In this article, we will be listing a complete checklist and brief description of plant and machinery movement and in general, why moving it with consideration is necessary. Throughout my years as an industrial consultant, I’ve witnessed numerous plant relocations – both successful and problematic. Last quarter, I worked with a manufacturing facility that rushed it’s equipment movement without proper planning, resulting in $200,000 in damaged machinery and three weeks of downtime.
When planning for a challenging task such as industrial plant movement, the secret to getting equipment relocated safely and effectively to it’s destination depends on several factors. I recently helped an automotive parts manufacturer relocate their entire production line across states. Following proper procedures, we completed the move with zero equipment damage and minimal production interruption. Poor transportation procedures can affect your company’s finances and put workers in danger. One of my clients learned this the hard way when they attempted to move their packaging equipment without professional help, resulting in serious damage to a critical machine and a workplace injury.
So, it’s necessary to consider everything, from a well-developed plan for the entire process to giving instructions to the undertaking team. Through my experience with hundreds of plant relocations, I’ve developed this guide to ensure safe and efficient movement.
This article will cover the things you should consider before moving a plant.
Contents
Making A Checklist for Successful Plant Movement
Since a plant is a significant part of your business and mild damage can harm the workflow, you cannot afford to make a little mistake while plant movement. I recently consulted for a pharmaceutical manufacturing facility that was relocating their sterile processing equipment. The stakes were incredibly high – even minor damage could compromise their FDA validation and cost millions in delays. So, making a checklist with all the necessary things enables you not to forget or overlook a single detail.
Last month, I worked with a food processing plant planning their facility expansion.By implementing a detailed checklist, we prevented potential cross-contamination issues and maintained their food safety certification throughout the move. Another client, a precision electronics manufacturer, saved over $50,000 in potential damage by following our comprehensive checklist system. Their sensitive testing equipment required special handling procedures that would have been overlooked without proper documentation.
Developing a Plan
The most crucial step in the procedure is developing a comprehensive plan for the move. I recently assisted a large printing company with their facility relocation. Their biggest concern was maintaining production during the transition. Create a strategy that outlines the timing of the movement of every piece of equipment. Working with a metal fabrication plant, we created a phased movement plan that allowed them to maintain 80% of their production capacity throughout the relocation. It eliminates confusion on which plant components must be disconnected and disassembled and when to do that.
One of my clients, a plastic injection molding facility, avoided costly mistakes by following our detailed disconnection sequence plan. A well-chalked-out plan is even more crucial if the factory wants to keep running during the transition. I helped a textile manufacturer relocate their facility while maintaining 70% of their production capacity – this was only possible through careful planning and scheduling. The plan included specific time windows for moving each piece of equipment, with backup plans for potential delays or complications.
Currently Upgraded Layout
Always verify the accuracy of the drawings for your facility. Last year, I consulted for a chemical processing plant that was relocating their entire operation. When reviewing their facility drawings, we discovered several critical discrepancies that could have caused serious problems during the move. Use the layout of the latest upgraded version to make things 100% right. A recent project with an electronics manufacturer highlighted the importance of this – outdated drawings nearly resulted in expensive equipment being placed in areas without adequate power supply. The category, department and location of each piece of equipment of the plant should be in the drawings, together with the manufacturer, the motor plate information, the asset identification number and any other weight and utility specifications.
Working with a pharmaceutical company, we prevented a potential disaster by identifying specialized power requirements for sensitive equipment that weren’t marked on their old drawings. Before you start planning your move, a precise picture of the plant will ensure that operators install the plant in the new location and assemble the parts correctly. One of my automotive industry clients saved weeks of potential delays by thoroughly updating their facility drawings before their move.
Before you start planning your move, a precise picture of the plant will ensure that operators install the plant in the new location and assemble the parts.
