Sector Spotlight: Automotive Heavy Machine Moving

Automotive Projects from the Last 12 Months:

The Merritts Automotive machinery moving package aims to ensure that your machinery moving project is completed within the agreed time frame and with the least possible interruption to your business. This can also include operating out of standard working hours, evening or night and shift working, as well as weekends for moves that are time and/or production sensitive.

To illustrate the range of services we can provide, we have summarised the highlights of four projects which we completed this year on behalf of automotive clients.

1. INSTALLATION OF SEYI PRESSES FOR A SURREY BASED VEHICLE MANUFACTURER

 PROJECT SUMMARY:

Merritts were tasked with carrying out the installation of 2 x SEYI SLG2-400-S5 presses at the Surrey based facility of an automotive vehicle manufacturer. The project involves us collecting the machinery from docks, transportation to site, offloading and unpacking, moving into the facility, assembly, and connection.

DURATION:

Working to fit in with the client schedule, we  completed these works over a 4 week period.

HEAVY LIFTING EQUIPMENT

The following heavy machinery lifting equipment was required for this automotive machinery moving project.

• Merritts HGV’s & Trailers
• Enerpac Superlift Gantry SL125
• 7Te Forklift Truck
• 60/80 Versa-Lift
• 40/60 Versa-Lift
• 25/35 Versa-Lift
• Access equipment
• Specialist Tackle

COLLECTION, DELIVERY & OFFLOAD

The machinery arrived at the docks in packing cases on 8 flat rack trailers which we transported from the docks by road to the customer’s site. We then offloaded the cases from the trailers using Versa-Lift 60/80 fork lift trucks and transported the empty flat racks trailers back to the docks.

UNPACKING & MOVEMENT INTO THE FACILITY

• Machinery was unpacked from the steel and timber cases.
• The base frame sections of the machines were lifted by Versa-Lift 40/60 and Versa-Lift 60/80 and placed onto machinery moving skates.
• They were then moved into the facility and positioned in front of the awaiting machine pits.
• Steel plates were installed within the facility to ensure adequate floor protection.

BASE FRAME INSTALL

• Enerpac Superlift hydraulic lifting gantry was assembled over the machine pit.
• Slings were attached from the gantry to lifting points on the base frame.
• The base frame was lifted, moved over the machine pit, and lowered to the floor.

SIDE FRAME, TIE BARS AND SLIDE SECTION INSTALL

• The press slide sections were lifted and placed onto the base frames with the Versa-Lift 60/80.
• The tie bars were inserted into the side frame sections with the assistance of Versa-Lift 25/35 and 7Te forklift truck.
• The side frames were then orientated vertically using Versa-Lift 40/60 and Versa-Lift 25/35, and inserted into the base frame.

CROWN & ANCILLIARY EQUIPMENT INSTALL

• The crown sections were skated into the facility using Versa-Lift 60/80 and positioned in front of the presses.
• The crowns were then tandem lifted with 2 x Versa-Lift 60/80’s and positioned onto the presses’ side frame sections.
• Merritts assisted the machinery manufacturer’s engineers with the installation of the ancillary equipment.
• Following the installation, manufacturer’s engineers carried out the commissioning of the machines.

“I would like to say a big thank you to Merritts. The project planning and execution was delivered to an exceptional standard, resulting in the smooth installation of the heavy machinery.Your site operatives are a credit to your company. They were extremely helpful and nothing was too much trouble. We look forward to working with Merritts again in the future.”  Operations Manager, Surrey Based Vehicle Manufacturer

2. RELOCATION OF INJECTION MOULDING MACHINERY FROM GERMANY TO UK

PROJECT SUMMARY

Merritts were engaged by a leading manufacturer of automotive components to decommission and relocate 5 x Engel injection moulding machines from their plant in Germany for recommissioning within their production facility in the UK.

DURATION                   

We worked to a six week scheduled in order to fit in with the requirements of the project and the client timescales.

Germany Facility: Three weeks to decommission, strip, fully export pack and load out.

UK Facility: Three weeks to collect from docks, deliver, offload, unpack, position, assemble and recommission.

LIFTING EQUIPMENT

Personnel: Germany

•  1 x OEM Engineer
• 4 x Mechanical Engineers
• 2 x Electrician Engineer
• 2 x Lead Riggers

Personnel: UK

• 4 x HGV Drivers
• 1 x OEM Engineer
• 4 x Mechanical Engineers
• 2 x Electrician Engineer
• 2 x Lead Riggers

Lifting Equipment: Germany

• 200Te mobile crane
• 10Te FLT
• 7Te FLT
• MEWP
• Exported Merritts own rigging and lifting equipment

Lifting Equipment: UK

• SL 125 Super-Lift Gantry
• Versa-Lift 60/80
• 2 x 7Te FLT’s
• MEWP
• 2 x Tackle Vans

PROJECT DETAILS

Planning Phase:

Merritts project managers carried out a site visit in Germany to fully understand the requirements involved and to create a detailed scope of works for the project.

When the scope of works was finalised and our heavy machinery moving planning process completed , we issued method statements, risk assessments and lifting diagrams  to the customer for approval.

