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Commissioning: organization, carrying out, program and cost

At all times, industrial equipment was quite difficult from an engineering standpoint. Starting with the primitive from the point of view of the modern engineer presses and mixers and ending with an absolutely automated production of the most complicated parts for the space industry. In addition to the difficulties in the design of machines and units, there is also the complexity of operation. In order to maximally ease the work of maintenance personnel, to prolong the life of equipment, to avoid the production of defective products and to comply with all safety requirements, start-up operations must be performed before starting new machines.

What is the need for commissioning

Commissioning is almost as important as installing the equipment. Modern machines and units can be serviced by people without special education. "Outside" it seems that it is worthwhile to press just two or three buttons, and the products will come out from under the machine by itself. However, in order for this statement to become reality, it is necessary to take seriously the commissioning.

The organization of commissioning works should be planned in the project for the installation of equipment immediately after the installation of machines and units. Installation specialists are usually qualified to check the correctness of the unit settings. Even before the start of production, start-up operations will allow to determine how correct the factory settings are, identify errors in installation and assembly, if any.

Qualifications of specialists

Usually, the manufacturer of machines and equipment conducts training for specialists in setting up the operation of mounted industrial equipment. Most often, for installation, no high qualification is required, since any specialist with an average special education can conduct and connect the cables. If you have some experience, you can generally say that there are no qualifications for specialists engaged in installation.

Completely another matter is the commissioning of electrical equipment. Here you can not do without special knowledge and ideas about the device assembly, the ability to handle special programs, etc. In addition, if any errors are detected, the installer will have to make a decision to eliminate errors directly on the spot.

All this once again confirms the need for highly qualified specialists who carry out commissioning. Most often, installation and start-up of equipment are carried out by different people. If it is a question of complex industrial equipment, the manufacturer sends its specialists who have completed the training course and know all the subtleties of the installed machine tools.

Warranty service

The cost of modern equipment is quite high. Therefore, firms that establish production lines, strive to make maximum use of supplier's warranty obligations . Often, one of the conditions for the implementation of the guarantee is the commissioning of the prepared specialists. Only in the event that the equipment was launched by certified specialists, the manufacturer will sign the warranty obligations. At the end of the commissioning work, the warranty documentation is filled in, to which are attached the protocols of their implementation, the diagrams of the conducted studies and the scheme of individual settings.

What does the commissioning consist of?

The commissioning program consists of a set of measures to launch the equipment in operation. In general terms, we can talk about several blocks of commissioning: checking the correct installation and identifying factory defects; The introduction of customized settings of the customer and the operation of the equipment specified time; Training of the customer's personnel.

If everything is relatively simple with the first and last item of the program, then the second requires special attention. The fact is that each manufacturer has its own nuances and features of output. The equipment comes from the supplier with the so-called factory settings. However, the specific nature of production usually requires a change in the settings of the operation of the equipment and verification of its functioning under the new conditions.

Commissioning works just suggest control over the release of new products or proper operation after installation. Most often there is an agreement between the representatives of the customer and the executor about tracking the release of a small batch of products. It is possible that defects or failures will not be detected at the very first moment, and then specialists will be able to quickly orient themselves and make the necessary adjustments.

Training as part of commissioning

When commissioning is performed, training of personnel who will work on new equipment is of great importance. The quality of the finished product directly depends on the ability of workers to manage machine tools and aggregates. In addition, the faster the staff learn with new technical equipment, the more likely to win a competitive struggle, ahead of competitors with the release of a modernized product.

If it is a question of complex electrical equipment or gas boilers, then the ability of personnel to use new technology literally depends on security - both the lives of people and the enterprise as a whole. Therefore, during commissioning, special attention is paid to instructing the employees of the customer company. Most often, after the completion of such training, the commissioners issue a certificate confirming the primary skills of the workers.

How much is

Each type of work should be something appreciated. But since commissioning necessarily accompanies the installation of equipment, the cost of it is not allocated to a separate column. The cost of commissioning is usually already included in the total cost of the equipment and its installation, since these works are carried out by the equipment manufacturer. In some industries, however, there is another practice. In particular, when it comes to installing gas boilers or conducting additional environmental and technological tests, the cost of commissioning can be prescribed separately.

Particular cases of the cost of commissioning works

In addition, a separate column in the price list can be staff training. The usual practice is that all employees who will encounter new equipment are instructed. But there are situations when, due to staff turnover or some other reasons, you have to constantly instruct new employees. In this case, the enterprise-seller of equipment reserves the right to provide educational services for a fee.

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