INSTALLING MACHINERY IN A COMPANY: A PRACTICAL STEP-BY-STEP GUIDE

Estimated reading time: 8 minutes

TL;DR

• Careful planning is the basis for the successful installation of machines and the avoidance of costly delays
• Good team coordination eliminates chaos and downtime in the assembly process
• Choosing the right supplier influences the quality and speed of implementation
• Systematic training staff ensure maximum efficiency in the use of machinery
• Regular maintenance and maintenance minimise the risk of breakdowns and costly downtime

Table of contents

- Introduction
- Determining the purpose and scope of machinery installation
- Supplier selection and workflow planning
- Preparation of the production area for assembly
- Step-by-step procedure for machine installation
- The most common problems associated with machine installation
- Service and maintenance - what next after installation?
- Integration of machine installation into repetitive production
- What mistakes to avoid? - practical tips
- Summary of key tips and recommendations
- Putting the advice into practice and next steps
- FAQ

Introduction

The installation of machinery is a key stage in the development of any production facility. Properly planned and carried out, the process avoids costly downtime, reduces the risk of breakdowns and improves work efficiency. Increasingly, companies are choosing specialist companies such as Michale Automatics to take care of the professional implementation of machines and production lines. In this article, we will take a closer look at the most important aspects of machine installation and show you how to plan it step-by-step for maximum benefit. You will also learn how to prevent the most common problems and what to pay attention to during and just after the process.

Profit from reading this article:
- You will learn why careful planning is the basis of a successful machine installation.
- You will learn practical steps to implement the devices without the risk of chaos.
- You will understand how to coordinate work between different departments to avoid downtime.
- You will find tips related to the future service and maintenance of the installed machines.

Determining the purpose and scope of machinery installation

Before you even start the installation process, you need to be clear about what you want to achieve. Precisely defining your goal will allow you to anticipate possible difficulties, develop a timetable and set a budget.

Definition of the business objective

The first step is to understand how the installation of machinery will affect the company's overall strategy. Consider whether the machines are to increase production capacity, improve product quality, automate certain manufacturing steps or perhaps enable the handling of new products. Each of these considerations determines the choice of appropriate equipment and the plan for working with the installation company.

Technical analysis and production requirements

Another important aspect is the preparation of technical specifications. Among other things, it is necessary to take into account:

• Power of installed equipment.
• Required dimensions and installation conditions.
• The level of complexity of operation and possible integration with existing lines.
• Compliance of machines with applicable standards and certifications (safety, health and safety, environmental).

If your production facility uses production management software (ERP or MES), make sure that the new machines will be able to function in this environment without additional costs or difficulties.

Supplier selection and workflow planning

Once the objective and technical requirements have been defined, it is time to select the equipment supplier and/or the company carrying out the installation of the machinery.

Criteria for supplier selection

• Experience and recommendations: A company that boasts an extensive portfolio of completed projects tends to operate more efficiently and can minimise potential errors during installation.
• Comprehensive services: It is most convenient to work with a contractor that offers the 'full package' - from design to installation to training and service. Michale Automation (also referred to as Michale Automation) offers just such an integrated approach, saving time and simplifying the communication process.
• Industry-specific fit: Not every company has experience in an area requiring high precision or meeting strict industry standards (such as the food, pharmaceutical or automotive sectors). And the lack of this expertise often leads to extended schedules and additional costs.

Installation scheduling

The next step is to create a clear action plan. To this end:

1. Prioritise and phase the installation: Which machines or production lines must be commissioned first and which second.
2. Ensure synergy with other activities: If you are renovating a hall or upgrading other areas at the same time, ensure that these events do not clash with each other.
3. Set checkpoints: Divide large tasks into smaller stages and review progress once completed.

When creating a schedule, do not forget to have a time reserve. Unforeseen events, such as delivery delays or the need to buy additional components, can complicate the installation.

Preparation of the production area for assembly

Insufficient infrastructure or a lack of adequate hall preparation can immobilise a project for weeks.

Analysis of site conditions

Before you order a new machine, check carefully that the target space is available:

• Mains parameters in line with equipment requirements.
• Adequate ventilation and air conditioning (especially important if the machines generate a lot of heat).
• Reinforced floors or foundations for heavy equipment.
• Enough space to transport and manoeuvre machinery.

