B&W were approached by a major woodworking manufacturing company in Yorkshire to completely relocate a 5000 square metre production unit approximately 1mile.
The production lines consisted of 80 individual units (up to 15ton in weight) joined by conveyor systems.
These units were relocated, lined and levelled within a four week time scale in order to minimise production down time.
The project was planned, managed and undertaken by B&W ‘in-house’ engineers and equipment, including fork lift trucks, access platforms, cranage and transport.
The project was completed to the customer satisfaction and within budget.
B&W were awarded a contract by a meticulous vetting process to relocate a major pump manufacturer from South Manchester to North East Manchester.
The site of 10000 square metre contained over 500 machines varying in weight from 3ton to 44ton, was relocated in such a way as to minimise production downtime.
The project from commencement to conclusion was carried out successfully over a 9month period.
B&W engineers along with the manufactures engineers planned and carried out the relocation over ‘out of normal hours’ working (eg nights and weekend).
Through close attention to detail the contract was completed ahead of schedule and within budget
B&W were approached by major food manufacturer (having worked in partnership over many years on various relocation projects) to provide a solution for the relocation of a complete production facility from Chester, to an existing production facility in Banbury.
B&W were tasked with the complete removal of all equipment including stock, material, vessels and machinery, whilst there was a minimal loss of production within a very tight timeline. Also all the equipment had to be integrated within an existing production facility during full production.
B&W was able to achieve this through meticulous planning and adaptability resulting in maximising the removal/installation programme by employing two teams so both removal and installation could be undertaken at the same time
B&W successfully reduced transport times, improving installation times, by utilising all our own equipment, and employing both out of hours/weekend working and with full commitment by both B&W employees and the manufacturers own workforce
B&W were approached by one of the North West’s largest facilities management company through recommendation, to provide a package, for the staged relocation of an aerospace in Hull to Preston.
This to include machine shop, part production, production areas, jigs cells for various airframes assembly, parts material stock to mention but a few areas.
B&W were able through working closely with the client and various client advisors, and there production requirements, to provide them with an acceptable relocation programme, taking into account the client very demanding and exacting requirements.
This was further complicated due to high redundancy in Hull.
The program had to offer the maximum amount of flexibility to the client due to their production requirements, we had to be very pro-active in providing relocation solutions under difficult circumstance, the relocation lasted over 10 months and was a resounding success (leading to further contracts within the aerospace group).
We here at B&W were able to exceed the client’s expectations on the project and bring the contract to fruition within budget and time scale.
European Machinery Relocation Case Study
A UK based company (for whom B & W carry out all internal relocations) with a manufacturing facility in Poland approached B & W to relocate that facility some 20km.
B & W sent out a representative to Poland, carried out a feasibility study, priced the work and was awarded the contract.
The Polish company carried out the electrical and pneumatic installation prior to B & W arriving on site.
B & W dispatched a team of engineers from the UK, complete with all equipment and a 7 tonne fork-lift truck on a 70 tonne / metre crane wagon to affect the relocation.
The machinery was systematically disconnected (to suit the production needs), dismantled as required, loaded to transport and relocated to the new factory.
The machinery was offloaded directly within the new factory, positioned to a new floor plan, ‘lined and levelled’, fixed and reconnected.
The factory consisting of 25 machines was relocated successfully within five working days (10 hour days) and with minimal disruption to production.
The relocation was co-ordinated on site by our senior supervisor, the Polish plant manager (English speaking) and our contracts staff in the UK.
Three more such contracts were obtained in the same area of Poland by the actions of our personnel and drivers.
Gantry and Slinging Operation Case Study
A local company contacted B and W Machinery Ltd with a problem of installing a moulding press (weighing 25 Tonne) into a pit within a factory with very restricted headroom (maximum height 3.5 metres, press height 4.4 metres and pit depth 1.2 metres).
The company had been quoted for the removal of the roof and the use of a 300 tonne crane.
B & W dispatched our senior lifting engineer to carry out a survey, who made recommendations and offered our services for the installation, utilising our four-leg gantry system, at approximately one third of the quoted option.
The contract was awarded to B & W.
B & W prepared method statements, risk assessments and lifting plans for the operation and liaised with the safety officer to avert any issues whilst production was continuing. The area was cordoned off with safety barriers and all personnel informed of the forthcoming installation and how it was to be carried out.
The main press being transported (in horizontal orientation) because of its least travelling height, was carefully offloaded by our versa lift (27 tonne fork lift truck) and travelled into a position in the doorway.
The press was carefully skated through the factory and into the area of the installation under supervision by the engineer.
B & W’s gantry operators, set up the gantry around the pit and the press.
