By Dovydas Kersys · Chapter 2 of 58 in Machine Commissioning.

Before you begin: Follow the machine documentation, risk assessment, site procedures and lockout/tagout requirements. Commissioning can expose personnel to electrical energy, stored pressure and unexpected motion. Never defeat a safety function merely to make a test easier. Examples and diagrams are generic and must be checked against the actual machine.

Commissioning often brings electricians, mechanical technicians, automation engineers, OEM specialists, production, safety personnel and contractors into the same area. Clear technical ownership prevents unsafe assumptions and duplicated changes.

Why this matters during commissioning

Many startup delays are communication faults disguised as technical faults. Two people may change the same parameter, an electrician may correct wiring without updating the drawing, or a programmer may force an output while a mechanic is working on the actuator.

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Commissioning procedure

  1. Name a commissioning lead or responsible coordinator.
  2. Define who may energize, force I/O, modify PLC code, change safety logic, change drive parameters, or adjust process settings.
  3. Use a common fault/punch list with owner and status.
  4. State when a test requires the area to be clear and who gives the start authorization.
  5. Review unresolved changes at the end of each shift.

Common failure patterns

  • No clear owner for a fault.
  • Verbal changes that are never recorded.
  • Multiple laptops with different software revisions.
  • Starting motion while another trade believes the machine is still isolated.

Shift handover

A good commissioning handover tells the next shift what was proven, what changed, what remains unsafe or incomplete, and exactly which software/parameter versions are active.

  • Avoid vague statements such as “drive fixed.” Write what changed and what still needs testing.

Evidence to record

  • Current responsible person for each discipline
  • Latest approved software / drawing revision
  • Open punch items and owners
  • Test boundaries and temporary bypasses
  • Shift handover notes

FIELD RULE: When responsibility is unclear, stop and make it clear before continuing the test.

Continue the series

Adapted from Machine Commissioning for Maintenance and Automation Technicians, by Dovydas Kersys. © 2026 Dovydas Kersys. Featured cover image is an AI-generated editorial illustration.

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