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Industrial Line Installation: Key Steps to Avoid Surprises and Overruns

Before installing a line

The technical manager must consider various aspects and preparations to ensure a flawless installation. Recommended preparations include:

 

  • Technical specifications : Prepare a document containing the technical specifications of the products, the production volume, the rate, the different line reception tests.

  • FAT : Retrieve documents containing the results of tests carried out at the supplier's factory.

  • Pathway : Prepare and verify the route between the equipment unloading area and the installation zone.

  • Connections : Obtain energy connection diagrams.

  • Area Plans : Get detailed plans of the area where the line will be installed, including dimensions, access points.

  • Detailed Budget : Prepare a detailed budget that includes initial investment, operating and maintenance costs.

  • Permits and Authorization : Prepare the necessary permits and authorization for suppliers

  • Schedule : Establish a project monitoring plan with deadlines, milestones and responsibilities to ensure ensure adherence to the timeline.

1. Unloading and transport

When installing new machinery, the first step is to manage the unloading and transport of the equipment to the installation site with precision.

 

Upon arrival, the machines must be unloaded carefully to avoid any damage. This step requires the use of lifting equipment suitable for the size and weight of the machines. It is essential to select certified handling machines (cranes, forklifts, winches) to handle the expected loads. Incorrect equipment selection or handling can pose risks to both personnel and machines.

Lifting techniques must be carefully followed for each machine type, ensuring correct angles, movement speeds, and precautions to avoid load swaying. Once suspended, a machine can become unstable and dangerous, so operators must be qualified and trained in safety protocols specific to each piece of equipment.

After unloading, the machines are transported to their final installation location. This move, sometimes complex within the confined spaces of an industrial site, requires a planned, obstacle-free path. Equipment such as handling skates, overhead cranes, or temporary conveyors can be used to move the machines without risk.

Before the final installation, a thorough inspection of the equipment is necessary to detect any transport-related damages (cracked components, scratches on sensitive surfaces, missing elements). Identifying these potential issues early allows corrective action before commissioning, preventing early failures or accidents due to damaged parts.

2. Installation plan and layout marking

Implementing a precise layout plan and marking the floor for machine placement is a crucial step to ensure a smooth installation without surprises. This not only saves time during installation but also verifies the real feasibility of the factory layout, anticipating potential adjustments.

Floor marking involves outlining the equipment’s exact placement within the facility using paint or marking tape. This allows teams to quickly visualize the final positioning of each machine and verify if the layout matches the actual space dimensions and constraints. Good floor marking improves coordination during installation, guiding handling teams in their movements and tasks.

Discrepancies between the initial plan and actual site conditions—such as unforeseen obstacles or machine interference—can be identified during this phase. Recognizing these issues early allows for necessary adjustments, avoiding last-minute changes and minimizing additional costs.

3. Assembly and alignment

The assembly and alignment of industrial equipment are critical steps in the installation process. They require high precision to ensure that each component is assembled according to specific tolerances, thus guaranteeing equipment quality and longevity. Adhering to this plan avoids errors that could affect overall equipment performance.

Alignment is vital to ensure the equipment operates smoothly, preventing vibrations, friction, or misalignments that could cause premature wear. For installations requiring extreme precision, such as alignment to a hundredth of a millimeter, specialized tools like laser alignment systems are used. These systems offer unmatched accuracy in verifying and adjusting alignment, ensuring that each component is positioned correctly.

In production processes demanding extreme precision, such as engine manufacturing or pharmaceutical product packaging, perfect alignment is essential. Metrology plays a key role in verifying machine alignment and leveling. Precision instruments like calipers, dial indicators, or laser measurement devices help installers ensure that each machine is perfectly aligned and calibrated to meet specific operational requirements.

Assemble the industrial equipment according to the manufacturer’s instructions. Precise alignment is crucial for maintaining consistent quality. If your process requires installation precision down to the hundredth of a millimeter, laser alignment tools can be used to guarantee this level of accuracy.

4. Connection and integration

Once the equipment is assembled and aligned, the connection and integration phase is crucial to ensure that all units work together smoothly and safely. This step includes connecting to power sources, hydraulic systems, pneumatic systems, and any other necessary components, following technical specifications and established safety protocols.

One of the first steps in integration is connecting the equipment to power sources, whether electrical, hydraulic, pneumatic, or others. These connections must be made carefully to avoid risks such as power surges or short circuits. Using high-quality components that are compatible with the equipment's electrical requirements is essential for ensuring stable and continuous power supply.

For machines utilizing hydraulic or pneumatic systems, special attention is needed to ensure that every pipe, valve, and connector is installed correctly. This includes checking pressures and flow rates to ensure that the machines operate efficiently without risk of leakage or overheating. Configuring and adjusting these systems requires specific expertise to prevent malfunctions that could impact the entire production process.

