How do you modernise a live factory without disrupting output?
Plan with real data, deliver in modular phases, keep CDM and PUWER tight, and run staged cutovers in weekend or night windows so production stays on track.
Why factory modernisation is different
Brownfield sites come with legacy services, hygiene zoning and immovable production windows. The project lead must plan around shift patterns, allergens, segregation and retailer audits while protecting throughput. In practice, that means phased cutovers, out-of-hours installs and right-first-time commissioning with minimal downtime.
Data-first planning that proves ROI
Start with facts. Map current speeds, changeovers, downtime causes and energy loads. Model scenarios before a bolt is turned so priorities are clear. Track live KPIs during each phase, including OEE, rejects, giveaway and labour, so benefits are measured, not assumed.
Modular builds, faster installs
Speed comes from moving work off the critical path. Pre-wired skids and panels, tested off-site, drop in quickly. Standard PLC and HMI interfaces, along with plug-in conveyors or inspection systems, shorten commissioning and simplify future reconfiguration.
Controls, inspection and useful data
Treat controls as a system, not an afterthought. Aim for unified PLC and HMI, recipe control and sensible line control. Close the loop with inspection using metal or X-ray, checkweighing, and vision systems with automatic feedback, plus condition monitoring to spot failures early.
Safety, CDM and governance built in
Appoint CDM roles early and keep risk ownership visible from feasibility through to handover. Align with PUWER for guarding, interlocks, emergency stops and safe isolation, with competence documented. Use stage gates: feasibility, design, procurement, install, FAT and SAT, and validation, to keep quality traceable.
Hygiene and sustainability by design
For food and beverage sites, use stainless steel, open profiles, sloped surfaces, and the appropriate IP rating. Manage people and product flows across zones and plan fast, repeatable clean-downs. Build in energy visibility: deploy sub-metering for new assets, trim compressed-air demand, and reduce film and waste through better control.
What good looks like now
Zero surprises, with risks logged and mitigations costed in advance. Weekend switchover, Monday output. Benefits reported against the business case. Maintainable assets from day one, with spares, PPM and remote diagnostics agreed.
How FESS Group delivers
Through project management industrial services, We manage industrial projects on live UK sites. That includes scoping feasibility, coordinating suppliers, installing and integrating mechanical, electrical, and automation works, and supporting with training, documentation, and ongoing maintenance. From conveyor re-routes and inspection upgrades to full end-of-line rebuilds, we de-risk modernisation while production runs.
Factory modernisation checklist
- Business case agreed with throughput, labour and energy targets
- CDM duty-holders appointed, RAMS, permits and isolations defined
- Layouts, services and hygienic design signed off
- Controls architecture and data capture, including OEE, downtime and SPC, agreed
- FAT plans, SAT or validation and acceptance criteria documented
- Spares, PPM and training plan confirmed before handover
- Phasing and out-of-hours plan aligned to production windows
FAQs
- What is the most significant risk when upgrading a live factory?
Unplanned downtime from clashes between installation and production. Use phased cutover, out-of-hours work, isolation, and a tested rollback plan.
- How do we prove ROI on modernisation?
Baseline OEE, waste and energy first, then measure the same KPIs after each phase and tie gains to labour, giveaway and throughput.
- Do we need CDM for factory upgrades?
If construction elements are involved, CDM 2015 is likely to apply. Appoint the correct duty-holders and follow HSE guidance. [TODO: confirm site policy references.]
- Can we modernise without changing the whole line?
Yes. Start with high-impact nodes, such as inspection, conveyors, end-of-line packing or palletising, or controls standardisation.
- How do we keep hygiene standards during works?
Plan segregation, barriers and tool control. Schedule deep cleans and swab tests. Specify hygienic materials and clean-down-friendly layouts.
Call to action
Ready to modernise with less downtime and more certainty? Talk to FESS Group via our contact page: https://fessgroup.co.uk/contact-us/
