Machine Installation & Commissioning Checklist

0%

0 of 32 items complete

12 critical items still open - these are the highest-risk gaps.

Download checklist:

Pre-installation and site readiness

Site survey is completed and the machine layout is approved by the customerCRITICALFloor loading, flatness and anchor requirements are confirmedElectrical supply, earthing and isolator location are ready per drawingsCRITICALCompressed air, water, vacuum or other utilities are available at the right pressureAccess route for the machine is cleared, including doors and liftsSite safety induction and permits are arranged for the installation team

Delivery, rigging and positioning

Packages are inspected on arrival and any damage is photographed and reportedCRITICALLifting plan and equipment ratings are checkedCRITICALMachine is placed, levelled and anchored per the foundation drawingTransport locks and shipping braces are removed and recordedModules are connected mechanically and aligned to tolerancePacking materials are removed and waste is handled per site rules

Utility connection and pre-power checks

Power cables, earthing and bonding are connected and inspectedCRITICALInsulation and continuity tests are done before first power-upCRITICALAir, water and hydraulic lines are connected and leak checkedLubricants and fluids are filled to the specified levelsNetwork cables and remote access are installed per IT planEmergency stop circuits are checked before energising motionCRITICAL

Power-up, tuning and functional test

Controls are powered in stages and software versions are recordedCRITICALMotor rotation, axis direction and homing are verifiedSensors, limit switches and safety devices are tested one by oneCRITICALDrives and axes are tuned and parameters are savedDry cycle is run at reduced speed before full speedVision, gauging or measurement systems are calibratedProduct trials are run and adjustments recorded

Training and handover

Operators are trained on start, stop, changeover and basic troubleshootingMaintenance staff are trained on lubrication, adjustment and safe isolationAs-built drawings, manuals and program backups are handed overCRITICALSpare parts and tools are checked against the delivery listPunch list is written with owners and due datesCRITICALService contact, escalation path and warranty terms are communicatedCommissioning report is signed by both partiesCRITICAL

Complete the phases in order. Items marked critical are stop points: do not move to the next phase until they are signed off.

Track commissioning in your ERP

Optional review of how commissioning stages and installed-base data can be recorded in your ERP or service system.

Optional. The tool and every export work without this. No spam.

How to use the checklist

Use the groups as phases and complete them in order. The first phase is about the customer: unless the floor, power and utilities are ready, the team arrives to wait. The following phases cover rigging, connection, power-up and handover. Critical items are stop points where a sign-off is needed before continuing, such as insulation tests before first energisation. Export the completed checklist and attach it to the commissioning report so the record travels with the machine.

Send a site readiness request weeks before shipment.
Assign a named customer contact for each utility.
Photograph key stages as evidence.
Record deviations as they occur, not at the end.

Commissioning sequence

A sound sequence moves from static to dynamic. Check wiring and safety circuits unpowered, then energise controls without drive power, then enable motion at reduced speed and torque, and only after that run product. Each step has a purpose: it limits damage if something is wrong. Record every parameter change in a log; at a minimum save a project backup at the end of each day so a corrupted controller does not erase tuning work.

Documentation and handover

At handover, the customer should receive the as-built drawings, manuals, software backups, test records and a spares list. If the machine will be connected to MES or ERP, record interface settings and test evidence. Training attendance should be recorded because warranty disputes often involve operator practice. A dated punch list and a clear definition of when warranty starts avoid arguments later.

Common mistakes

Frequent issues are utilities not ready on arrival, missing transport lock removal, wiring changed on site without drawing updates, and software not backed up before changes. Another is skipping the dry cycle because of schedule pressure, which converts a fixable error into a crashed axis. Finally, undocumented verbal agreements with site staff cause disputes; capture any scope change in writing and tie it to a change order.

Frequently Asked Questions

What is the difference between installation and commissioning?

Installation is the physical work: positioning, anchoring and connecting the machine and utilities. Commissioning is bringing it to a working state through power-up, tuning, functional tests and trial runs, then handing it over. Formal acceptance testing usually follows commissioning.

How long does commissioning usually take?

It varies widely with machine complexity and site readiness. A simple stand-alone machine may take a few days; an integrated line can take weeks. Estimate from a task list and add time for utilities delays and operator training, which are the usual sources of slippage.

Who is responsible for site readiness?

Normally the customer, according to the contract and the site requirements document issued by the supplier. State responsibilities in writing: power, air, floor, network and permits. If the site is not ready, record the delay and its cost implications according to the contract terms.

Should commissioning include operator training?

Yes. Training during commissioning with the real machine and product is more effective than separate classroom sessions. Record attendance and topics covered. Include safe operation, changeovers, daily checks and fault recovery, and leave quick reference sheets with the operators.

If you want commissioning status, punch lists and installed-base records to flow into your ERP and service system, Netray can help design it.

Talk to an Expert Explore More Free Tools

Related Tools

Industry Templates

More Industry Templates tools

See all

Machine Installation and Commissioning Checklist