Real Case Study: How Commissioning a Custom-Built Special Machine Increased Production Output by 18%

In today’s competitive industrial environment—where even the smallest productivity improvement can generate significant savings—manufacturers are increasingly turning to fully customized automation solutions. Among these, commissioning a custom-built special-purpose machine is often one of the most profitable and impactful investments.This real case study, conducted within a precision metalworking company, demonstrates how commissioning a tailor-made machine directly led to a +18% increase in overall production output. It offers a clear view of how personalized industrial automation can reshape an entire production line.

The initial situation: a saturated production line with clear technical limitations

Before launching this project, the company faced several recurring issues that limited its ability to meet growing demand. These included:

• Long and unpredictable changeover times, causing significant production downtime

• Numerous micro-stoppages difficult to identify and troubleshoot

• Repetitive, low-value manual tasks consuming operator time

• Lack of real-time quality tracking and full production traceability

• Difficulty maintaining consistent cycle times on aging equipment

These issues are common in many industrial sectors and typically require more than fine-tuning to resolve. The company decided to pursue a more advanced strategy: the development and commissioning of a fully customized special-purpose machine designed around its exact needs.

Designing the special-purpose machine: a complete, fully tailored engineering process

The machine was designed through a close collaboration between the manufacturer and a specialized automation integrator. The goal was to remove specific pain points while increasing overall flexibility and reliability.

The resulting solution included:

• A robot-assisted automatic loading and unloading system

• An inline vision inspection module ensuring continuous quality control

• Full product traceability with direct MES connectivity

• A modern, easy-to-use HMI interface to simplify operation

• Reduced human error through targeted automation of critical steps

Because it is built to address unique operational constraints, a special-purpose machine delivers performance gains that standard commercial equipment simply cannot match. It integrates seamlessly into the existing production ecosystem without requiring major layout changes.

Commissioning: a structured and strategic process for a smooth, disruption-free startup

Commissioning (FAT/SAT) is often one of the most crucial phases in industrial automation projects. In this case, it was performed in three major steps.

Factory Acceptance Tests (FAT): eliminating risks before installation

Before delivery, the integrator performed an exhaustive test sequence:

• Simulated production cycles under near-real conditions

• Calibration of all sensors and vision systems

• Validation of robot trajectory speeds

• Testing of all safety functions and emergency logic

This significantly reduced the risk of on-site issues.

Site Acceptance Tests (SAT): seamless integration into the production environment

Once installed, the machine was integrated into the existing production flow:

• Synchronization with conveyors and peripheral equipment

• Communication tests with the MES and quality systems

• Adaptation of safety areas to match the plant layout

This allowed the production line to resume quickly.

Operator training: an essential step for fast adoption

Training sessions included:

• HMI navigation

• Alarm handling

• First-level maintenance tasks

• Best practices to optimize production cycles

The team was fully autonomous within the first weeks.

Measured results: a verified and sustainable 18% increase in output

Four months after commissioning, the benefits were clear and measurable:

• +18% increase in overall equipment effectiveness (OEE)

• 27% fewer micro-stoppages, thanks to precise diagnostics

• 32% improvement in cycle time stability

• 6% improvement in product conformity rate, due to automatic inspections

• Noticeable reduction in operator workload and fatigue

The project’s ROI was calculated at only 14 months, an exceptional result for a custom-built industrial machine.

Why a custom special-purpose machine delivers transformational value

Unlike standard machines—built to meet generic needs—a custom machine:

• Eliminates bottlenecks specific to YOUR production line

• Optimizes every step of the process with zero compromise

• Significantly improves repeatability, safety and product quality

• Integrates naturally with the existing workflow and digital systems

• Can evolve over time with new modules, new formats or future expansions

For manufacturers aiming to boost productivity without rebuilding their entire line, a custom special machine is often the most efficient and cost-effective solution.

A concrete example proving the power of custom industrial automation

This case study clearly shows that custom-built special-purpose machines are not only for large industrial groups. With the right engineering partner and a structured commissioning approach, any manufacturer can drastically improve production performance.The 18% output increase achieved in this project proves that a special machine is far more than an equipment upgrade—it is a strategic investment with long-term impact.

Looking to find out whether a custom special-purpose machine could increase your production output?Request a technical pre-study.

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