Manufacturing Challenges: Bringing New Machinery Into the Plant

Bringing new machinery into a plant succeeds or fails in four places: the specification, the acceptance test at the OEM, the connection to the plant network, and commissioning to the target rate. Write every requirement down before the purchase, including the controls standard the machine must match. Witness a FAT or VAT and fix deviations before the machine ships. Decide how the machine will be isolated and connected before it arrives, because the OEM rarely owns that. Then commission it step by step, with a punch list that has an owner and a date for every item.

A common challenge for manufacturing facilities is bringing in new equipment. The sections below follow the machine from the first conversation with an OEM to the day it runs at rate.

Before Manufacturing Equipment is Acquired

Depending on your facility, you’ve either designed your own custom machinery or you’ve acquired standard machines specific to your process. An example of a standard machine would be a case packer, palletizer, filler, etc. They’re standard because they’re needed in most facilities and multiple groups have been through numerous iterations to optimize the process.

There’s little value in going down the path of creating a palletizer from scratch: it’s going to be expensive and it’s rarely going to add any advantage to your process.

Note that this doesn’t mean that you can’t customize a specific portion of a machine to better suit your needs. If we continue with the example of a palletizer, there are groups that will create custom end-of-arm-tooling (EOAT) that will be used for custom picking and placing your product onto a pallet.

So, what are the challenges in acquiring custom equipment and “standard” equipment?

Pre-Purchase Custom Equipment Challenges

It’s very easy to overspend on custom equipment. Engineering time can balloon as change requests and adjustments are made to the original scope. It’s critical to understand your requirements, the skillset of the group you’ve chosen to execute the project, and the guardrails in place that will either help you change the scope or limit you from building out your vision.

What does this boil down to?

• The completeness of the engineering design is key.
• The alignment of expectations when it comes to change requests is key.
• Understanding the deliverables (timeline) is key.

Pre-Purchase Standard Equipment Challenges

Standard equipment is much easier to purchase. You should be able to find multiple vendors that would be able to build the machine you’re looking for, and based on the following criteria select the right one:

• What does the vendor provide beyond the machine? Will you be getting on-site support for the VAT / FAT? Will you be able to call them for a specific period in time? Can you get them to come into the facility when your line is down? Can they customize certain components of the machine to suit your needs?
• Does the machine fit what you currently have on site? I’ve seen this mistake time and time again… A manufacturing plant standardized on Rockwell Automation products brings in an OEM that will only sell them a machine that runs on Siemens. This is a bad idea…
• What are the details of the agreement between you and the OEM? Are they liable for a certain run rate before you sign off on the machine? Are they liable for the installation and commissioning? Are they liable for training your staff on how to operate and maintain the asset?

What does this boil down to?

• You need to shop around; standard equipment is typically manufactured by multiple OEMs.
• You should understand what the OEM provides beyond the asset.
• You need to understand how the machine will integrate into your facility.

It helps to turn those questions into a short list the purchase agreement must answer before it is signed.

Item to agree in writing	Why it matters later
Products, SKUs and rated speed	The machine is built to what is written, not to what was discussed
Run rate the OEM must demonstrate, and where	Sign-off without a demonstrated rate moves the risk to you
Controls platform and component brands	A machine off your standard means new software, spares and training
Network and data requirements	Addressing, isolation and the tags SCADA or MES need are cheapest to build in
Installation, commissioning and on-site support	Decides who is on site when the line is down
Training, documentation and spare parts	Decides whether your team can support the machine after the OEM leaves

Vendor Acceptance Tests (VATs) / Factory Acceptance Tests (FATs)

A significant amount of money and effort is often spent on VATs / FATs. These initiatives aren’t just boondoggles for the engineers. These activities are key to understanding the issues and rectification steps before you sign off on the machine. The international reference for structuring them is IEC 62381, which covers the factory acceptance test, the site acceptance test and site integration testing, and our guide to the factory acceptance test for plant controls walks through running one day by day.

Here’s a simple scenario:

• The OEM agrees to build a case packer using a vision system specified by the end-user.
• During the part acquisition process, the OEM realized that the parts they needed weren’t available.
• Without informing the end-user, the OEM decides to proceed using a different vision system their team is familiar with.
• The end-user engineering team shows up at the OEM for the VAT and realizes that the vision system can’t be integrated with the rest of their current line.
• The end-user engineering team mandates that the OEM purchases the correct parts, which will be installed at the end-user site to match what was agreed upon.
• The above saved the end-user $30,000 in engineering integration costs to retrofit the different brand vision systems AND saved the need to train and stock the new parts.

The moral of the story is that a VAT / FAT is used to detect anomalies BEFORE they make it to the plant floor. By investing the resources to validate the equipment before it’s signed off on, end-users can ensure that it has been built to spec, has no issues running at the specified rates, etc.

Integrating New Machinery Into Your Plant Network

In the current smart manufacturing (Industry 4.0, IIoT) world, it’s extremely rare not to have some sort of connectivity between various assets and a central location. Depending on how the OEM handles their control system design and how your IT / OT engineers decide to bring this machine onto the network, you may run into challenges.