Once power sources and fluid systems are connected, each wiring must be checked to ensure compliance with the provided electrical schematics. Cables must be securely fastened and properly insulated to prevent short circuits or electrical shocks. Rigorous inspection is essential to avoid accidental disconnections, which could lead to production downtime, equipment damage, or even accidents.

This connection phase also includes verifying that all connections meet current safety standards, such as those related to industrial installations (e.g., NF, CE, IEC standards). Protection against overloads, grounding, and electromagnetic compatibility requirements are considered to ensure the installation is secure and operational without compromising safety regulations.

5. Safety testing

Before commissioning a new industrial machine, it is essential to conduct thorough safety tests to ensure compliance with current standards and the safety of operators. These safety tests are designed to check that all protection and safety devices are correctly installed and functioning as intended. Adhering to international regulations, such as ISO and CE standards, is a priority to avoid any risk of accidents during equipment operation.

One of the crucial elements of this testing phase is the emergency stop button, which allows the immediate interruption of the machine's operation in case of a problem. The tests include activating the emergency button to verify that the machine stops instantly and does not restart without manual reset. It is also important to ensure that this button is accessible from all sides of the machine, allowing any operator to quickly access it, even in emergencies.

Checking safety doors and other removable protections is also essential. These components prevent access to dangerous areas during machine operation. The tests verify that the machine automatically stops when a door is opened, and that protections remain locked while the machine is running. Finally, to enhance safety, the tests include cutting off power (electrical, hydraulic, pneumatic) via a central system that leaves the machine inoperative until a manual restart. These cut-off devices must be visible, well-positioned, and easily accessible for rapid intervention if necessary.

6. Testing and calibration

In-depth testing of machine functions is essential to ensure that all moving parts operate correctly. This includes precise calibration of sensors, controllers, and other instruments to ensure reliable measurements and optimal performance. Once these tests are validated, the machine proceeds to ramp-up, with camera and sensor calibration. During this phase, the supplier may request specific materials, such as cartons, bottles, or bags, to adjust and fine-tune the equipment.

After all components are assembled, functional integration tests are performed to verify synchronization between each machine and the others. These tests include validating performance parameters, checking connection points, and conducting load tests to evaluate the robustness of all connections. A technical coordinator or commissioning manager supervises this phase to quickly identify and resolve any issues, ensuring smooth system integration.

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7. Communication testing

Communication testing between the new production line and the factory's management systems is a critical step to ensure smooth and continuous information flow. These tests verify that each machine exchanges data correctly with other equipment and centralized management systems, such as SCADA or ERP. Effective communication allows real-time monitoring of production operations, facilitating task coordination and dynamic process adjustments.

To integrate the production line into the factory network, communication tests between the line and the management system are essential. This includes checking network connections, protocol compatibility (e.g., Modbus, OPC UA, Ethernet/IP), and real-time data synchronization. Information such as production rates, downtime, and alerts must be transmitted instantly to allow quick decision-making. Additionally, it is crucial to ensure that all notifications and alerts from the line are accessible to supervisors, enabling rapid responses to any issues.

The communication between machines, often organized via an "exchange table," is another key aspect of these tests. The machines must be able to share signals and control data to synchronize their actions and maintain continuous flow. This includes exchanging data on quality and production parameters (weight, temperature, speed) and automatically adjusting speed to maintain the overall production rhythm. Effective coordination between machines prevents interruptions, optimizes efficiency, and ensures consistent quality.

Finally, the security of the exchanged data must be validated to protect production information from intrusion. Tests must include security protocol checks and data reliability. By simulating communication loss scenarios, it ensures that machines react securely and are capable of resuming synchronized operations once communication is restored. These tests guarantee a successful commissioning and a stable, efficient industrial production process.

8. Closing the punch list from FAT

Closing the punch list resulting from the FAT (Factory Acceptance Test) is a crucial step in the installation of an industrial line. This phase involves ensuring that all issues raised during tests at the supplier’s facility are addressed before the equipment is commissioned on-site. The FAT verifies that the equipment meets the expected specifications and standards by identifying any deviations or necessary adjustments to guarantee optimal operation.

Initially, it is important to review the open points from the FAT. These punch list items or non-conformities may include technical issues (mechanical, electrical, or automation-related), performance discrepancies compared to the predefined criteria, or safety and quality aspects that need correction. For example, if equipment shows safety failures or insufficient performance, corrective actions must be taken to ensure it meets operational requirements.

Once the checks and corrections are completed, each punch list item should be closed in the tracking system. This involves updating the status of each item (marked as "resolved" or "closed") and archiving evidence of resolution, such as photos, test reports, or written validations. This final step ensures traceability of corrective actions and assures the buyer that the equipment is ready for installation and safe operation, meeting quality, performance, and reliability standards.

