How do you move production kit on a live site without blowing the budget or the schedule?
Freeze the scope early, treat the job as a construction project, build as much as you can off the critical path, choose the correct lifting method, and plan recommissioning so day-one output is realistic.
Fix the scope and phase around production
Scope creep burns cash. List everything that moves, what is scrapped or sold, and what stays put. Phase the cutover around your busiest windows using weekend lifts, night shifts or a cell-by-cell approach. Agree acceptance criteria up front, including power on checks, dry runs and target run rates for day one and week one.
Run it under proper governance
Treat machinery relocations like construction. Appoint CDM duty holders and keep RAMS and permits tight. Plan isolations, hot works, working at height, confined spaces and traffic routes. Survey utilities to avoid conflicts with drains, gas, power, or data. Good governance avoids rework, injuries and delays.
Build more off the critical path
What you can prepare offline is usually cheaper. Pre-assemble skids and pre-wire panels, then complete FATs before move day. Fabricate and label services so that the install is plug and play. Update template components and print simple visual SOPs to speed recommissioning.
Choose the right lift and plan the route
Match the lifting method to the load and the access. Forks, skates, gantries or cranes each have limits. Check access widths, floor loading and ground bearing pressures. Plan internal and external routes, door removals and temporary works. Confirm hire durations and book specialist operators and a banksman where needed.
Protect power, air and controls
Temporary services keep the site running and reduce call-outs. Number cables, label terminations, and save PLC and HMI programs before you split anything. Back up device parameters and recipes. Agree I O, alarms and handshakes in advance, so assets talk to each other when you land them.
Recommission for first time quality
Start from a known datum. Level and align machines, set conveyors and transfers, and stage reject paths. Calibrate inspection kit and verify with real product and films. Complete PUWER checks for guarding, interlocks and emergency stops, and keep LOLER records for lifting accessories used on site. Keep evidence with the asset file.
Costing checklist
- Full asset list with weights, dimensions and centre of gravity
- Phase plan tied to production windows
- Access and route surveys plus ground bearing checks
- Confirmed lifting method and hire durations
- Offline builds, pre-wired kits and FAT evidence
- Spares and temporary services plan
- CDM roles, RAMS, permits and PUWER or LOLER covered
- Recommissioning plan with acceptance criteria and KPIs
FAQs
- What drives most of the cost in a large relocation?
Cranes and other lifting, long hire windows, packaging and protection, and delays caused by poor access or late isolations. The correct lifting method, off-line pre-builds, and a tight phase plan cut these costs. - Is it cheaper to move or replace older machinery?
It depends on age, spares and energy use. If reliability is poor, the move cost plus future downtime may exceed the value of a newer, more efficient replacement. - How long does recommissioning take?
Simple conveyors can run the same day. Complex lines need time for alignment, inspection, setup, and validation. Saved PLC or HMI programs, labelled services and preset change parts shorten this. - Do we need CDM for moves inside a factory?
If construction like activities are in scope, CDM 2015 is likely to apply. Clear roles and a single plan usually save money by improving coordination and reducing surprises. - What inspections are required after the move?
PUWER checks on guarding, interlocks and emergency stops, plus functional tests on inspection and safety systems. Keep records with the asset file.
Call to action
Ready to relocate with less downtime and more certainty? Talk to FESS Group via our contact page: https://fessgroup.co.uk/contact-us/
