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Realizations

Commissioning of the machine park

Project Specification
Area 1,200 m²
Completion time Seven weeks
Team 14 specialists (automation engineers, electricians, fitters)
Machines 18 production devices
Systems PLC control, integration with MES

About the project

Project characteristics

An automotive customer needed a smooth startup of a new machine park in a German plant. What mattered was time, precision and confidence that production would take off on schedule. The new lines were to handle export orders, so every day of delay meant real losses.

Scope of work

Implementation stages

Setting up machines on the shop floor, connecting systems, assembling support structures.
Switchgear, cable routing, power systems, connecting machines to the network.
Commissioning of all equipment, calibration of systems, full acceptance testing.
Acceptance protocols, parameter measurements, safety tests.
Impart knowledge of machine operation, safety procedures and problem diagnosis.

Challenges and solutions

Design challenges and their solutions

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Short lead time

The customer could not afford line downtime. Every day of delay meant lost production.

Cooperation of multiple teams

Electricians, fitters, automation specialists. They all worked simultaneously. Communication and division of tasks were key.

Integration with existing systems

The new machines had to work with subsystems already in operation. This required additional testing and adaptation.

Stage and night works

We launched each site in stages, conducting parallel and night work so as not to block neighboring sectors.

Project Manager on site

A dedicated coordinator was on site throughout the project. He kept an eye on the schedule, responded to problems, and communicated with the client daily.

Test cycle for each machine

Each machine went through a full test cycle after commissioning. The results were reported to the customer on a regular basis.

Effect

End results

Project completed ahead of schedule

Production took off after just seven weeks. We met (and even beat) the deadline.

The lines passed the tests without any objections

All the equipment has received positive test results. The customer has gained confidence in the quality.

Workers ready to work

After the training, the client team worked independently. They knew how to operate the system and respond to basic problems.

Client commissioned another project

This is the best feedback for us. A few months later, we received an order to expand another hall.

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