1. Start With A Site Readiness Walkthrough
Before any power-up, the line must be checked as a complete system. On a retrofit job in Kempton Park, Johannesburg or further afield in Durban or Cape Town, we look at the conveyor route, pallet build area, guarding positions, access for maintenance, and the condition of existing electrics and air supply. This is where small issues are easiest to catch, such as a misaligned stop, a loose cable tray, or a pallet position that does not match the drawing.
A proper readiness walkthrough also confirms that the team knows who is doing what on the day. Production, maintenance, safety and control staff should all understand the sequence, the isolate points, and the stop procedure if something looks wrong.
- Confirm floor space, clear access and marked work zones
- Check conveyor direction, height and transfer points
- Verify supply air, power and network points are available
- Make sure guarding, fencing and gates are in place
- Agree the startup team and shutdown contacts
2. Dry Runs Prove The Motion Before Product Enters
Dry runs are used to test movement without product or packaging, so the line can be checked safely and methodically. The robot or cobot should cycle through pick positions, pallet layers and transfer points while the conveyors run empty. This shows whether the timing, reach and clearances are correct before anyone starts feeding cartons, bags or cases into the system.
At this stage, the focus is on repeatability. We check that the machine stops where it should, resumes correctly after a fault, and does not create unexpected pressure points on the conveyor. If the cell includes multiple infeed streams, each stream is tested one at a time and then together.
- Run the robot through full cycle paths at reduced speed first
- Test emergency stop buttons and safety gates
- Check sensors, photoeyes and interlocks one by one
- Confirm pallet patterns, layer counts and end stops
- Log any alarm, hesitation or missed signal for correction
3. Controls Checks Keep The Retrofit Talking To The Line
A retrofit only works properly when the controls are speaking the same language as the existing conveyor line. Commissioning includes checking start and stop logic, jam signals, product presence signals, pallet release, fault reset and any handshakes between old and new equipment. If the site has older panels or mixed equipment, this part can take longer and must be handled carefully.
The aim is not just to restart, but to restart in a controlled way with product still in place and no danger to operators. This needs clear recovery steps and it should be written down before production begins.
- Test local and remote start points
- Check fault messages are clear and practical
- Confirm the line recovers safely after a stop
- Review how the system behaves after a power loss
- Make sure reset procedures are simple enough for shift teams
4. Safety Guarding And Risk Checks Must Be Site Specific
Every site needs its own risk assessment. A line in Gqeberha with coastal humidity, or a dusty Midvaal plant with long operating hours, will present different risks to a compact inland facility. Guarding, fencing, warning lights, access doors and presence sensing must suit the actual layout and the way people move around the line. General rules are useful, but they do not replace a proper site review.
Commissioning should verify that all safety devices stop the equipment as intended and that no bypass is left in place after testing. Operators should only be trained on the correct method to enter the cell, clear a stoppage and resume production. If the site has forklifts, stretch wrappers or manual pack stations nearby, those movements must also be included in the checks.
- Review the risk assessment with operations and maintenance staff
- Test every gate, interlock and stop circuit
- Confirm signage, floor markings and exclusion zones
- Check interaction with forklifts, trolleys and manual stations
- Remove temporary test bypasses before startup
5. Supervised Production Startup Should Begin Slowly
Once dry runs and safety checks are complete, the line can move into supervised production startup. This is usually done with a limited volume of product, reduced speed if needed, and close monitoring by the commissioning team and site staff. The point is to find the small adjustments that only appear under real conditions, such as slip on a conveyor, an awkward case size, or a pallet pattern that needs fine tuning.
During this stage, the team should watch cycle times, product flow, pallet quality and operator response. If anything drifts, it is easier to correct it early than after a full shift. It is also the right time to confirm that the pack and pallet areas are being kept clear, because clutter causes avoidable stoppages.
- Start with a controlled production rate
- Monitor cycle time, jam frequency and pallet quality
- Check how operators respond to faults and restarts
- Adjust settings before increasing throughput
- Keep a short shift log of issues and fixes
6. Handover, Training And Support After Commissioning
Commissioning is not complete until the people on site can run the line with confidence. Handover should include the operating sequence, cleaning points, fault recovery, basic maintenance and what to do when a sensor, gripper or conveyor section gives trouble. The best handover is practical, not overcomplicated, and it should match the way the plant actually works on day and night shift.
At ReAutomated, support may include operator training, maintenance guidance, spares planning and follow-up visits after startup. For manufacturers in Johannesburg, Pretoria, Durban, Cape Town, Gqeberha and the East Rand, that support helps keep the line stable after the commissioning team leaves. It also gives the site a clear plan for routine checks and breakdown response.
- Issue a clear operating sequence and fault guide
- Train operators, setters and maintenance staff separately where needed
- Confirm spare parts and consumables are identified
- Set review dates for the first weeks of production
- Record open items and assign follow-up actions