Once the RAMS and lifting methods had been approved, Merritts arranged for their mechanical, electrical, and rigging personnel to fly out to Germany to begin machine decommissioning works.

On site, Germany:

• Merritts ensured machinery was disconnected from mains services and oils were drained.
• Moving parts on the machinery were locked off with OEM transit brackets.
• Merritts used the facility’s overhead crane to lift the Viper robots from the machinery and place onto bearers within pre-manufactured timber cases. This process was also used for the machinery’s tie bar pullers.
• Merritts mechanical and electrical engineers then separated the clamp and injection units on each machine.
• The clamp and injection units were then skated to an outside position and craned from a specially designed level steel platform and lowered onto pre manufactured steel and timber packing bases.

Export Packing Services:

As an extension of our machinery transport and installation services, we are able to safely package industrial machinery and equipment and transport it to any destination in the world.

On this project, the automotive machinery and parts were fully vacuum packed in foil bags and cases formed around them. The cases were loaded to flat rack trailers and lashing inspection certificates received. The cargo was shipped from Germany to Felixstowe, UK.

Reinstallation at the UK facility:

• Merritts arranged customs clearance of goods and collected all OOG cases from Felixstowe and delivered to the Cheshire facility.
• Merritts erected the Enerpac Superlift gantry on site to offload all OOG machinery.
• All items were offloaded and unpacked to allow positioning, as instructed by the client.
• Machinery was skated into position with assistance from the Versa-Lift.
• Merritts mechanical and electrical engineers reassembled and reconnected the machinery.
• Peripheral equipment, including the Viper robots was positioned using the on site overhead crane.
• When all machinery had been rebuilt and reconnected, the OEM engineer recommissioned the machinery.

3. INSTALLATION OF ALUMINIUM EXTRUSION MACHINERY FOR A DERBYSHIRE BASED SUPPLIER TO THE AUTOMOTIVE INDUSTRY

PROJECT 

Our brief on this heavy machinery moving project included the provision of lifting equipment and a mechanical installation team to offload and install an SMS HybrEx extrusion machine and a OMAV furnace into a brand new aluminium extrusion manufacturing facility in Derbyshire.

In total, the aluminium extrusion press weighed in at over 170 Tonnes.

SMS HYBREX INSTALLATION:

SMS machine works were completed over a 3 week period.

• Merritts prepared the site by laying steel plates within the facility to ensure adequate protection for the floor.
• Merritts Enerpac Superlift Gantry was offloaded from transport and assembled outside of the facility, in line with the access door.
• The SMS machine’s ancillary items were offloaded from transport with Merritts’ Versa-Lift 60/80, taken inside the facility, and placed in a holding area.
• Applicable site roadways were cordoned off whilst lifting was in progress to ensure public safety.
• The Superlift Gantry was used to offload the 2 main sections of the SMS press. These consisted of a 26Te platen and a 67Te platen & cylinder section.
• The sections were placed onto suitably rated machinery moving skates and moved into the holding area within the facility.
• The gantry was then dismantled and reassembled inside the facility, over the machine pit.
• The large sections of the SMS machine were moved from the holding area via Versa-Lift 60/80 and machinery moving skates and placed into position for the Superlift Gantry
• The gantry was then used to lift the sections and to position them within the pit.
• Merritts engineers worked with the SMS engineers to level and bolt down parts.
• Ancillary items were collected from the holding area with 7Te FLT and Versa-Lift 60/80. Again, Merritts assisted SMS engineers with assembly of the machine.

Equipment Allocation:

• Superlift Gantry
• Versa-Lift 60/80
• 7Te FLT
• MEWP
• 2 x Tackle vans

Personnel Allocation:

• Foreman
• 2 x Rigger
• 2 x Engineer
• Assistant

4. OMAV FURNACE INSTALLATION

Working on behalf of the same client, we also installed an OMAV furnace, for specialist heat treatment of products.

The works to install the OMAV furnace were completed over an 8 week period. As a brand new facility it was important that Merritts liaised with the on-site project manager to co-ordinate works within the build schedule and other construction and production line changes that were taking place.

• Main machine sections were offloaded from transport using Merritts Versa-Lift 60/80. Ancillary items were offloaded with 7Te FLT. All items were moved into the facility.
• Versa-Lift was used in tandem with a 7Te FLT to position the main sections of the OMAV machine.
• Merritts mechanical engineers worked with the OMAV engineers to assemble all machinery and equipment including the OMAV furnace, run out, handling unit and ageing oven.
• OMAV engineers carried out final commissioning of the machinery.
• Method statement, risk assessments and lift plans were provided for approval by the customer before works commenced

Equipment Allocation:

• Versa-Lift 60/80
• 7Te FLT
• 2 x Tackle vans

Personnel Allocation:

• Foreman
• 2 x Rigger
• 2 x Engineer

Merritts have been the perfect partner to work with throughout the project. Their machinery installation knowledge has been of great value and they have worked cohesively with the OEM engineers to complete the works well within the expected timeframe. Their attention to health and safety issues and professionalism when on site has been exemplary and we look forward to working with them again on future projects.  Technical Production Director

The above are just four examples of case studies that demonstrate our significant expertise removing, transporting and installing heavy machinery for the automotive sector. If we can help on your next heavy machinery moving project please get in touch.