponds. Over 18 months, their team enabled more than 10 improvement initiatives, providing P3M support and technical facilitation.
Notably, Co-Lab led an initiative to determine the best asset investment approach for our In-Pond Manipulator. This work was crucial as we approached a critical programme decision on whether to introduce a new capability or extend the life of the existing asset. They facilitated a series of workshops, culminating in a detailed technical recommendation that guided the programme’s approach.
We highly recommend Co-Lab for engineering consultancy and technical facilitation of complex challenges.
- Dan Bowman, Head of Operations, Legacy Ponds, Sellafield Ltd
Challenge
Understanding Impact and Options for Asset Intervention
With new capabilities for sorting, segregation, consolidation, and cleaning being deployed within the First Generation Magnox Storage Pond, the programme reached a critical decision point regarding the long-term use of its In-Pond Manipulator. This asset plays a central role in ongoing operations, supporting safe and efficient handling of materials within the pond.
The introduction of upgraded systems and processes created an opportunity to reassess the manipulator’s role, condition, and performance. The programme needed a clear understanding of the impact these changes might have on the asset, as well as a thorough evaluation of the available intervention options.
This meant exploring whether to invest in new equipment, upgrade existing systems, or extend the asset’s operational life through targeted maintenance. Any decision would have to balance technical performance, safety, cost, and schedule, while ensuring the manipulator remained fully capable of supporting the facility’s mission.
Solution
Facilitating Strategic Engineering Workshops
Co-Lab facilitated a structured series of engineering optioneering workshops, bringing together technical specialists, operational staff, and programme leaders to evaluate the full range of intervention options for the In-Pond Manipulator. Each option was assessed against a balanced set of criteria covering time, risk, cost, technical performance, maintainability, and alignment with operational requirements.
The process produced a clear, evidence-based comparison of the available choices, supported by scoring matrices, impact assessments, and visual summaries to aid discussion. This enabled stakeholders to see not only the relative merits of each option, but also the trade-offs involved in terms of delivery timescales, cost implications, and potential operational disruption.
The final output was a comprehensive intervention options pack, presented to the Legacy Ponds Programme Board. This provided the board with a well-structured information base to support strategic decision-making, ensuring that any investment in the asset would be aligned with programme priorities, regulatory requirements, and long-term operational needs.
Process
Structured Approach to Solution Definition and Evaluation
The project followed a structured, iterative process to identify and assess asset intervention options. It began with a stakeholder analysis to gather insights and ensure diverse perspectives were considered. Evaluation criteria were then developed and weighted to reflect key factors like cost, safety, and operational impact.
A framework was established to define solutions consistently, supported by research and creative thinking to generate a wide range of ideas. These were compiled into a longlist, refined into detailed options, and evaluated using the scoring system.
The preferred solution was selected based on this assessment, and a clear execution plan was developed for implementation.
Benefits
Driving Informed Decisions and Optimised Asset Deployment
Informed Decision-Making – The structured engineering optioneering workshops provided a balanced, time-efficient, and cost-effective approach for asset intervention, supporting strategic decisions at the Legacy Ponds programme board.
Optimised Asset Intervention – Enabled the safe and efficient deployment of solutions for in-pond manipulators, ensuring continued operations within the First Generation Magnox Storage Pond.
