How to Commission a Custom Automated Machine

Working Together – A Close Collaboration for Seamless Machine Commissioning

Commissioning a custom-built automated machine isn’t just a handoff—it’s a partnership. From day one, success depends on open communication and a shared understanding of the project’s goals. True collaboration means more than just checking boxes—it means building trust. For the builder, early and consistent feedback reduces the risk of misalignment and ensures the machine being developed isn’t just functional, but truly optimized for the customer’s process. In the end, commissioning becomes smoother and faster because both teams have already worked together to align expectations, define success, and anticipate challenges before they arise.

We don’t leave you in the dark at any stage in the project process. As a custom automated machine builder, we know the best outcomes happen when work happens side-by-side, clarifying requirements, constraints, and production goals early in the process. This collaboration not only streamlines design but also fast tracks the commissioning process. Here’s our experience on how to commission a custom automated machine.

When Commissioning Starts on the Project Management Timeline

Commissioning doesn’t begin when the machine shows up at your facility—it starts much earlier.

Clear requirements should be established before design begins, setting the stage for pre-commissioning work during the machine runoff phase. This approach allows many verification steps to be completed before the machine leaves the builder’s floor, speeding up installation and reducing downtime once it arrives at your site.

Some of these machine requirements may include:

• Machine production rate – How quickly a machine can produce a specific number of units of a product within a given time frame
• Whole system footprint – the space the automated system will use on the manufacturing floor
• Digital connectivity between the machine and the manufacturing plant – fluid, real-time access to monitor machine performance and output
• Preferred automation equipment – Based on current machines in facility and customer preference
• Spare parts – A list of spare parts and what to keep stocked based on wear rating
• Machine manual – Contains information pertinent to the operation of the machine

The Commissioning Checklist

To commission a machine means to formally put it into operation, ensuring it functions as intended and meets specified requirements. This generally starts during runoff, where the machine builder and customer confirm that the system meets all agreed-upon requirements before shipment. A thorough debug process performed before this stage ensures all stations in the system operate as they should so the machine can run smoothly in its new home.

The commissioning checklist involves:

• Verification – confirming the machine matches the original specifications.
• Testing – running production-like cycles to confirm consistency and performance.
• Documentation – recording proof that the machine is installed correctly, operates safely, and integrates with other systems.

Commissioning also plays a critical role in seamless system integration. Beyond proving that a machine can run, this process confirms that all components are installed properly, operating at peak efficiency, and capable of sustaining production demands. Whether it’s a new automation system or an upgrade to existing equipment, a comprehensive commissioning checklist helps ensure the solution delivers long-term performance and minimal disruption on the production floor.

Training & Documentation

Training is a key part of commissioning. It can start as early as the runoff stage at the machine builder’s facility, giving operators and maintenance teams a head start. In many cases, in-depth training happens after installation, once the system is operating in its real production environment.

Complete machine documentation covering operation, maintenance, and troubleshooting is finalized and shipped with the equipment so your team has a reliable reference and working manual from day one.

Detailed Machine Breakdown & Shipping

Custom automation systems are precision-built, so the breakdown and packing process is labeled with extreme detail and carefully handled during disassembly. Components are secured, labeled, and packaged to ensure they arrive exactly as intended, ready for efficient reassembly at the customer’s facility.

Beyond careful packing, shipping logistics also play a vital role in protecting the integrity of the system. Machines are often crated, cushioned, or climate-protected depending on their sensitivity, and transportation routes are planned to minimize vibration and impact. Clear labeling and organized documentation travel with the shipment so the receiving team has a precise roadmap for reassembly. This level of detail helps reduce downtime, prevents misplaced components, and ensures the machine can be brought back online quickly and confidently at the customer’s facility.

Customer Facility Installation – The Final Check

Once on-site, the machine is reassembled, integrated into the production line, and connected to utilities. The final step in the commissioning checklist happens here: confirming that the machine runs to spec under real production conditions. At this stage, the machine builder and manufacturer work together—fine-tuning settings, confirming performance metrics, and signing off on a system that’s fully ready for operation.

Commissioning a custom automated machine is more than a final step—it’s the bridge between concept and reliable production. When requirements are defined early, collaboration stays strong, and commissioning follows a structured checklist, manufacturers gain a system that integrates smoothly, operates efficiently, and delivers long-term value. With careful planning, detailed documentation, and thorough testing, the commissioning process ensures that a machine doesn’t just run, but runs right—setting the stage for sustained productivity on the factory floor.