You have invested a significant amount of capital into a new coil packing line. You expect it to solve production bottlenecks and boost your factory's output. But the reality of commissioning can be a nightmare. You face unexpected delays, frustrating technical glitches, and an unprepared team. Your big investment is quickly turning into a major headache, costing you more money each day. Every hour of a messy startup means missed production targets, a frustrated team, and mounting pressure from management. You start to doubt if you made the right decision, and the supplier who promised you the world is suddenly hard to reach. It’s a situation I’ve seen many times.
A smooth startup is not about luck; it is the result of a clear, disciplined process. The key to ensuring a new coil packing line gets up and running without costly delays involves five distinct stages. It starts with meticulous pre-installation planning long before the machine arrives. This is followed by a supervised and detailed mechanical and electrical installation. Next comes comprehensive training for both operators and maintenance staff. After that, you must conduct rigorous Factory and Site Acceptance Tests (FAT/SAT) to verify performance. Finally, a successful commissioning is cemented by a clear plan for post-handover support and continuous optimization.
I have been in your shoes. I’ve walked the floors of countless factories, including my own, and I know that feeling of anxiety mixed with excitement as a new piece of equipment is uncrated. I've learned that you can turn that anxiety into confidence by knowing exactly what to focus on and when. It’s about managing the process, not just waiting for it to be over. Together, let’s walk through the essential steps I’ve developed over 20 years in this industry. This is the roadmap that will make your next commissioning a predictable success.
How Critical is Pre-Installation Planning for a Successful Commissioning?
Imagine this: your brand-new packing line is scheduled to arrive tomorrow. But when the truck pulls up, you realize the factory floor isn't ready. The foundation hasn't been prepared, the required power supply isn't in place, and there is no clear path to move the heavy components into position. The supplier's engineers are on-site, ready to work, but they can't do anything. Their time is wasted, your money is being spent on their hotel rooms, and the entire project timeline is thrown into chaos before a single bolt has been tightened.
Pre-installation planning is absolutely critical for a smooth startup. It is the foundation upon which a successful project is built. This phase involves a detailed verification of the site layout against the machine drawings, confirming all utility requirements like power, compressed air, and data ports. It also includes preparing the concrete foundation to the correct specifications and coordinating the logistics for the machine's safe arrival and placement. Getting this groundwork right prevents the most common and costly delays, ensuring a seamless start to the physical installation process.
In my experience, more than half of all commissioning delays are caused by poor preparation. A factory manager's job is incredibly demanding, and it's easy to overlook these details. But this is where a good supplier acts as a true partner. They should provide you with a comprehensive pre-installation checklist weeks, if not months, in advance. This isn't just a document; it's a conversation. Let’s break down what this planning really looks like.
Verifying the Foundation and Layout
A coil packing line is heavy and involves powerful, fast movements. The foundation must not only be level but also strong enough to handle the dynamic loads without cracking or shifting. I once worked with a client who installed a large wrapping machine on a standard concrete floor. Within six months, hairline cracks began to appear around the machine's base. The vibration was slowly destroying their floor. We had to shut down the line, break up the concrete, and pour a new, reinforced foundation pad. It was a costly and disruptive lesson. You must get the supplier's foundation drawings to your civil works team early. They need to check the load-bearing capacity and prepare the site correctly. The layout is just as important. Use tape or paint to mark the exact footprint of the machine on your floor. This helps everyone visualize the space, check for obstructions, and plan for operator and forklift access.
Confirming Utility Connections
Modern automated lines are hungry for power and clean compressed air. It's not enough to just have a power outlet nearby. You need to verify the exact voltage, phase, and amperage requirements. A mistake here can damage sensitive electronic components. For compressed air, the issue is often quality. Many factories have "wet" air with oil and water contaminants. This will destroy the pneumatic valves and cylinders in your new machine. You must confirm the pressure (bar/psi) and quality requirements. Often, this means installing a dedicated filter-regulator-lubricator (FRL) unit for the new line. Also, don't forget data connections. Many machines now have remote access capabilities for troubleshooting, which requires an Ethernet port.
