Commissioning a production line - a comprehensive step-by-step guide

Estimated reading time: 12 minutes

TL;DR

• The launch of a production line affects the productivity and competitiveness of the company
• Careful planning stage and analysis reduces the risk of costly downtime
• Automation and robotisation can significantly reduce labour costs and improve quality
• Dry-run tests and operator training prior to final launch are essential
• Regular maintenance and service guarantee the long-term stability of the line

Table of contents

• Introduction
• Significance of the production line launch for the company
• Pre-implementation planning and analysis
• Steps in the implementation and commissioning of the production line
• Support, service and maintenance
• Key challenges and practical guidance
• Examples of the use of automation and robotics
• Performance indicators
• The most common mistakes and how to avoid them
• Summary - step by step towards success
• FAQ

Introduction

The commissioning of a production line is a key stage in the development of any industrial plant. A properly designed and implemented line influences the performance, cost reduction and company competitiveness. In the age of automation and continuous technological advances, more and more companies are choosing not only to streamline their existing solutions, but also to make completely new investments that increase production potential.

This article explains why it is so important to take a professional approach to the launch of a production line and how to implement it in your company step by step. You will also learn what to look out for to avoid unnecessary downtime and what mistakes to beware of.

Operating in the field of mechanical engineering, industrial automation and robotic workstation implementations, the Michale Automatics team is often confronted with questions regarding the organisation, costs and planning of installation processes. Our practice shows that a well-prepared plan and the proper integration of modern solutions - including robotisation - play a key role in the success of the overall project.

The following material provides an in-depth guide to planning and implementing a new production line or reorganising an existing one so that it delivers tangible benefits. We also cover system integration and industrial automation, and highlight practical solutions that work well in day-to-day operations.

Significance of the production line launch for the company

The commissioning of a production line is not only a complex technical process, but also an important step in business development. A properly designed and implemented line influences:

• Increasing productivity: Allows a higher volume of orders to be handled and reduces downtime.
• Minimising errors: Modern technology reduces production losses.
• Cost control: Automation reduces long-term labour costs and streamlines processes.
• Increasing competitiveness: It allows rapid response to market needs and increased production flexibility.

The benefits of effectively running a production line can be enormous, especially in the context of global trends and increasing quality requirements. At the same time, many important aspects need to be kept in mind - from the selection of machinery to the training of personnel.

Pre-implementation planning and analysis

A careful planning stage determines whether the investment costs will pay off in the anticipated time frame and whether the line will run smoothly.

Definition of business objectives

Before starting the project, it is important to establish what objectives the production line is intended to fulfil for the company. Is the priority to increase productivity, reduce costs, improve quality or perhaps flexibility for a variety of products? Clear requirements will help in selecting the right technology.

Selection of machinery and technology

The next step is to choose a technology solution. Depending on the industry, different equipment may prove optimal. Increasingly, companies are relying on automation and robotisation - especially where process repeatability is key. It is worth remembering that Michale Automatyka is an official distributor of SIASUN robots, which are characterised by high performance and reliability.

Budgeting and scheduling of work

The budget has a great impact on the success of the project. It is worth assuming a safety margin, as unforeseen costs can arise at any time. A detailed work schedule keeps processes running smoothly and avoids common pitfalls such as missed deadlines or a mismatch between machine delivery and storage space.

Steps in the implementation and commissioning of the production line

Once a precise plan has been established, objectives clearly defined and a budget secured, the time comes for implementation. The diagram below shows the most important stages:

Detailed design and preparation

• Analysis of the production hall layout and design of the machine set-up
• Consideration of logistical aspects, including transport of raw materials
• Preparation of technical documentation (drawings, diagrams, bills of material)

Assembly and integration of systems

• Delivery of machines and their installation at the target site
• Linking equipment into a coherent system, including connectivity between controllers and HMIs
• Implementation of control software (PLC, SCADA, MES/ERP)

Tests and initial start-up

• First "dry" tests - no production load
• Optimisation of performance parameters, temperatures, pressures, etc.
• Correction of settings in machine controls and programmes

Final implementation and certification

• Start of actual production in the presence of engineers and operators
• Certification and technical acceptance according to industry and health and safety standards
• Detailed operator training and final documentation

Support, service and maintenance

In the case of modern production lines, the post-launch period is crucial for maintaining production continuity. Regular maintenance and optimised solutions avoid failures that could stop the entire production cycle.

The role of service and maintenance cycles

All equipment has a certain lifespan and requires periodic maintenance. Therefore, the service process should be planned from the beginning. A professional company - such as Michale Automatics - offers post-installation support and a quick response to any faults. If you are interested in a comprehensive offer in this area, it is worth visiting
our website dedicated to service and maintenance of stands.

Optimisation and modernisation

Even after a professional start-up of a production line, minor changes may be necessary. The flexibility and modular design of the line allow for quick modifications, while additional sensors or robotisation increase productivity and improve OEE rates.

