By Dovydas Kersys · Chapter 45 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.

Introducing real product, material, liquid or process conditions changes loads, sensor behavior, timing and quality. Commissioning should add these variables gradually.

Why this matters during commissioning

A sequence that works empty may fail when product blocks a sensor, adds inertia, changes valve pressure drop or creates thermal load.

Advertisement

Commissioning procedure

  1. Introduce minimum practical quantity/throughput first.
  2. Verify product detection and tracking.
  3. Observe motor current, pressure, temperature and actuator timing under load.
  4. Check reject/scrap paths and jam detection.
  5. Confirm quality-critical setpoints and measurements.
  6. Increase rate only after stable cycles.

Common failure patterns

  • Sensor sees machine structure but not actual product color/material.
  • Conveyor speed droops under load.
  • Cylinder cushion correct empty but too slow under load.
  • Product arrives before downstream equipment is ready.

Evidence to record

  • Measured value and test point
  • Expected value / expected state
  • Observed value / observed state
  • Pass/fail result and any deviation
  • Name/date or responsible person where required

FIELD RULE: Product is part of the machine system. Commission the interaction, not only the equipment.

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.

Advertisement