Assembly of machinery in a manufacturing company - how to carry it out step by step

Estimated reading time: approx. 12 minutes

TL;DR:

• Proper planning and analysis is the foundation of efficient machine assembly.
• Site preparation includes delivery, unloading and checking the stability of the substrate.
• Mechanical assembly, electrical and pneumatic installations are carried out in stages.
• Initial commissioning and safety testing is the key to correct calibration.
• Staff training ensures the effective and safe use of new equipment.

Table of contents

- Introduction
- Why is the assembly of machinery crucial?
- Step 1: Planning and analysis
- Step 2: Preparing the stand
- Step 3: Mounting proper
- Step 4: Tests and calibration
- Step 5: Staff training and operation
- The most common challenges and how to overcome them
- Machine assembly costs - what to look out for?
- Is it worth carrying out the installation yourself?
- Additional steps towards automation
- Summary - key recommendations
- Summary
- FAQ

Introduction

Machine assembly plays a key role in the start-up of a new production line and the replacement of equipment with more efficient and modern solutions. Today's companies - both large and smaller - rely on efficiency, repeatable quality and safety. Therefore, the correct installation of machinery contributes not only to increasing production efficiency, but also to reducing faults and downtime, which can generate high costs. In this article, we will show you how to carry out the entire process step by step, what to pay special attention to and what mistakes to avoid. We invite you to read on, especially if you are interested in what measures to implement so that the fitters and the entire crew complete the installation of the new equipment quickly and safely.

At Michale Automation, we deal with machine implementation and complex industrial automation projects. If you are looking for guidance on how to go through the machine assembly process from the planning stage to final testing and training, you are in the right place.

Why is the assembly of machinery crucial?

The correct assembly of machinery affects three fundamental aspects of a business:

• Product quality: A well-installed machine runs steadily, which translates into repeatability and higher quality products.
• Employee safety: Installation errors can cause failures resulting in accidents. Maintaining installation procedures reduces the risk of damage to equipment and dangerous situations in the workplace.
• Cost-effectiveness: The faster and more correctly the machine is installed, the shorter the downtime and the lower the operating costs. In addition, the machine operates at the recommended capacity, which translates into a better bottom line.

Because of these benefits, it is worth ensuring that the installation work is carried out correctly - from the selection and preparation of equipment through to final testing.

Step 1: Planning and analysis

Definition of production requirements

Every project should start with a thorough analysis of the needs and expectations of the new machine or process line. It will be different to assemble a simple hydraulic press and a powerful assembly line for automated production. It is therefore crucial to gather information on:

• Target production volumes and possible future volume changes.
• Handled materials and operating parameters (e.g. temperature, humidity).
• Industry requirements and safety standards (e.g. in the food, pharmaceutical or automotive industries).

At this stage, it is a good idea to consider the integration of machines with other systems, if only in the context of planned robotisation. We are also an official distributor of SIASUN robots, so if you plan to automate part of your processes in the future, make sure your new machine will be compatible with industrial robots and other elements of your production line.

Site analysis

Another important step is to verify the premises conditions. The following should be taken into account:

• Availability of electricity, water, compressed air and other utilities needed to operate the machine.
• Dimensions of the working area (is the room large enough for the machine and operators?).
• Does the space meet health and safety requirements and provide safe passageways, operational and evacuation access?
• Planning of possible modifications to the hall space (e.g. floor reinforcement, separation of work zones).

Timetable and responsibilities

The more complex the project, the greater the need for clear separation of tasks. Determine:

• Machine delivery date.
• Who is responsible for transporting and lifting the heavy items (it is recommended to hire a specialist team that is experienced in assembling heavy machinery).
• The order of work of the various teams (e.g. electricians, plumbers, mechanical fitters).
• Who is responsible for final testing, safety and technical acceptance.

Careful planning reduces the risk of delays and costly downtime.

Step 2: Preparing the stand

Delivery and unloading of the machine

The planning stage is followed by the delivery of the equipment to the plant - an operation that can be quite a logistical challenge. Large structures often require specialised cranes or heavy-duty forklifts. It is important that the equipment is unloaded in accordance with the manufacturer's guidelines and in a way that ensures the full safety of the operators.

Some companies choose to have their machinery transported and assembled by external operators who specialise in industrial relocation. This is a sensible solution if you do not have the resources in-house or want to minimise the risk of damage during transport.

