Integrated machinery lines · Lifecycle phase
Commissioning the line: from machine acceptance to handover
Commissioning is where six accepted machines become one working line. This page shows the steps of the phase on RL-1, who is responsible for each, what each step must deliver and when the next one may start — so that the line’s documentation is complete when the line is handed over.
Page context
- Line
- Reference line RL-1: end-of-line packaging (RL-1)
- Stations
- Infeed and accumulation conveyor → Filler and capper → Labeler → Inspection and reject → Case packer → Palletizer and stretch wrapper
- Lifecycle phase
- Commissioning and acceptance
- For
- System integrators, Safety engineers, Technical writers
- Page type
- Lifecycle phase — Shows one phase: steps, roles and deliverables
Z1 · Filling
- Infeed and accumulation conveyorSystem integrator
- Filler and capperSupplier A
Z2 · Labeling and inspection
- LabelerSupplier B
- Inspection and rejectSupplier B
Z3 · Case packing
- Case packerSupplier C
Z4 · Palletizing
- Palletizer and stretch wrapperSupplier D
Factory acceptance per machine
Responsible: Each supplier, with the integrator
Activities
- Test each machine at the supplier’s site against its specification
- Test the line interface with a simulated line controller
Deliverables
- FAT report per machine
- Machine technical documentation and instructions
- Interface test record
Next step may start when: Each machine passes its FAT; open points have an owner and a date.
Virtual commissioning of the line control
Responsible: System integrator
Activities
- Run the line controller against a simulation model of RL-1
- Test start, stop and restart sequences and buffer behavior
Deliverables
- Tested line control software
- Updated signal list
Next step may start when: All sequences in the test plan run in the simulation.
Installation and integration on site
Responsible: System integrator and suppliers
Activities
- Set up and connect the machines and conveyors
- Test every signal in the signal list end to end
- Commission the safety controller zone by zone
Deliverables
- I/O and signal check records
- As-built electrical documentation
Next step may start when: Every signal is tested; each zone stops and resets as specified.
Validation of the safety functions
Responsible: Safety engineer (integrator)
Activities
- Validate each safety function of the line against the safety concept
- Check the line risk assessment against the built line, including interaction hazards
Deliverables
- Validation report
- Updated line risk assessment and residual risk information
Next step may start when: All safety functions are validated; residual risks are covered in the instructions for use.
Site acceptance and handover
Responsible: Operating company and integrator
Activities
- Run the line at rated output over the agreed period
- Train operators and maintenance with the line instructions
Deliverables
- SAT report
- Line technical file, declaration of conformity and instructions for use
- Training records
Next step may start when: The operating company accepts the line; the documents are handed over.
| Document | Level | Written by | Used on these pages |
|---|---|---|---|
| Machine instructions for use | Machine | Each supplier | Linked from task and troubleshooting pages |
| Line instructions for use | Line | Integrator (technical writing) | Task, troubleshooting and reference pages |
| Line risk assessment | Line | Integrator (safety engineering) | Safety messages on task pages |
| Signal list and interface specification | Line | Integrator (automation) | Interfaces and signals |
| Technical file and declaration of conformity | Line | Integrator as manufacturer of the assembly | When a line becomes one machine |
Documentation runs alongside, not after
Line documentation that starts at handover is written from memory. On RL-1 the technical writer joins at virtual commissioning: the start and restart sequences tested there become the restart procedure, the signal tests feed the interface reference, and every open point from the tests is checked for its effect on the instructions. The validation of the safety functions is the last check that the safety messages match the line as built.