There’s always more than one way to “skin a cat,” so let’s take a look at a few options below:

Architecture #1: Flat Network

In small facilities and those that haven’t been modernized, you’ll often find what’s called a “flat network.” These topologies will frequently involve multiple unmanaged switches (or managed ones left in their default, unconfigured state) scattered throughout the facility.

The engineering / maintenance teams on the OT side will often maintain a log of devices in a spreadsheet with an IP address for every PLC, HMI, VFD, IO block, etc.

If your facility is small enough, it’s possible to operate this way…

Once a new machine arrives, your team can simply add all the network devices onto their spreadsheet, re-assign IP addresses based on the facility table, and move onto operating the machine.

Generally speaking, here’s what you’ll end up with in this case:

IP address	Device	Status
192.168.0.10	Line 1 Filler PLC	Existing
192.168.0.11	Line 1 Filler HMI	Existing
192.168.0.12	Line 1 Filler VFD1	Existing
192.168.0.13	Line 1 Filler VFD2	Existing
192.168.0.14	Line 1 Capper PLC	Existing
192.168.0.15	Line 1 Capper HMI	Existing
192.168.0.16	Line 1 Capper IO	Existing
…	…	…
192.168.0.116	Line 6 Palletizer PLC	New
192.168.0.117	Line 6 Palletizer HMI	New
192.168.0.118	Line 6 Palletizer VFD1	New
192.168.0.119	Line 6 Palletizer VFD2	New
192.168.0.120	Line 6 Palletizer Vision System	New

These are private addresses in a single 192.168.0.x range, so every device in the plant shares one subnet and one broadcast domain. Our guide to IP addresses in industrial automation covers how to plan the ranges instead.

Is this a problem?

In general, it’s not a problem for a small operation; it starts to become a problem as you add more devices onto the network. It becomes more of a problem if you add “traffic heavy” devices (vision systems).

Architecture #2: Separate VLANs / NAT Via Managed Switch

Managed switches come in many different price points in the industrial automation space. It’s often difficult to figure out what you need without consulting an expert. The world of IT has dealt with many of these challenges for decades; there’s a different feature set for a facility of every size.

Using a managed switch, you can isolate the machine you’ve just brought in from the rest of the facility.

Wait a minute; why would we want to isolate? I thought we wanted to connect…?

Well, do you really need the traffic of the VFDs, vision systems, IO modules, safety modules, and many other peripherals on the network? Chances are, your engineers only need to connect to the PLC and HMI. Furthermore, if they’ve gotten there, and they’re using standard equipment, they should be able to “tunnel” to anything else they might need. For example, you can reach a PowerFlex drive through a ControlLogix PLC.

In short, the managed switch can be configured to only allow certain traffic through. With NAT, the machine can even keep the OEM’s standard internal addresses while the plant sees each exposed device at an address from the plant’s own plan, so two identical machines no longer collide. This is the zones and conduits idea from ISA/IEC 62443 applied to a single machine.

Architecture #3: Segmentation Using PLC Ports

Many “modern” PLCs (not all) feature two Ethernet ports. It’s important to note that on some of them both ports act as one interface with one address, like a built-in switch, while others can have each one configured separately, with its own address on its own network.

Why is this important?

Well, it allows the machine builder / OEM to keep the entire machine control system standardized and allows the end-user to simply set an IP address on the PLC port for communication purposes.

Although the nuances between the approaches are small, it’s important to understand the trade-offs. The table compares them on the same terms.

Architecture	What the plant sees	Skills needed	Best for	Main limitation
1. Flat network	Every device in the machine	Low	Small plants with few networked devices	No isolation; traffic and faults spread plant-wide
2. Managed switch, VLAN or NAT	Only the devices you choose to expose	Network configuration expertise	Plants with many machines or traffic-heavy devices	Switch cost and someone to own its configuration
3. PLC second port	The PLC, and devices reachable through it	Low to moderate	Standard OEM machines with a dual-port PLC that supports separate networks	Not every device can be reached through the PLC

The first architecture should only be used in facilities with little equipment on the network and with low IT / OT networking skills. This approach is going to “keep things simple,” but isn’t going to provide any network resiliency should there be excessive traffic.

The second architecture is a solid approach. It requires OT / IT networking knowledge and an expert who would configure the switch properly. Keep in mind that an industrial managed switch can be expensive depending on what you need: how many devices are connected, which vendor / platform you’re using, how much control you need, etc. The simple approach is to purchase a switch from the same OEM as the control system. Notice that there might be better alternatives.

The third approach uses the OT infrastructure already in the machine to create different access points into the PLC. This is usually simple to implement and segments the machine very well from external access. Note that this provides less “flexibility” in terms of being able to access all devices on that network. For example, you won’t always be able to tunnel through the PLC to all devices using this architecture. If you need access to a specific network devices using scheme #2, you can always add them to the NAT / VLAN tables.