Key challenges and practical guidance

Launching a production line involves a number of challenges, both technical and organisational. Here are some tips to consider.

Managing change in the organisation

• Employee engagement: Good communication prevents fears and builds awareness.
• Training: New developments often require new health and safety skills and procedures.
• Communication: The ongoing flow of information is crucial - from the planning department to management.

Safety and regulatory compliance

• Safety procedures: Emergency stops, safety sensors, guards, etc.
• Documentation and warning signs: They must always be accessible and legible.
• Technical acceptance: Some industries have strict legal and hygiene requirements.

Robotisation of selected areas

Unnecessary automation: Not every process is worth fully robotising. For others, like packaging, robots bring immediate productivity gains.

Systems integration: Well-implemented robotisation works in tandem with humans to improve safety and flexibility.

We often implement
robotisation of packagingwhich eliminates errors and speeds up the preparation of goods for dispatch.

Examples of the use of automation and robotics in line commissioning

When implementing a new production line or modernising an existing one, more and more companies are investing in advanced automation. Trends in industry clearly show a growing interest in eliminating human error and speeding up processes.

Automatic quality control systems

Vision systems constantly analyse product parameters. Defects are recognised in a fraction of a second, resulting in a reduction in shortages. Operators can focus on supervision as the automated system sorts out defective components.

Works in repetitive operations

Transporting materials, packaging or stacking items on pallets are areas where robots are particularly suited. They also allow companies struggling with staff shortages to free employees from monotonous tasks and reduce staff costs.

If you are looking for equipment with a high load capacity and durability, it is worth looking at the model
SR25A from SIASUN robots, which provides performance and reliability in a wide range of applications.

Real-time data integration

Modern production lines increasingly work not only with PLC-type systems, but also with MES or ERP platforms. This allows quality indicators and energy consumption to be monitored in real time, enabling a rapid response to changes.

Performance indicators

Once the production line is up and running, efficiency should be analysed regularly to assess whether the investment is meeting the objectives and whether it needs further optimisation.

OEE (Overall Equipment Effectiveness)

One popular indicator that combines availability, performance and product quality. Allows a comprehensive assessment of line performance.

Manufacturing unit cost / ROI

Return on investment (ROI) calculations help managers and investors to understand the financial benefits. It is worth considering not only the cost of production itself, but also energy savings, reduced scrap and higher productivity.

In the context of robotisation, it is worth running simulations and using an ROI calculator, e.g. for welding robotisation:
ROI calculator.

The most common mistakes and how to avoid them

Lack of a comprehensive project

A common mistake is to start implementation without full technical documentation and a timetable. This leads to unforeseen complications and, ultimately, additional costs.

Insufficient testing before the final launch

Rushing to start up a line can result in numerous failures in the first few weeks of production. Reliable testing is an investment in a stable future.

Wrong choice of robotisation

Robotisation is a very versatile solution, but it is not always economically justifiable. It is worth conducting a detailed process analysis to avoid duplication of existing machines or unnecessary costs.

Summary - step by step towards success

Establish the aims and objectives of the project: Clarify what you want to achieve by upgrading your production line.

Make a sound analysis: Consider the whole process - from the layout of the hall to the selection of equipment.

Ensure a good design and timetable: This is the basis for successful implementation.

Bet on proven partners: The contractor's experience translates into quality and timely implementation.

Include training and service: Qualified staff and fast service are a guarantee of production continuity.

A high-quality production line is the heart of a successful business. When properly planned and commissioned, it brings tangible savings and real efficiency gains. The key to success is to look at the entire process systemically: from the business objective, through detailed design to comprehensive integration and service care.

If you would like to find out more about the comprehensive range of design and implementation of advanced solutions, we encourage you to visit
pages with a broad overview of services. And if you are interested in a broader view of industrial systems integration, check out also
robotisation in your establishment.

With many years of experience in the industrial automation sector and close cooperation with leading robot manufacturers, we know how to make the process of commissioning a line run smoothly and without unnecessary downtime. If you have additional questions about robotic welding, packaging or other aspects of implementation - please do not hesitate to contact us.

We hope the article has helped you understand how to plan and execute a production line start-up step by step. We'd love to hear your insights - leave a comment or send an enquiry. Subscribe to our newsletter to keep up to date with future articles. Good luck with your modernisation plans!

FAQ

How long does it take to implement a new production line?
Time depends on the complexity of the project and the type of industry. For simple solutions, a few weeks may be sufficient, but more complex lines require up to several months for full implementation and testing.

Can robotisation replace all workers?
Robotisation relieves people of repetitive tasks, but it does not always mean a full replacement of staff. Many employees gain new competences and supervise automated processes.

Does the investment in automation only pay off for large companies?
Today, technology has become more affordable, so even small and medium-sized businesses benefit from automation. A sound analysis of potential savings and productivity gains is key.

Is post-launch service support required?
Yes. Even the best machines and systems require regular servicing to maintain high efficiency and minimise the risk of failure. A maintenance and rapid support plan is the basis for production continuity.