Moving a live manufacturing site without derailing output or overspending? The short answer: define business outcomes up front, run the project under CDM with tight RAMS, phase the move to protect production, prebuild services off-line, choose the right lift-and-shift methods, and validate performance rapidly at the new location. With the right partner coordinating mechanical, electrical and controls, a factory relocation can be safer, faster and more cost-effective than you think.
1) Set objectives and freeze scope early
Decide why you’re moving—capacity, cost, consolidation, compliance—and capture measurable targets (throughput, labour, energy). Build a definitive asset list (machines, tooling, mezzanines, services) and agree what’s moving, scrapped or sold. Lock acceptance criteria for day one (power-on, dry run) and week one (target run-rate).
2) Govern like a construction project (CDM-ready)
Most relocations involve construction-like risks. Appoint duty holders (Client, Principal Designer, Principal Contractor), complete design risk reviews, and develop RAMS for isolations, hot work, working at height and traffic management. This governance removes surprises and protects timelines and budgets.
Authoritative resource (non-competitive): HSE guidance on CDM 2015 — https://www.hse.gov.uk/construction/cdm/2015/index.htm
3) Survey, design and lay out the new site
Confirm floor loading, access, door sizes, fire routes, hygiene zoning and utilities capacity. Create layouts that improve flow and cleanability versus the old site. Reserve space for maintenance access, change parts, and future expansion.
4) Phase around production windows
Plan weekend/night cutovers, or move by cell/line to maintain output. Build a single integrated programme with dependencies, isolations, permits and sign-offs. Include rollback options in case commissioning flags a late issue.
5) Prepare assets off the critical path
Pre-assemble skids (pumps, CIP), pre-wire control panels, and complete FATs before move day. Label cables, pneumatics and product-contact parts; back up PLC/HMI programs, recipes and network settings. Create quick-start SOPs with photos to speed recommissioning.
6) Choose the right lift-and-shift method
Match lifting to mass, footprint and access. Skates and toe jacks for internal moves; hydraulic gantries or Versa-lifts for tall/heavy assets; mobile cranes where external lifts suit the route. Protect with shrink-wrap, bracing, desiccants and shock/tilt indicators to avoid hidden damage costs.
7) De-risk services and controls
Pre-fabricate cable kits, containment, air drops and brackets so installation is plug-and-play. Validate earthing, power quality and compressed-air quality. Standardise PLC/HMI platforms where possible and plan line control/OEE integrations at the same time.
8) Plan transport like a supply chain
Complete route surveys (bridges, low wires, permits), book timed slots, and coordinate escorts if needed. Photograph condition before/after; confirm insurance levels and claims windows. For long hauls, consider dedicated vehicles and temperature tolerance for sensitive equipment.
9) Commission for first-time quality
Sequence dry runs → product trials → retailer format checks. Verify alignment and levels, safety interlocks, and emergency stops. Agree go/no-go criteria and document SAT results alongside PUWER checks before the first saleable packs leave the line.
10) Communicate relentlessly
Run daily stand-ups across production, engineering, H&S and contractors. Keep a live risk register and a single source of truth for drawings and permits. Plan training for operators, maintenance and hygiene teams before handover.
How FESS Group helps
FESS Group provides turnkey factory relocation services across the UK—decommissioning, lift and shift, transport, re-installation, alignment and recommissioning, plus mechanical, electrical and controls integration. We phase works around production windows when relocating a factory to cut downtime, and we stay on site through stabilisation to reach target speeds quickly.
Factory relocation checklist
- Business case agreed with throughput/labour/energy targets
- CDM duty holders appointed; RAMS, isolations and permits in place
- New-site surveys completed (access, services, hygiene, fire routes)
- Phase plan aligned to production; rollback plan documented
- Off-line builds and FAT evidence ready
- Lifting plan and equipment booked; ground-bearing checks complete
- Controls backups (PLC/HMI), labelling and spares pack prepared
- Transport route surveys, insurance and condition reports confirmed
- SAT/PUWER completed; acceptance criteria met; training and PPM scheduled
FAQs
1) How early should we start planning a factory relocation?
Begin at least 6–12 months ahead for large moves. Early surveys, CDM appointments and phase planning protect production and reduce premium costs later.
2) What causes most delays and extra costs?
Missing surveys (access, services), late scope changes, and underestimating commissioning time. Freeze scope, prebuild off-line and set clear acceptance criteria.
3) Can we keep producing while we move?
Often yes. Phased cutovers—by line or cell—plus weekend/night works help maintain output. Temporary services (power, air, lighting) can bridge gaps.
4) Do we need new risk assessments if the machinery is unchanged?
Yes. Location, services and access change risks. Update RAMS and complete PUWER checks at the new site before use.
5) How do we prove success post-move?
Baseline OEE, waste and energy before the move, then compare post-commissioning. Record SAT, safety checks and run-rate achievements against your acceptance criteria.
Ready to relocate with less downtime and more certainty? Book a consultation or request a site assessment today: https://fessgroup.co.uk/services/factory-relocation-services/
