I recently re-ran the model and identified several breakers with arc flash ratings exceeding 40 cal/cm² and reaching upto 140 cal/cm2.
I'm interested in knowing if similar issues have been encountered at other sites and what short-term actions were implemented to maintain production. While I'm focusing on long-term solutions, such as procuring remote racking devices and exploring potential protection changes to reduce these ratings, I would like to understand any immediate measures that can be taken within industry best practices.

I don't know what your distribution looks like, but if there is any way to change out a fuse (for a faster one), change relay settings, etc. to an upstream device. If that's not possible, then can you utilize distance temporarily to bring down the AFIE? For example, use an insulated hot stick to hit the open or close button on a circuit breaker?

Mike

Need more information. Can you post some screenshots of your model with your input data displayed?

Also, unless you have some extremely high arcing fault current the only way you're getting 140 cals is if your protective device doesn't operate or doesn't operate before the 2 second rule if you are applying that.