Database Of All Equipment
Have you considered the varying regulatory requirements when altering places? I recently helped a food processing plant relocate across state lines, where different local regulations significantly impacted their equipment setup requirements. Will the equipment you already have be compatible with the new location? A client in the electronics manufacturing sector faced this challenge when moving from one country to another – voltage differences meant some equipment needed modification. Before the movement, keep a database of all equipment details and information, including the asset tag or ID and all utility and control tie points. Working with a large brewery, we created a comprehensive database that proved invaluable when reconnecting their complex piping systems.
You can turn the database into a more useful one by taking photos and videos of all equipment, including any specific setup needed for a piece of machinery and it’s correct measurement. During a recent textile plant relocation, our detailed photo documentation saved countless hours during reassembly. Trenches, pits, drainage systems and safety rails are all examples of foundations that need documentation. A chemical processing facility I worked with avoided serious compliance issues because we thoroughly documented their specialized containment systems. Record more than you think you’ll need to be safe – this advice saved a pharmaceutical client significant time and money during their facility relocation.
Checking The Condition of All Parts
Start by gaining access to everything you’re thinking about moving. In a recent project with a metal fabrication plant, this preliminary inspection revealed several machines that required maintenance before moving. Then, thoroughly inspect the machinery that needs to be transported. Working with a printing company, our detailed inspection prevented damage to delicate components during transit. Check if every part of the plant is in good operating order.
A food processing client discovered several worn-out conveyor systems during this process, saving them from moving equipment that would need immediate replacement. Finally, get rid of unnecessary equipment before the transfer. This procedure, which involves documenting the state and applicability of each piece of equipment, is overseen by a plant engineer. Last quarter, I helped an automotive parts manufacturer evaluate their equipment before a major relocation.
By evaluating the equipment’s state, one may find that a machine is not worth transporting to the new location and that replacing it would be less expensive than moving large pieces of equipment. This assessment saved one of my clients over $100,000 by identifying equipment better replaced than relocated.
Hire a Group of Professionals
A corporation will want to select a skilled industrial plant movement contractor to execute the transfer due to the intricate nature of such a challenging transportation operation. I recently worked with a semiconductor manufacturer who initially considered handling their move internally. After showing them the complexities involved, they opted for professional movers, avoiding potential disasters. Employing a group of experts who act as dependable, experienced partners in this process will save you time, effort and money. A recent project with a pharmaceutical company demonstrated this perfectly – professional movers completed the relocation in half the time an internal team would have required.
Keep in mind that:
If you intend to utilize contractors to carry out the move, use a document to give any special instructions to be careful with the moving parts or other crucial elements that need extra care. Working with a precision machine shop, we developed detailed handling instructions that prevented any damage to their sensitive equipment.
Ensure that the plant manager, the utility installer and the contractor handling the plant movement all work together effectively, coordinating with each other. During a recent chemical plant relocation, this coordination prevented potentially dangerous situations during the movement of hazardous material processing equipment.
FAQs
How long does a typical plant relocation take?
What’s the biggest risk during plant movement?
Do I need to shut down production completely during relocation?
How much does professional plant movement typically cost?
Should I replace old equipment instead of moving it?
How do I prepare electrical systems for the move?
The Bottom Line
The bottom line is that you can continue the workflow at your factory or manufacturing plant while it is on it’s way to being placed at a new location. A recent success story involves a food processing plant that maintained 60% production capacity throughout their entire relocation process. It is possible when you engage a reputable plant and machinery transport company to get your job done. I’ve seen this proven time and again, most recently with an electronics manufacturer who completed their move with zero production downtime. However, to perform the plant movement quickly and safely, seeking professional help is the soundest choice. This was demonstrated clearly when a printing company attempted their own move, resulting in significant equipment damage, before calling in professionals who completed the job efficiently and safely.
Through my years of consulting on plant relocations, I’ve seen these principles save companies millions in potential losses and weeks of unnecessary downtime. Each successful move reinforces the importance of proper planning, documentation and professional execution. Remember, the cost of professional help is always less than the cost of mistakes during a plant movement.