Creating a Logistics Plan
Getting the machine from the delivery truck to its final spot is a project in itself. You need a clear plan. Will you need to hire a crane? What is the capacity of the forklifts you have on site? Are the doorways and aisles wide and high enough? I always recommend doing a "dry run" walk-through of the delivery path. This simple action can reveal forgotten obstacles like low-hanging pipes or cable trays. Coordinating with your team and the supplier’s team ensures that on delivery day, everyone knows their role, the right equipment is ready, and the machine can be moved into place safely and efficiently.
| Pre-Installation Checklist Item | Purpose | Consequence if Ignored |
|---|---|---|
| Foundation Drawing Review | Ensure floor can support the machine's static and dynamic loads. | Cracks in the floor, machine vibration, poor alignment. |
| Utility Confirmation | Match factory supply (power, air) to machine's needs. | Damaged electronics, pneumatic failures, delays. |
| Layout Marking | Visualize machine footprint, access paths, and safety zones. | Inefficient workflow, safety hazards, rework. |
| Logistics Planning | Plan how to safely move machine parts from truck to installation site. | Damage to machine or facility, safety incidents. |
| Team Briefing | Align your team and the supplier's team on the plan and schedule. | Confusion, delays, and inefficient use of resources. |
What are the Key Checkpoints During the Mechanical and Electrical Installation?
The supplier's technicians are on your factory floor, assembling the new packing line. They seem to know what they are doing, but as a manager, you have a responsibility to verify their work. You're not sure what to look for, and you don't want to get in their way. But are they following the drawings precisely? Is every component being aligned correctly? Are they taking any shortcuts?
Ignoring the details during assembly is a recipe for long-term problems. A single misaligned sensor can cause intermittent faults that are impossible to trace. A few loose bolts on a fast-moving part can lead to a catastrophic failure. An incorrectly wired electrical cabinet is a serious safety hazard and can cause chronic breakdowns. If you don't catch these issues during installation, you will be fighting the consequences for months, long after the technicians are gone. The key is to have a clear checklist and work with the installation team. By actively monitoring key mechanical and electrical checkpoints, you can ensure the machine is built right the first time.
The most important checkpoints during installation involve verifying the machine's physical setup and its electrical integrity. This includes using a precision level to confirm the machine frame is perfectly level and aligned. It means double-checking the tension of all critical bolts, chains, and belts after assembly. It requires you to personally walk through the safety system, ensuring every guard, safety switch, and emergency stop is installed and functioning correctly. Finally, before any power is turned on, a point-to-point check of the electrical wiring against the schematics must be completed.
As an engineer who has built a factory, I can tell you that the installation phase sets the machine's personality for its entire life. A machine that is assembled with care and precision will run reliably for years. A machine that is rushed will always be troublesome. You and your team must be active participants in this stage.
The Foundation of Performance: Level and Alignment
Think of the machine's frame as its skeleton. If the skeleton isn't straight, none of the limbs will move correctly. We insist that installers use a machinist's level (not a simple carpenter's level) on the precision-milled surfaces of the frame. The machine must be level to within the supplier's specified tolerance. If it's not, shims must be placed under the machine's feet before it is anchored to the floor. An unlevel machine will cause premature wear on bearings, guides, and drive components. It is the single most common cause of mechanical issues down the road. You should ask the lead technician to show you the level readings at key points on the frame.
Inside the Electrical Cabinet
The electrical cabinet is the brain of the machine. Before it's powered up, you or your electrician should do a walk-through with the supplier's technician. Open the cabinet doors. Are the wires neat and tidy, run through wire ducts? Or is it a "rat's nest" of cables? Check that every wire is labeled according to the electrical diagram. This is critical for future troubleshooting. Ask them to show you the main ground connection. A poor ground is a major safety risk. All high-voltage and low-voltage wiring should be physically separated to prevent electrical noise that can interfere with sensors and controls.
