How to Secure the Commissioning of Industrial Machines: Field-Proven Best Practices

Alex
2 days ago
2 min read

Commissioning an industrial machine is a critical phase: a wrong parameter, an overlooked safety device or a misaligned axis can lead to accidents, production downtime and major financial losses.This guide presents the proven field methodology used by top automation engineers to ensure safe, reliable and efficient machine commissioning.

Preparation: The Most Underestimated Step of Commissioning

Successful commissioning starts long before you power up the machine.

✓ Documentation Validation

Updated electrical and pneumatic diagrams
Confirmed network architecture (IP scheme, VLANs, routing)
Recorded software versions (PLC, HMI, drives, safety CPU)
FAT/SAT test plans approved

✓ Software Preparation

Functional block verification
Dependency analysis between sequences
Offline simulation (TIA Portal, EcoStruxure, Studio5000, etc.)

Goal: eliminate surprises and ensure smooth first startups.

Securing the Machine Before First Power-Up

Before energizing anything, perform a full field inspection.

Mechanical Checks

Tightening and alignment
Clearance in moving areas
Lubrication levels
Verified rotation direction

Electrical Checks

Insulation / continuity testing
Correct cable tagging
Wiring–schematic consistency
Tightened terminals and relays

Safety Checks

Light curtains tested
Door switches, interlocks, pull cords, emergency stops
Safety mapping validated
Stopping time measured

Golden rule: Never energize a machine until all safety systems are verified.

Progressive Power-Up and Axis Validation

Powering up the machine must be phased and controlled.

Power control cabinets only
Run PLC diagnostics
Enable drives locally
Test axes at low speed
Switch to automatic mode only after full validation

Critical Points

Motor/encoder direction
Drive gains too aggressive → vibration
Incorrect homing
Abnormal no-load current

This phase exposes 80% of preventable issues.

Sequence Testing: Validate the Machine Step by Step

The machine must be verified sequence by sequence:

Transition logic validation
Prevention of simultaneous impossible actions
Fault messages evaluation
Tuned timers to avoid collisions

An automation engineer must stop the ramp-up immediately if:

movement behaviour is inconsistent,
abnormal heat is detected,
motion profiles are too fast,
a sensor signal fluctuates unexpectedly.

Functional Safety Validation and Compliance

Before entering production, safety testing is mandatory.

Safety Tests

Emergency stop → machine must stop within the required time
Redundant safety sensor tests
SIL/PL validation according to design
Safety chain verification (generic Pilz/Sick/Siemens style, no branding)

Required Documentation

Safety test report
Operator/maintenance signature
As-built updated schematics

A machine must never be declared compliant without this validation.

Operator Training and Knowledge Transfer

Long-term safety depends on your workforce.

Train operators & maintenance teams
Provide clear “Start / Stop / Reset / Fault” procedures
Deliver quick-response troubleshooting guides
Explain machine limits and safety risks

A perfectly commissioned machine becomes unsafe if operators misuse it.

Post-Commissioning Monitoring: The Secret to Stability

The first 72 hours are crucial.

Monitor:

Repetitive fault history
Drive/motor current consumption
Cabinet temperature
Product quality
Axis synchronisation

A structured feedback loop prevents early failures and improves performance.

The result of good practices

Securing machine commissioning is not a formality. It requires structured preparation, rigorous verification, phased startup, detailed safety testing and continuous monitoring.Applying these field-proven methods drastically reduces:

safety risks,
downtime,
quality issues,
and accelerates stable full-speed production.