Our lift engineers attached slings to the press at the pre-appointed position and under the guidance of our appointed person and the gantry supervisor; the press was carefully manoeuvred (rolled and moved forward) into the pit and into the vertical orientation, just avoiding the roof trusses in the process (as forecast in our lifting plan).
The operation was concluded with a clearance of debris and equipment stowed to transport and we left behind a suitably satisfied client.
Full Turnkey Package Case Study
B&W Machinery Installations Ltd were approached by a company from the North East of England to relocate its automotive component manufacturing facility to the South West of England.
B&W mechanical and electrical surveyors visited both sites to carry out a feasibility study. Time restraints of production and the costing were issued to the client. This study was accepted and our services were employed.
B&W's only question to the client was, can the plant been decommissioned and placed to positions for relocation? A positive answer was forthcoming and our electrical engineers disconnected the feed supplies.
Our electrical and mechanical engineers systematically ‘match marked’ all the cables, switches, pipes (hydraulic and pneumatic) and machinery and recorded in schedules, photographed and videoed the equipment to assist in the rebuilding of the plant.
Upon completion of the above, our engineers dismantled all the ancillary equipment, guards, etc and secured them to purpose built pallets. The pallets were loaded to B&W transport (for despatch) when the loads were full.
The heavy items, presses, loaders and manipulators (including robots) were all uplifted from the factory using gantries, versa lifts and fork lift trucks (always utilising the most efficient and cost effective means possible) and skated to a loading area.
All equipment was shrink-wrapped and sheeted against the vagaries of the weather.
These pieces were craned or lifted by versa lift to B&W transport (low loaders, semi low loaders or flats) and relocated to the new factory.
Because of the machinery requirement was ‘last out first in basis’, our transport manager and installation supervisor coordinated the logistics of fifteen wagons being called in the required order and time.
The machinery was re-assembled in the same configuration as at the previous site on to the prepared foundation and reconnected to the services.
Following exhaustive tests of circuits, rotation of motors, guards and E-stops, pipe-work (to ensure no leaks) the machinery was handed over to the manufacturers commissioning engineers.
Full production was gained within the time restraints imposed upon B&W by our client.
The project time scale was ten weeks and was completed within the ninth week and within the tight budgetary control of our client.
Storage and Transport Case Study
A UK based crane manufacturer approached B&W Machinery Installations Ltd with a requirement for transport and also for storage of their equipment prior to transportation to site.
- B&W fleet of trailers include extendable trailers 45ft’ – 95ft fully powered steer, purpose build for this type of operation.
- B&W storage facilities comprise of
- New 10,000 square ft purpose buit building with 15 ton overhead crane storage of crane beams of 30 metres easily within our compass
- 6,000 square ft serviced by 30 ton overhead crane
- 10,000 square ft serviced by two 6 ton overhead cranes .
- The storage facility has secure roller shutter doors, passive lighting within the compound and secure lockable perimeter gates.
- B&W also has 10,000 square foot of secure outside storage serviced by our cranage and fleet of fork lift trucks
B&W prepared the transport documentation (including notification to the relevant departments, Highways Agency, Police Authorities, etc), prior to sending our trailers for the cranes and bringing them into our storage facility.
B&W offloaded the cranes into the storage bays under controlled conditions, carefully blocking the beams to keep the crabs clear of the floor. All electrical boxes were sheeted against the ingress of dirt.
Upon instructions from the customer, the beams were reloaded to transport and dispatched to the required site.
Machinery Dismantling and Container Packing
A Chinese company approached B&W to despatch ten wire mesh making looms to a company outside Beijing. The looms were 8 metres long x 5 metres wide x 3 metres high x 20 tonnes each.
Transporting by flat racks was a non-viable financial option. The Chinese were offered the option to dismantle the looms and transport in standard containers, making it within budget.
B&W prepared method statements and risk assessment for the contract prior to starting.
B&W dismantled the looms into sizes compatible with standard container sizes. In all instances ‘match marking’ the components, photographing and recording into schedules all components, wiring and pipe-work was removed to assist the rebuilding in China.
All the small components were coated in anti rust-proof liquid and carefully loaded into packing cases. The rollers were coated in anti rust-proof liquid, wrapped in protective jackets and carefully loaded to stillages. The main frames and struts were packed on to purpose built pallets and secured.
All the equipment was loaded into containers; the equipment was secured within the containers using ‘treated’ timber and 5 tonne ratchet straps (each piece having a minimum of two straps and a footprint and framing of timber, B&W’s minimum standard).
All the equipment loaded to the containers, were recorded in container contents lists (these are cross-referenced to the aforementioned dismantling schedules) to give client the facility to call up the required container / containers for the rebuild.
On completion of the contract, all documentation, photographs and bills of laden were emailed to the client.
Some three months later the client emailed to inform us the looms had been rebuilt and to compliment us on the paperwork.