If part of your operations will be automated or robotised, it is worth considering whether you plan to add more elements in the future. Companies such as Michale Automation also offer to implement line and station robotisation as part of the same project or in successive phases, so factoring in possible expansion can save you the trouble in a few years' time.

Coordination of internal departments

Prepare employees and assign them roles within the machinery installation project. Employees from the maintenance department should be ready to assist with the configuration of the equipment, and health and safety specialists should be ready to verify safety conditions. The cooperation of the purchasing department and logistics is essential to ensure a smooth supply of parts and avoid downtime.

Step-by-step procedure for machine installation

Once you have the equipment selected and a plan in place, it's time for the actual installation activities.

1. delivery and unloading of machines

• Check that the outlet to the unloading area is clear and safe.
• Ensure that each component is included and that there is no transport damage.
• Important: Report any irregularities right away to avoid problems with complaints.

2. Pre-assembly and configuration in the hall

• The assembly team, often on behalf of the equipment manufacturer, assembles the main components.
• The correctness of the electrical, pneumatic and mechanical connections is checked.
• Initial offline (or pilot) tests are carried out to ensure that everything is working correctly and that there are no unplanned vibrations or leaks.

3. integration into existing systems

- After the initial set-up, the machine is then connected to the plant infrastructure and, if necessary, to existing lines.
- At this stage, issues may arise that require additional control programmes, sensors or even upgrading a section of the line.
- If you wish to implement more advanced automation solutions, it is worth consulting companies with experience in robotic workstations. From there, it is not a long way to further automation, an exemplary case of which is presented at robotisation.

4. running tests and calibration of machines

• Once the machines have been connected and the initial integration is complete, it is time for a trial run in a production environment.
• As part of the movement tests, the required parameters (temperature, speed, pressure) are set.
• The quality of the resulting products or operations carried out is checked. If necessary, calibration is carried out.

5. employee training

• Even the best line or machine won't work if staff don't know how to work it properly.
• Schedule job training at a stage when the machine is already in operation, but before full production starts.
• Take into account the different levels of operator sophistication - operators, maintenance services and even the technology department should be familiar with separate aspects of equipment administration.

The most common problems associated with machine installation

Despite good planning, challenges sometimes arise that are worth taking into account in advance in order to prevent them in time.

Downtime and underestimation of time

• Sometimes an installation project has been planned optimistically. Then, with every unforeseen situation - delayed delivery, transport failure - the whole schedule slips.
• Solution: Include as realistic deadlines as possible in the plan and add time reserves to key milestones.

Miscommunication between teams

• If the engineering department does not liaise with the health and safety department, it may be that the installed equipment does not meet the company's safety guidelines and needs to be reconfigured.
• Solution: Organise project status meetings with representatives from all relevant departments (technical, health and safety, purchasing, logistics, etc.).

Deficiencies in infrastructure or resources

• It may be that the necessary compressed air system is missing and workers do not have access to the right tools.
• Solution: Prior analysis, a thorough review of available resources and ongoing control of the 'to-do' list.

Service and maintenance - what next after installation?

Once the installation is complete, it is crucial to keep the machinery running. Neglecting regular maintenance and repairs can destabilise even the best-designed production line.

Periodic reviews and preventive decomposition

• Routine maintenance allows early detection of signs of performance degradation or wear and tear of vital components.
• Large companies usually implement cyclical inspection plans (e.g. quarterly or every six months), but smaller establishments can also learn from these practices.

Warranty and post-warranty service

It is worth signing a service contract with the company that installed the equipment. Such a contract often includes a rapid response from service technicians, access to spare parts and regular software updates (if the machine has them). Michale Automatika has the appropriate service facilities - this ensures that service and maintenance of the workstations runs smoothly and does not cause prolonged downtime. Detailed information can be found at servicing and maintenance of stations.

Integration of machine installation into repetitive production

If your company has largely repetitive production processes, the machines installed should be optimally designed for continuous, reliable operation. In such cases, robotisation technologies may prove useful in the area of tasks that do not require daily reprogramming of the line.

