Comprehensive relocation of Kautex injection molding machines from Germany to Poland.
The Process of Relocating Injection Molding Machines
1. Initial Planning and Dismantling
The relocation of injection molding machines begins with a meticulous planning phase. This involves scheduling the dismantling of each machine in coordination with the factory's production timeline to minimize disruption. Mechanical and electrical disassembly is crucial, with electricians carefully labeling all connections for efficient reassembly at the new location. Special attention is given to disassembling support robots, ensuring their center of gravity is correctly identified for safe transport.
2. Loading and Transportation
Loading the machines onto transport vehicles is a task that requires precision, akin to a complex game of Lego. Each load is strategically planned to optimize transport costs and space. The heaviest loads, sometimes reaching 56 tons, necessitate special permits for oversized transport. The logistics team is responsible for securing all necessary documentation and coordinating the timing of the transports over distances that can exceed 1,000 kilometers.
3. Arrival and Unloading
Upon arrival at the new location in Poland, a dedicated team, separate from the one in Germany, handles the unloading and installation of the machines. This simultaneous operation ensures that the relocation process is as time-efficient as possible.
4. Reassembly and Commissioning
The final stage of the relocation is perhaps the most critical—connecting and commissioning the machines. This task is carried out by the same team that performed the dismantling, supplemented by additional workers to manage multiple machines concurrently. Despite the inherent stress of this phase, maintaining a calm demeanor and adhering to the work schedule is vital for a successful startup.
Equipment and Machinery Utilized:
Basket lifts for reaching high components
Forklifts for moving machines and parts
Transport rollers for shifting heavy loads
Hydraulic lifts for precise lifting and positioning
Chain hoists for controlled lifting operations
Slings and hooks for secure attachment of machine parts
Hydraulic cranes for heavy lifting tasks
Challenges and Solutions:
One of the main challenges in relocating injection molding machines is ensuring the safety and integrity of the equipment during transport. This is addressed by using the appropriate lifting and securing tools, as well as by employing experienced operators who are skilled in handling heavy machinery. Additionally, the coordination between different teams across countries is crucial to minimize downtime and ensure a seamless transition from one facility to another.
By following these steps and utilizing the proper equipment, the relocation of injection molding machines can be executed with precision, ensuring that they continue to function effectively for many years post-relocation.