9. Technical training of personnel

After the commissioning and startup of the line, technical training of personnel becomes a critical step to ensure safe and effective use and maintenance of the equipment. This training is essential not only to ensure productivity but also to guarantee operator safety and the durability of the installation. Adequate training covers several key aspects, including understanding safety instructions and usage practices.

For the safe use of the line, operators must be trained in safety rules, best practices, and emergency stop procedures. This part of the training includes practical demonstrations on how to use the controls, the machine interface, and incident management. Mastery of these elements reduces accident risks and contributes to optimal equipment use, thereby minimizing production interruptions caused by improper handling.

Finally, for effective maintenance, technicians receive training to conduct routine checks, inspections, and preventive maintenance. They also learn diagnostic and repair methods to respond quickly in case of failure. The supplier may offer training tailored to different skill levels, with support materials like manuals and technical sheets. Through this program, personnel acquire in-depth skills, which reduces the risk of errors, optimizes line performance, and enhances overall site safety.

10. SAT Execution

The SAT (Site Acceptance Test) is a crucial step in the validation process of industrial equipment, aimed at confirming that installations meet the buyer's requirements under real production conditions. This phase ensures that machines or production lines operate according to the expected performance criteria before being integrated into operation. The test includes several key elements, such as defining a detailed test plan developed in collaboration with the supplier, which determines the acceptance criteria and performance checks, such as operational yield, production speed, cycle times, and rejection rates.

The execution phase of the SAT occurs under real conditions and strictly follows the test plan. Each performance indicator is measured and analyzed to produce a reliable and quantified report on machine performance. The results are then compared to the goals set to validate the equipment's compliance. If all criteria are met, the SAT is considered successful, and the machine can be officially integrated into production. If not, the SAT identifies non-conformities that require careful management, including detailed documentation of the issues and a corrective action plan to be implemented by the supplier.

In the case of non-compliance, the supplier makes adjustments and organizes a new round of tests to ensure the expected performance is achieved. This cycle repeats until the SAT is fully satisfactory. A complete SAT report is then prepared, including performance data, corrected non-conformities, and final test results. This final report is critical not only for validating the installation but also as a reference for future maintenance and equipment optimization. A successful SAT guarantees that the machine is operational, reliable, and meets quality standards, thus fulfilling the buyer's expectations.

11. Acceptance report

The signing of the acceptance report is a key step during the commissioning of a production line or industrial machine, as it constitutes the final acceptance of the equipment and marks the beginning of the warranty period. This document certifies that the equipment meets the performance criteria and agreed specifications, based on the results of the Site Acceptance Test (SAT). It includes a description of expected performance, any non-conformities identified, corrections made, and specific usage conditions. Signing this document officially confirms that the equipment is ready to enter production and should be considered carefully to avoid future oversights.

Before signing, it is crucial to assess any performance discrepancies. If these discrepancies could significantly impact production, it is best to delay signing and schedule a new SAT, giving the supplier the opportunity to resolve the issues. This precaution protects the buyer's interests by ensuring that the equipment is fully operational and compliant with requirements before officially accepting it. By ensuring that the specifications are met, the buyer minimizes unforeseen costs during operation and maintains reliable traceability of tests and verifications, which can be essential in case of disputes during the warranty period.

12. Delivery of documentation

A complete technical documentation package for an industrial machine includes several key elements that facilitate its handling and maintenance. It includes a user manual to guide operators on controls, settings, and safety instructions, as well as a maintenance manual detailing procedures for part replacement and routine maintenance to prevent breakdowns. A list of spare parts is also provided, along with references for quickly ordering necessary components, reducing downtime. The CE certification attests to compliance with European safety standards, and a format change manual allows for easy adaptation of the machine to various types of production. This comprehensive documentation ensures a direct link between the manufacturer and the maintenance teams, allowing them to intervene efficiently, optimize repairs, and maintain the machine in good working condition.

Conclusion

By following these key steps of preparation and implementation, you not only guarantee a well-executed installation that meets standards but also ensure rapid and optimal production startup. A technical coordinator serves as the liaison between the various stakeholders, anticipates potential obstacles, and oversees tests and adjustments to ensure each component works in perfect harmony.

Good to know

Communication and monitoring

 

It is essential to work closely with the supplier or manufacturer of the systems throughout the process, as they are the experts who can guide us at every step.

Coordination with staff : Coordinate the installation with the plant personnel to minimize the impact on existing operations.

Communication : The installer must communicate effectively to ensure that the installation or industrial transfer project progresses efficiently. Managing the coexistence of multiple companies and relaying information to the client are critical to ensuring the compliance of the equipment installation.

Maintaining continuous and effective communication with suppliers throughout the process is absolutely crucial.

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