In times of digitalisation, machine relocations are no longer purely analogue processes. With the possibilities of retrofit relocation, companies can utilise an upcoming production relocation to make their systems fit for the possibilities of a digital world.

The importance of digitalisation

With the increasing use of networked, digitalised and automated technologies, another industrial revolution is currently taking place. For industry, whether in vehicle construction, mechanical engineering or transport, this revolution is known as Industry 4.0. At the heart of this industry are two fundamental developments: Networking and self-control.

Networked systems make it possible to exchange data and information intelligently and react quickly to new developments. In Industry 4.0, all machines, and the goods they produce will therefore be equipped with sensors. The advantage: they communicate with each other continuously and optimise their processes themselves on an ongoing basis. But that’s not all: in addition to production, sales, development and even customers and suppliers will also be integrated into the networked world.

What lies behind the term retrofit

In order not to miss the connection to a digitalising world, companies should use a relocation to modernise existing systems, processes, and equipment and, for example, make them fit with new sensors – this is what distinguishes the digital component of the retrofit above all. This subsequent digitalisation makes it possible to optimise the utilisation and maintenance of systems and prepare for new requirements for future production processes.

The three phases of relocation and the accompanying digital retrofit

Phase 1 – Planning

This is the most important phase: – in this phase, the retrofit specialists gain an impression of the deadlines that have been set and what needs to be relocated physically and at process level. The subsequent necessary steps are taken on this basis. Benjamin Bielefeld, Innovation Manager at SCHOLPP partner Hörmann Rawema Engineering & Consulting GmbH, explains: ‘Today, nobody walks through the factory halls with a tape measure and metre rule. We measure the machines with a 3D laser scan and use this as the basis for modelling a 3D model, which we use as a guide when positioning the system at the new location, for example.’

However, this is only the physical component. The analytical view also applies to the detailed mapping of the commercial processing, the work situation, the sequence, and optimisation of the production processes with all the associated parameters and the sensible retrofitting of sensors. A careful balance between investment costs and operating costs is particularly important here, as competing objectives are often the reason for planning errors. The later these are discovered, the more expensive they are to correct. Berlin Brandenburg Airport (BER) is a notorious example of this. This makes the ‘total cost of ownership’ factor, which is often neglected in relocations, more important.

Phase 2 – Relocation

Once the planning phase has been completed, the next step is implementation. Machines and systems are expertly dismantled, safely transported, and temporarily stored and, if necessary, prepared for their renewed long-term use through maintenance measures. The various steps of the relocation are accompanied by continuous controlling of the relevant parameters (cost, time, quality). This guarantees that the things that need to be there first are in the right place at the right time and that costs and quality parameters remain within the planned range. Initial upgrading measures, e.g. new sensor technology, new control systems, adapted processes, can also be implemented during this phase.

Phase 3 – Finalisation

Once on site, all equipment, IT systems and media, i.e. the entire infrastructure, must be set up so that production can start up quickly. Retrofitting is a success when equivalent operation is guaranteed and significant potential for improvement has been realised. ‘With retrofits, we turn black boxes into white boxes,’ explains Benjamin Bielefeld, ’because with the sensors we install and the resulting digital evaluation options, our customers are often able to influence process parameters that were previously not measurable or known at all.’

Trust between the client and the external service provider for the relocation and a common goal are therefore an essential basis during all three phases. The business objective can include various aspects. For example, switching from diesel forklift trucks to electric forklift trucks not only saves costs, but also makes an energy-saving contribution to environmental protection. In this way, a relocation becomes an entrepreneurial revitalisation.