A Deep Dive into Safety Systems
Safety is not just about pushing the big red E-stop button. A comprehensive safety check is non-negotiable. With the power off, manually actuate every safety switch on every guard door. Does it register on the safety relay or PLC input? If the machine has light curtains, check that they are mounted correctly and cover the entire danger zone. Check that all warning labels are in place and are in the correct language for your operators. A good supplier will perform a formal safety handover with you, documenting that every single safety function has been tested and verified. This protects your people and your business.
| Installation Checkpoint | A Good Installation Looks Like... | A Rushed Installation Looks Like... |
|---|---|---|
| Mechanical Alignment | Machine is perfectly level. All moving parts are aligned with gauges. | Machine is "eyeballed." Parts are forced to fit. |
| Electrical Wiring | Wires are neat, labeled, and match schematics. Grounding is solid. | Wires are messy and unlabeled. Loose connections. |
| Bolt Torquing | Critical bolts are tightened with a torque wrench to spec. | Bolts are tightened with an impact gun, risking over/under tightening. |
| Safety System Check | Every E-stop, interlock, and light curtain is physically tested. | A quick check of one E-stop button. |
| Documentation Handover | The lead technician walks you through the as-built drawings. | You are handed a generic manual at the end of the job. |
Why is Comprehensive Operator and Maintenance Training Non-Negotiable?
You have just installed a state-of-the-art, fully automated packing line. It’s a beautiful piece of engineering. But your operators are afraid to touch it. They don't understand the control screen, they don't know how to load new packing materials, and they call for help every time a minor fault message appears. They fall back on old, slow, manual methods whenever they can.
This is a scenario where the investment in hardware is completely wasted because of a lack of investment in people. Your new line runs at a fraction of its potential speed. Your maintenance team is overwhelmed with simple requests that operators should be able to handle. Production slows down, and the ROI you promised your boss is nowhere in sight. Worse, an untrained operator is an unsafe operator, which increases the risk of accidents and injuries. A machine is only as good as the team that runs it. Comprehensive training is not an optional extra; it is a core part of the investment that unlocks the machine's true value.
Comprehensive training is non-negotiable because it is the only way to achieve consistent, efficient, and safe operation. Good training empowers your operators to take ownership of the machine and run it with confidence. It also equips your maintenance team with the skills to perform preventative tasks and troubleshoot problems quickly, minimizing downtime. This dual approach—empowering operators and upskilling maintenance—is what ensures your new line will deliver on its promise of higher productivity and lower costs.
When I built my own factory, I learned this lesson firsthand. I hired skilled engineers, but I realized that the people who create the most value are the operators and technicians on the floor every single day. If they don't understand the "why" behind the machine's operation, you will never achieve excellence. That's why we don't just sell machines at SHJLPACK; we build capabilities within our clients' teams.
Different Training for Different Roles
One size does not fit all when it comes to training. You need to separate the curriculum for operators and maintenance staff.
- Operator Training: This should focus on the Human-Machine Interface (HMI). Operators need to master starting up and shutting down the line, selecting recipes for different products, changing consumable materials (like stretch film or strapping), and clearing common, low-level faults. The goal is to make them confident and self-sufficient in daily operations.
- Maintenance Training: This goes much deeper. Your technicians need to understand the mechanical and electrical systems. They need to learn how to perform scheduled preventative maintenance, like lubrication and belt tensioning. They should be taught how to calibrate sensors, replace motors or cylinders, and read the electrical and pneumatic diagrams to troubleshoot more complex problems.
Learning by Doing, Not by Watching
PowerPoint presentations in a classroom have their place, but they are not a substitute for hands-on learning. The best training happens on the factory floor, with the machine running your actual products. I insist that our trainers have the client's team perform the tasks themselves. Let the operator change the film roll. Let the technician adjust the sensor. Making mistakes in a controlled training environment is a powerful way to learn. It builds muscle memory and true understanding that a lecture never can.