Commissioning New Machinery: Post-Deployment Challenges

Once your machine shows up on site, the time starts ticking for the following activities:

Step	What happens	What it proves
Assembly and installation	Engineers and technicians piece the machine together to the OEM’s specifications	The machine is built and placed as designed
Pre-power-on checks	The team validates connections made by the construction crews, checks grounds and terminations	It is safe to apply power
Power-on checks	The machine is powered and voltages to breakers, motors and devices are verified	Power distribution and devices are healthy
Dry run	The machine is run without any materials	Motion, sequences and interlocks work
Wet run	The machine is fed materials to make the final product	The machine can make good product
Ramp to OEE target	Engineers and technicians tune and adjust; it is extremely rare to see a machine run at the specified rate on day one	The machine runs at the rate it was bought for

At this stage, the exercise is purely operational. A skilled project manager will keep a list of various issues that need to be addressed by each group, ensure that there’s a date & owner, and follow up with the parties that need to handle the specific tasks: process engineer, mechanical engineer, electrical engineer, QA supervisor, technician, construction crew, OEM, and others. Our commissioning support service runs exactly this list for plants that do not have the people to spare.

Personal Machinery Deployment Experience

We’ve certainly been part of multiple new machine start-up activities. I’ve personally traveled to Italy, Japan, and Germany for VAT equipment before it was brought on-site in the US, commissioned, and run at a manufacturing site. Here are some of our learnings:

Pre-Purchase Design & Validation

Before a commitment is made to purchase new equipment, it’s important to understand what is needed and what will be delivered. For some of the projects I’ve been on, assets similar to the ones at the facility were purchased. It’s important to note however, that requirements change: the machines need to run faster, provide higher performance, and be able to run different SKUs than originally purchased for.

The above ultimately means that a lot of time should be invested in creating these specifications and clearly communicating them to the OEM (in writing!)

I’ve learned that if you fail to mention any of these requirements, you’re likely to be disappointed with the machine, or spend a lot of engineering time retrofitting it once it is delivered.

FATs & VATs Learnings

Different groups, OEMs, vendors approach FATs and VATs differently. As you build the relationship, you can expect the number of “surprises,” or deficiencies to decrease. However, as you start working with a new group, it’s well worth your money to send a team of engineers for a week or two (depending on the process complexity) to validate the equipment. As discussed above, we’d often find deviations from the prints, which if not rectified, would cost the end-users thousands of dollars or more.

Commissioning Learnings

The OEM, or machine builder, has no responsibility beyond their machine. They aren’t going to help you integrate the machine into your facility (with some small exceptions). They’re going to ensure that it runs, and that it runs to your agreed upon specifications. It will be up to you and your team to get it connected to the plant SCADA, MES, ERP, etc. The challenges at this stage lie primarily on the networking side (there are electrical challenges as well, but that’s a different story); you can manage this multiple ways as specified above. It’s easy to fall in the trap of “wrong” integration that makes it difficult to alter later on. Get IT and OT involved with the right experts to make this happen.

Frequently Asked Questions About Bringing In New Machinery

What are the biggest challenges when bringing new machinery into a plant?

The challenges cluster in four places: an incomplete specification that lets scope and cost grow, an OEM whose controls platform does not match the plant’s standard, deviations from the agreed design that nobody catches before shipping, and integration into the plant network and SCADA or MES, which the OEM usually does not own. Each is cheapest to fix at the phase where it first appears.

What should be in the specification for a new machine?

At minimum: the products and SKUs it must run, the rated speed and the run rate the OEM must demonstrate, the controls platform and component brands that match your standard, network and data requirements, documentation and spare parts, and who is responsible for installation, commissioning and training. Put every requirement in writing. Anything left unstated is something the OEM is free to choose.

What is the difference between a FAT and a VAT?

Both are acceptance tests run at the machine builder’s facility before shipment. FAT, factory acceptance test, is the common term across industries; VAT, vendor acceptance test, is used by some plants for the same activity. Either way, the end user’s team witnesses the machine running against the specification and records every deviation, so problems are fixed at the OEM rather than on the plant floor.

How should a new machine be connected to the plant network?

Isolate the machine and expose only what the plant needs, usually the PLC and HMI. Three common patterns are a flat network, which is simple but scales poorly, a managed switch using VLANs or NAT to isolate the machine, and the PLC’s second Ethernet port as the plant connection. Choose based on the plant’s network skills, the traffic the machine generates and how much remote access is needed.

Who is responsible for integrating a new machine with SCADA and MES?

Usually the plant, not the OEM. Most machine builders are responsible for the machine running to the agreed specification and nothing beyond it. Connecting it to SCADA, MES and ERP, assigning addresses and fitting it into the plant network falls to the plant’s engineering and IT teams, or to an integrator they hire. Agree this in writing before the purchase order, not at commissioning.

Conclusion

Involving the right groups in conversations around new equipment purchases is critical to every manufacturer. Small, medium or large, every plant will face challenges when it comes to designing, purchasing, and commissioning equipment. Utilization of various Root Cause Analysis Tools such as the 5 Whys can help with getting these machines onto the plant floor. When the machine is part of a larger project with an integrator, our guides to working with systems integrators and writing the integrator’s scope of work cover the contract side, and our owner’s engineer service puts someone on your side of the table from specification to handover.