<p>This study addresses the challenges faced by Thailand’s coastal manufacturing sector, which is vulnerable to floods, tsunamis, and fires. Traditional disaster response systems often suffer from inefficiencies in data recording and delayed responses, leading to significant financial and human losses. This research proposes an intelligent disaster response system that integrates Facilities Management and Control Systems (FMCS) with 5D platform technology. It is the first application of 5D technology in manufacturing disaster response. The system improves efficiency and accuracy through real-time data collection, big data analysis, and machine learning for faster anomaly detection and response. A case study, with an investment of USD 30,000, shows potential savings of USD 8,000 annually by preventing 1–2 floods and 2–3 small machine fires. The results indicate that the system can reduce disaster-related losses, improve economic efficiency, and be scaled to other sectors and scenarios. This innovative solution strengthens disaster response in Thailand’s coastal factories and offers a scalable model for global manufacturing industries.</p> Graphical Abstract <p></p>