By Dovydas Kersys · Chapter 6 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.
A readiness review is the final gate before a machine enters a higher-risk test stage. It confirms that the necessary mechanical, electrical, utility, safety, controls and personnel conditions are simultaneously acceptable.
A startup gate checks the whole system, not one discipline at a time.
Why this matters during commissioning
Many startup incidents occur because one discipline assumes another discipline has finished. A readiness gate makes dependencies explicit.
Commissioning procedure
- Confirm mechanical guards, fasteners, lubrication, couplings and travel paths are complete.
- Confirm electrical inspection, protective earth, breaker settings and control power checks are complete.
- Confirm air, hydraulic, cooling, vacuum and process utilities are available and within limits.
- Confirm safety proof-testing has reached the level required for the planned test.
- Confirm software backups and parameter baselines exist.
- Clear the area and brief everyone on what will move or energize.
Common failure patterns
- Starting because “everyone looks ready.”
- Utilities present but unstable or incorrectly regulated.
- Machine controls ready while mechanical travel stops are not set.
- No known rollback point for software.
Evidence to record
- Readiness checklist revision
- Outstanding exceptions
- Approved test scope
- Responsible person
- Date/time of authorization
FIELD RULE: If a required readiness condition is uncertain, it is not green.
PART II
Safety and Pre-Energization
Safety and Pre-Energization
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Adapted from Machine Commissioning for Maintenance and Automation Technicians, by Dovydas Kersys. © 2026 Dovydas Kersys. Featured cover image is an AI-generated editorial illustration.