Creating Your Internal Experts
In every team, there are a few individuals who are more technically curious and learn faster. Identify these people during the training. These are your future "super users" or internal champions. Give them extra time with the supplier's trainer. They will become the first point of contact for other operators and can help train new hires in the future. This strategy builds a sustainable, in-house expertise that makes your factory less reliant on outside support for everyday issues.
| Training Topic | Operator Focus | Maintenance Focus |
|---|---|---|
| HMI / Control Panel | Daily operation: Start, Stop, Recipe Selection. | Advanced settings, alarm history, diagnostics screens. |
| Fault Recovery | Clear simple jams, reset common alarms. | Diagnose root cause of alarms, trace sensor/actuator faults. |
| Material Changeover | How to safely and quickly load new film/straps. | How to adjust guides and settings for new material types. |
| Preventative Maintenance | Daily cleaning and basic visual inspections. | Full PM schedule: lubrication, filter changes, inspections. |
| Mechanical Systems | Identify parts by name. | Disassemble, replace, and align key components. |
| Electrical/Pneumatic Schematics | Not required. | How to read diagrams to trace and solve problems. |
How Do You Properly Conduct a Factory Acceptance Test (FAT) and Site Acceptance Test (SAT)?
The supplier calls you and says, "The machine is built and ready." But how can you be sure? How do you know it will perform as promised when it's running your specific steel coils, with your specific packing material, at the speed your production demands? Just taking the supplier's word for it is a massive gamble.
If you skip a formal acceptance test, you are accepting a machine blindly. You might approve a machine that can't handle your product range or meet your cycle time requirements. Once that machine is delivered to your factory and you've made the final payment, getting the supplier to fix fundamental performance issues becomes a difficult, expensive, and frustrating battle. You lose all your leverage. The Factory Acceptance Test (FAT) and Site Acceptance Test (SAT) are not formalities; they are your contractual and practical safety nets. They are structured events designed to prove, with your own eyes and your own materials, that the machine does exactly what you paid for.
A proper Factory Acceptance Test (FAT) is conducted at the supplier's factory before the machine is shipped. You bring your own products and packing materials to test the machine's full functionality and performance against a set of pre-agreed criteria. Any issues found are fixed by the supplier in their own facility, where it is faster and cheaper to do so. The Site Acceptance Test (SAT) is a repeat of the key FAT tests, conducted at your factory after installation. Its purpose is to confirm that no damage occurred during shipping and that the machine performs correctly in its final operating environment.
I view the FAT and SAT as the most important milestones in any equipment purchase. This is where promises are turned into proven performance. A good supplier will welcome these tests as a chance to demonstrate the quality of their work. A supplier who tries to rush or avoid a detailed FAT should be a major red flag. This is your chance to hold them accountable.
Defining the Acceptance Criteria Before You Sign
The rules of the test must be defined long before the test happens. They should be written into your purchase contract. Don't accept vague terms like "machine will run well." You need specific, measurable criteria.
- Performance: What is the target cycle time or throughput (e.g., packs 60 coils per hour)?
- Quality: What defines an acceptable wrap? No film tails? Straps are tight and correctly positioned? No damage to the coil edge?
- Range: The machine must successfully run the smallest, largest, narrowest, and widest coils in your product range.
- Changeover: How long does it take to switch from one coil size to another? This should be a timed test.
- Reliability: The machine must run continuously for a set period (e.g., 2-4 hours) with your product, without faults or operator intervention. This is the most important test.
FAT is for Finding Problems, SAT is for Confirming Solutions
The purpose of the FAT is to find every possible problem. You want things to go wrong at the supplier's factory, not yours. This is where you test the limits of the machine. The SAT, on the other hand, is a confirmation test. It's to prove that the machine that worked perfectly at the FAT still works perfectly after being disassembled, shipped, and reassembled on your floor. The SAT is typically shorter and focuses on the key performance and reliability tests.
Who From Your Team Should Attend?
As the manager, you must be there. But do not go alone. Bring your lead operator and one of your best maintenance technicians. The operator will test the machine from a user's perspective, checking if the workflow is logical and easy. The maintenance technician will look at the machine with a critical eye for serviceability. Can they easily access lubrication points? Are components easy to replace? They will see things that an engineer or manager might miss. This also builds a sense of ownership and excitement within your team.
| Test Item | What to Test at FAT | What to Test at SAT |
|---|---|---|
| Full Functional Test | Test every single function and sequence described in the manual. | Re-test the main operating sequences. |
| Performance/Speed Test | Run the machine at the contracted speed with your most difficult product. | Confirm the machine still meets the contracted speed in your facility. |
| Product Range Test | Run the largest/smallest/heaviest/lightest products specified in the contract. | Run a sample of your most common products. |
| Sustained Reliability Run | Run continuously for 2-4 hours without faults to test for overheating and reliability. | Run continuously for 1-2 hours to confirm stable operation post-installation. |
| Safety System Verification | Test every single safety interlock, E-stop, and light curtain. | Re-verify all safety functions, as they were disconnected for shipping. |
| Punch List Creation | Create a detailed list of all required fixes and modifications before shipment. | Create a final, small punch list for minor adjustments. |
What Should You Expect from Your Supplier After the Line is Officially Handed Over?
