Production Relocation – Comprehensive Technical and Logistics Solutions Worldwide
You want to relocate your production line to another site and you are looking for an experienced team with extensive expertise in handling complex tasks? Our team possesses the required expertise – worldwide.
Your Contact Person
Details on relocation stages
Planning steps (general)
- Permits/Applications
- Components/Infrastructure (storage facilities, laboratory, servicing, etc.)
- Fire protection (building, technical)
- Auxiliary systems (energy, water, air, refrigeration, exhaust, air conditioning, etc.)
- Material flow
- Installation plan/Foundations
- Relocation period, activities (disassembly, installation)
- Technical inspections/Training
- Personnel for production training
- Start-up/Start of production
Preparations for disassembly
- Insurance policies, liability
- Select disassembly team members (electrical, mechanical)
- Tools, lifting tools, forklifts, cranes
- Containers, electrical power for construction, telephone, fax, heating
- Forwarding agent, transportation permits
- Intermediate storage facilities, cleaning facilities
- Work permits (nights, weekends)
- Fire protection, checking of occupational safety and health regulation requirements
- Instruction of qualified personnel
- Preparation of packaging material
- Determine documentation (identification labeling, packing lists, etc.)
- Check disposal channels (oil, products, metal, etc.)
The quality of disassembly preparations decisively influences schedule effectiveness, occupational, fire and environmental safety and protection and represents the basis for controllability of the overall risk for the supplier and the customer.
Disassembly, cleaning and disposal
- Labeling of system components
- Comparison/Review of foundation dimensions with foundation plans
- De-energize the system (power, oil, etc.)
- Draining of supply lines
- Disconnection of electrical cables
- Electrical/Electronic disassembly
- Disassembly of measurement technology
- Backing up controller programs
- Disassembly and cleaning of mechanical components
- Disposal of residual substances
Disassembly work represents the simplest part of relocation measures; however, the quality of disassembly work determines whether installation procedures will be carried out on-schedule and whether the system will work correctly after installation.
Packaging and transportation steps
The type of packaging
- Containers
- Pallets
- Crates
- Foil/Film
is determined by the type of transportation
- Truck
- Rail
- Ship
- Plane
and by the point of destination
- Within site
- Within Germany
- Overseas
Insurance policies, liability and transportation documents are important.
Preparations for installation
- Preparation of foundations (measurement, construction)
- Assure infrastructure:
- Power
- Heating system
- Cranes/Forklifts
- Local suppliers
- Containers
- Phone
- Fax
- Interpreters
- Human resources
- Organize intermediate storage facility
- Apply for permit
- Prepare supply systems (power, water, refrigeration, air)
- Organize waste disposal
- Adaptation measures of the relocated system (steel construction, pipelines, cabling, etc.)
Essential points of installation preparations include the system foundation, energy supply, licenses and permits and the adaptation of the relocated system to the new environment.
Installation steps
- Structural steel installation
- Installation of electrical control cabinet
- Component assembly
- Pipeline installation
- Installation of measurement technology
- Wiring
- Connection to control cabinets
- Connection of supply systems
- Connection of exhaust systems
- Adjustment and leveling of components
- Filling of systems with oil, lubricants
Installation work must be complete i.e. all mechanical, electrical, measurement technology and control work must have been carried out so as to ensure that the quality of production performance is the same as prior to disassembly.
The relocation team is selected primarily on the basis of installation skills followed by disassembly capabilities.
Steps for start-up/inspections/training
- Inspection of safety equipment
- Functional test of individual units
- Functional test of control units and drives
- Rotational direction check
- Setting/Adjustment of pneumatic and hydraulic equipment
- Signal exchange test
- System start-up with production material
- Optimization of control systems
- Start-up / Run down test / Safety criteria test
- System optimization, depending on recipes
- Acceptance test
- Training and instruction of operating personnel
Project example: Production line relocation in China
MES has successfully relocated a factory in China including all auxiliary systems. The relocation of the existing three finishing lines was carried out individually and successively. Once the first production line had been successfully put into service again, the second line was relocated. In this way the production downtime was kept to a minimum. Production was optimized and capacities were expanded at the same time.
Stages
Our Service
- Stage 1:
- Relocation of first industrial rubber finishing machine along with thermal oil burner and mixing unit.
- Stage 2:
- Relocation of second finishing machine complete with thermal post-combustion unit. Production was also optimized.
- Stage 3:
- Relocation of third finishing machine
- Tripling of finishing capacity
- Doubling of production speed
- Conversion of heating system to thermal oil
- Project implemented without interruption to production
- Optimized material flow
- Expanded production capacity
- New burner technology integrated into thermal post-combustion unit
- Optimized technical safety
- Enhanced ease-of-use
- Installation of new thermal oil heater
- Installation of new measurement equipment
Thomas Steinwachs
Head of Service