Growing an existing production line is never an easy thing. First, there is the current production operation which in most cases needs to keep running. Second, the production crew needs minimal training on the expansion line. Retraining can be costly with production line slowdowns because mission critical staff have a hard adapting to the new equipment. However, with careful planning both issues can be relieved of most worries.

One of the first issues to be addressed is to establish a measurable goal of how the production line should grow. That is if more completed products need to be produced each day, and then what is that new number? There may be times when the daily production number is fine but it would be nice if that production could be done in one shift rather than two. If it is increased speed that is desired then what are those numbers?

Determine Numbers
Once numbers are established, determining the right equipment to make that happen is next. This is a two-step process. First, talk with the floor personnel and with the supervisors. See how an increase in the line will affect their area and what equipment they will need for the increase. Do not forget to talk to shipping and receiving as they will have increased needs as well. Second, contact the equipment manufacturers and material handling companies about the desired increase to production.

Planning
The next step is to start planning the equipment installation. Talk with an experienced material handling installation company so they help in the planning. This is probably the most crucial step because thorough planning will keep downtime and disruptions to a minimum.

Of course there will be obvious issues like space requirements to review. But one of the more serious issues will be time, when will production be able to be stopped or disrupted long enough to install equipment? An experienced installation crew should be able to do much of the work while the plant is operational and not disrupting production or personnel. However, there will come the time when the new production line needs to be brought online. That switch would be good to plan around a holiday weekend or a time when the plant is already likely to be closed for a longer than average period.

Prepare Personnel
Finally, the issue of getting personnel accustomed to the new production is vital. However, if they were fully involved with the planning and installation process it will go a long ways to having them accept the changes. No one likes having change thrust upon them, but everybody likes making change happen. So, the last step starts with the first step. In everything keep the production line staff involved. Pull some production line staff into meetings with the equipment and material handling companies when the topic at hand affects their area. Have other staff involved someway with equipment installation, even when the plant is closed. At every point let them know what is going on and remind them that what is coming is the fruition of their ideas and suggestions. This will have them excited for the first day on the new line, rather than grumbling about something new and disruptive.

The key points to remember is to involve production line staff early and keep them involved, plan the installation thoroughly, and get an experienced installation company for the new equipment.