Reinforcing the ground and ensuring stability

It is not always sufficient to place the machine on the existing floor. High dynamic loads can lead to cracks in the substrate during operation. Therefore, even before installation, it is important to assess:

• Can the floor withstand the maximum load generated by the machine?
• Is a foundation or expansion joint required?
• Will there be vibration isolators to reduce machine vibration?

Taking these factors into account from the outset prevents problems - vibrations, damage and even incorrect quality measurements.

Step 3: Mounting proper

Mechanical assembly

The first stage is usually the assembly of the structure, i.e. connecting the individual segments of the machine and checking that all components meet the manufacturer's specifications. The fitters check that the components have not been damaged during transport and that they fit together as planned.

Even if the machine arrives in a partially assembled state, there are always issues of fit and possible adjustments. Once the mechanical assembly is complete, it usually moves on to checking the parallelism or perpendicularity of the surfaces, as well as fitting safety devices and guards to protect the operators.

Electrical and pneumatic installations

Once the machine has been mechanically assembled, it is time to connect it to the media useful for operation. In many machines, the key points are:

• Electrical wiring (connection of motors, sensors, controllers and operator panels).
• Pneumatic system (if the unit uses compressed air).
• Sometimes plumbing or refrigeration, depending on the specific sector (e.g. food).

It is worth remembering to label the cables properly and keep the control cabinets tidy so that any failures can be diagnosed more easily in the future. At this stage, you can also consider implementing IIoT (Industrial Internet of Things) sensors, which allow you to monitor machine operation in real time and collect production data.

Integration with control and monitoring systems

In many companies, the installation of machines is not limited to connecting the power supply - it is a growing standard to connect the machine to higher layers of production systems, such as MES/ERP systems. In this way, productivity, material consumption or downtime can be monitored. Integration includes, for example:

• Operator panel and PLC configuration.
• Connecting to the company network to exchange data with the cloud or other company departments.
• Installation of software for monitoring and reporting key indicators (e.g. OEE).

This adds a digital dimension to the assembly process and the company is better prepared for the eventual expansion of the line with robotic solutions.

Step 4: Tests and calibration

Initial start-up and safety test

Once assembly is complete, it is time for the 'moment of truth'. The first start-up should take place in the presence of personnel who understand the specifics of the machine in question, often also with the support of the manufacturer's service. During commissioning, operating parameters, vibrations, temperatures or pressures are checked - any alarms need to be evaluated immediately and corrected if necessary.

Special attention is paid to operator safety. It checks:

• That all guards and safety devices have been properly fitted.
• Whether the emergency shutdown system (so-called safety mushrooms) is working.
• Whether the key role of elements (e.g. light barriers, curtains) detects people in the danger zone.

Calibration and adjustment of parameters

In a lot of machines, calibration is necessary, for example:

• Work table levelling and guide alignment.
• Configuration of measurement sensors and control systems (e.g. PID in drive systems).
• Matching pressure values in pneumatic and hydraulic systems.

Accurate machine alignment is extremely important in industries where precision counts, such as metalworking or the production of components for the pharmaceutical industry. When stable results are obtained in subsequent runs, the assembly can be considered to have passed the initial tests successfully.

Step 5: Staff training and operation

Transfer of knowledge to operators

Even the most advanced machine will not produce the desired results if the operators do not know how to use it. Therefore, the final touch of professional installation is detailed training. This should include:

• Discussion of start-up, shut-down and reset procedures.
• Recognition and response to basic alarms and error reports.
• Principles of safe maintenance.

At Michale Automation, we always recommend that training is attended not only by the maintenance department, but also by the process engineers and selected production line operators. This ensures that the whole team gains a consistent knowledge and knows who to turn to when problems arise.

Regular maintenance and service

Installation is only the beginning of a long operational journey. To maintain performance and extend the life of your unit, remember to schedule regular inspection and maintenance. If you need support in this area, we invite you to learn more about our service and maintenance services:
Service and maintenance jobs at Michale Automation

Regular maintenance prevents costly breakdowns and keeps performance at its highest level. Many manufacturers make the maintenance of their warranty contingent on performing scheduled inspections, so it is worth being diligent about this part of the process.

The most common challenges and how to overcome them

Imprecisely described project requirements

One of the most common mistakes is underestimating the technical requirements or incompletely describing the operating conditions. This results in changes only being made during installation. To avoid problems, it is always advisable to make detailed specifications while still preparing the project.