This solution need not only apply to huge factories. Also smaller companies can significantly reduce labour costs and improve quality if they implement automation or robotisation of selected stages. Examples of similar implementations can be found at robotisation of repetitive production.

What mistakes to avoid? - practical tips

• Inadequate staff training: Even top-of-the-range machines can be ineffective if operators do not know how to use them to their full potential.
• No back-up plan: In emergency situations (e.g. an unforeseen power cut), it is useful to have procedures in place to help minimise the negative effects.
• Inadequate safety rules: Machines generate high powers and speeds. Disregarding health and safety regulations is not only a matter of financial penalties, but also a real health risk for workers.
• Omission of long-term analyses: Installing machinery is an expensive investment. When making your choices, take into account not only the purchase price, but also the prospect of several years of use and possible expansion of the line.

Summary of key tips and recommendations

The installation of machinery is a multi-stage process in which success depends mainly on expert planning and smooth execution. In terms of the most important guidelines, it is worth bearing in mind:

• Clearly defined business objectives: Determine what specifically you want to achieve (increased production, improved quality, technological flexibility).
• Precise technical requirements: Identify all areas of integration - power grid, space dimensions, management software, health and safety conditions.
• Precise schedule: Plan the assembly stages, add time reserves and hold regular status meetings.
• Infrastructural preparation of the hall: Take care of access to energy, ventilation, compressed air and proper transport of machinery inside the plant.
• Division of responsibilities: Designate specific contacts for health and safety, purchasing, installation and servicing.
• Efficient communication: Collaboration between machine managers-maintenance department-BHP-logistics prevents errors and downtime.
• Regular servicing and maintenance: After installation and commissioning, ensure the long-term reliability of the machines through regular maintenance and repairs.

If you are looking for comprehensive support in the area of industrial automation and machine installation in your company, take a look at Michale Automation website.

Putting the advice into practice and next steps

Finally, some recommendations on what you can do right now to make the most of the knowledge you have gained and prepare for the installation of machines in your company:

1. Draw up a checklist of key resources and skills at your site. Include both technical and human resource requirements (e.g. health and safety specialists or electricians).
2. Discuss the machine installation project with the team and present the business objectives. This will keep all employees motivated to work together to achieve a positive outcome.
3. Consider linking machine installation to further process robotisation if your company needs increased productivity, repeatable quality or reduced labour costs.
4. Contact an installation partner who can provide support from the consultation phase to after-sales support. Sometimes it is better to rely on one specialist company (e.g. Michale Automation) to avoid communication problems between different subcontractors.

The installation of machinery is an investment in the growth and competitiveness of a company. Preparing the hall, selecting the right equipment, planning the work schedule and carrying out tests are just some of the elements that guarantee the success of a project. It is worth taking care of comprehensive support - from consultancy, through machine design and installation, to staff training and post-implementation service.

If you are looking for reliable information on machine installation and maintenance services, we recommend visiting Michale Automation website and consider collaborating on similar projects. This will give you the confidence that your production line will be implemented according to best practice and that any problems will be detected at the earliest possible stage.

We also encourage you to read additional material related to the service and maintenance of workstations and installation machinery for repetitive processes. Share this article with your colleagues and industry peers - may the machine installation go just as smoothly for you and bring long-term benefits to your production operations.

We wish you the best of luck with your machine installation project and invite you to leave a comment or contact the experts at Michale Automation. Every step taken according to plan and the best industry standards brings you closer to a stable and efficient production facility.

FAQ

How long does it take to install machinery in a company?
The installation time depends on the size of the project, the specifics of the machines and the availability of the relevant resources. This can range from a few weeks to even several months for more complex implementations.

Does the installation of the machines require stopping all production?
Not always. Many companies install in stages, so that part of the line can operate normally and only specific areas are shut down for installation and testing.

How to keep workers safe during installation?
A detailed risk assessment should be carried out and collective and individual protection measures should be applied. It is important to involve the health and safety services already at the planning stage and to carry out regular inspections.

Can the production line be expanded with additional machines in the future?
Yes, if it has been properly designed. It is advisable to plan space and resources for possible expansion or robotisation at the installation stage.