The commissioning is finally complete. The SAT was successful, your team is trained, and you have made the final payment. The supplier’s engineers pack their bags, shake your hand, and leave. The next week, a new alarm that you've never seen before stops the line during peak production. You try to call the supplier, but you can only get a generic voicemail. You send an email, but the reply is slow and unhelpful.
This is the exact supplier trust crisis that experienced managers like you fear most. You feel abandoned. Your complex, expensive machine has become a black box, and a small problem is now threatening your entire production schedule. The partnership you thought you were building now feels like a simple, cold transaction that ended the moment your money was received. A good commissioning process doesn't end when the technicians leave.
A true partner's work is not finished at the handover. In fact, the handover marks the beginning of a long-term relationship. After the line is officially commissioned, you should expect a clear structure for post-commissioning support. This must include a comprehensive warranty, a detailed recommended spare parts list with clear ordering instructions, and reliable, fast access to remote and on-site technical support. A supplier who is invested in your success remains your partner long after the sale is complete.
As someone who has been on both sides—buying equipment for my factory and supplying it to others—I know that post-sale support is what separates a transactional vendor from a true partner. This is where we at SHJLPACK strive to be different. We built our reputation on being there for our clients for the long haul.
The "Hypercare" Period
The first two to four weeks after a new line goes live are critical. This is what I call the "hypercare" period. Your operators are still learning, and you may encounter unique situations or product variations you didn't test for in the FAT/SAT. A good partner will be in close contact during this time. They should schedule daily or weekly check-in calls. For very complex lines, it is often a good idea to have one of their engineers remain on-site for the first week of full production. This costs a little extra, but the value in terms of smooth ramp-up and immediate problem-solving is immense.
A Smart Spare Parts Strategy
The supplier will give you a spare parts list that can be long and expensive. A good partner helps you prioritize it. You don't need to stock one of everything. We help our clients categorize their parts list:
- Critical Spares: These are custom or long-lead-time parts whose failure would stop the line for weeks. You must have these on your shelf. (e.g., a proprietary controller, a special motor).
- Important Spares: These are components that will fail eventually, but the supplier should have them in stock for quick shipment. You might stock some, but you rely on the supplier's inventory. (e.g., common sensors, pneumatic valves).
- Standard Parts: These are commodity items like standard bearings, bolts, or fuses. You can and should source these from your local industrial suppliers to save money.
Building a Relationship Focused on Growth
The relationship shouldn't just be about fixing what's broken. It should be about continuous improvement. After six months, are you still getting the same throughput? Has your product mix changed? A true partner will follow up to discuss optimization. I recall a client in the steel industry. Six months after installation, we did a remote session to analyze their machine's data. We noticed a small hesitation in the wrapping cycle. By making a five-minute programming tweak remotely, we increased their line's throughput by nearly 8%. That is the value of a long-term partnership.
| Support Aspect | Transactional Vendor | True Partner |
|---|---|---|
| Warranty | A legal document used to deny claims. | A promise to fix issues quickly and fairly. |
| Technical Support | A generic email address with slow response times. | A dedicated contact, remote diagnostics, and a clear escalation process. |
| Spare Parts | Sends a huge, expensive list. "Buy it all." | Helps you create a tiered, cost-effective stocking strategy (Critical/Important/Standard). |
| Follow-up | Disappears after the final payment is made. | Schedules check-ins to discuss performance, optimization, and future needs. |
| Overall Goal | To sell a machine. | To help your business grow and succeed. |
Conclusion
A smooth commissioning is not an accident. It is the result of careful planning, active participation, and choosing a partner who is invested in your long-term success.