Insufficient staff preparation

Sometimes a company invests in a state-of-the-art production line, but forgets to properly train key people. The result is downtime as soon as a minor fault occurs. This is why it is so important to involve the maintenance team and operators from the very first tests.

Prolonged installation work

Lack of a schedule or a poorly coordinated sequence of work (e.g. shifting responsibility between electricians and mechanical fitters) are common reasons for delays. This is why it is so important to assign responsibility and verify progress on an ongoing basis.

Machine assembly costs - what to look out for?

The cost of complex installation depends mainly on:

• Size and complexity of the device.
• Access to specialised equipment (cranes, forklifts, precision fitting tools).
• Staff numbers and experience.
• Possible modifications to the hall (foundations, reinforcement).
• The need for additional installations (e.g. compressed air, refrigeration).

In the long term, it is also worth planning to invest in robotisation and automated workstations, which can further improve production efficiency and reduce labour costs. If you are interested in robotisation, check out the offer
robotics at Michal Automation.

Is it worth carrying out the installation yourself?

For smaller or simpler machines, in-house resources are often sufficient, especially if you employ experienced mechanics and electricians. However, if the assembly involves very advanced solutions (e.g. robotic lines), it is worth engaging professionals and the manufacturer's authorised service.

The assistance of a specialist team is particularly advisable if you want to integrate the new machine precisely with the rest of the production process - for example, with the existing control automation. A well-maintained line, configured comprehensively, will run stably for a long time.

Additional steps towards automation

A well-conducted machine assembly facilitates the implementation of further automation steps, such as the installation of industrial robots or cobots. If you are planning to expand your machine park in the future with more automated workstations or to combine it with vision and monitoring systems, take care:

• Placement of an appropriate number of sensors and communication interfaces.
• Plan for reserve hall spaces for further modules.
• Implement controllers that will provide scalability (such as PLC systems with extended capabilities).

For more inspiration, see our offer on
robotisation of weldingif you are active in the steel processing industry, and
robotisation services in various processes.

Summary - key recommendations

- Always start with a detailed analysis of your needs and requirements - this is the foundation of the entire machine assembly project.
- Prepare the installation area (reinforce the floor, ensure access to necessary utilities) to avoid surprises.
- Use a breakdown of the assembly into stages: mechanical installation, electrical and pneumatic connections, testing and training.
- Don't forget safety and emergency systems.
- Once the installation is complete, carry out operator training in order to exploit the full potential of the equipment.
- Nurture the machine through regular maintenance and service to maintain its high reliability and prolong its life.

Summary

Properly executed machine assembly is an investment in the future of your plant. With the right strategy, a competent team of fitters and a well-considered timetable, the machine quickly starts to function as expected, generating real profits. At Michale Automation, we know the importance of support at every stage of implementation - from planning and preparation to final testing and staff training. As a company specialising in mechanical engineering, industrial automation and the implementation of robotic workstations, we provide full installation support, as well as assistance with subsequent operation.

We encourage you to browse our robotisation services and to visit the Services, where you will find more information on how to develop your business towards automated production. If you have additional questions or would like to consult on your machine assembly project, please feel free to contact our team.

We also encourage you to follow our blog, comment and share your experiences. If you're keen to optimise your production processes, also check out the articles on automation and robotics - you'll find plenty of inspiration and practical tips there.

We wish you success in the installation of your machines, satisfaction with your new investments and a quick return on your investment! Your plant will gain greater efficiency, higher quality and an additional competitive edge in the market. Good luck!

FAQ

What are the key benefits of properly executed machine assembly?
You gain higher production quality, worker safety and efficient use of resources. A correctly installed machine reduces downtime and operating costs.

Is it worth using a professional installation team?
Yes, especially with advanced or large lines. A professional team will ensure proper site preparation, installation and testing, reducing the risk of faults and delays.

How long might it take to install a new machine?
Time depends on the size and complexity of the machine. The assembly of a simple machine may take a few days, while extensive production lines may require several weeks or even months.

What is key when you first start the machine?
Safety verification (check of guards, emergency stops) and thorough functional test of all components. Any irregularities must be corrected immediately.

What is the importance of post-assembly operator training?
Trained operators increase work efficiency and safety. They are able to operate the machine as directed and are quicker to respond to minor faults.