As one of the leading equipment movers in the UK, we’ve handled thousands of complex factory relocation projects over the last four decades.
During that time, we’ve helped manufacturers of all sizes to improve their operations by dismantling, removing and relocating whole production lines and facilities.
Minimising downtime and disruption to clients’ production timescales is of the utmost importance, and it’s why specialist support is vital to ensuring an efficient, safe and considered move.
Why would a business need to relocate its factory?
Changes in manufacturing demand are among the most common reasons a business chooses to relocate its factory in the UK.
Whether it’s driven by a need for more or less space, access to specialist labour or a new market, or to be closer to customers or the wider supply chain – factory relocation is a business-critical activity that needs the greatest attention to detail at every stage, from planning to execution.
Having support from an experienced service provider throughout that process is incredibly important, due to the following potential complications.
What are the challenges in factory relocation?
A factory’s full or partial relocation is not without its challenges as manufacturers try to strike a balance between minimising the impact of operational downtime and ensuring high-value, complex machinery is moved quickly and safely.
The three significant challenges involved with factory relocation in the UK are:
1. Planning the move
Relocating a factory requires considerable planning. Bespoke site surveys are a crucial part of this stage as they help movers to familiarise themselves with the factory’s inventory, identify challenging items, plan the moving sequence, identify health and safety risks and pinpoint access issues that may require specialist attention. The latter is significant as working inside factories and close to production lines typically involves confined or congested spaces.
A rigorous approach to planning must also consider if production needs to continue during the move and how aspects of it can be staggered to make this possible.
Minimising operational disruption later on in the process hinges immensely on this planning process. Being able to base seemingly unimportant predictions on decades of experience is critical, and is something that can’t be worked around by simply investing in more expensive kit.
2. Interrupted production
Out-of-service machinery impacts output, which in turn affects revenue. Manufacturers must carefully consider when factory relocation projects will take place within their production calendar, as well as the time it takes for machinery to be dismantled, removed, packed, relocated, installed and recommissioned for use.
As losses for large manufacturers can be more than £78,000 per hour, it’s critical to appoint a specialist mover who understands the need for efficiency and operates outside of traditional hours and across weekends to keep downtime to a minimum.
To get this kind of service, you have to go with an operator that has the scale to fit around these potential operational complications. Cutting corners at this stage can leave you exposed to huge losses, and simply won’t be worth it.
3. Ensuring no damage
High-value machinery and specialist equipment can be challenging to move. Manufacturers require specialist help to ensure that machinery is protected, secured during transit and kept safe at all times.
Not only will the cost of the damaged machinery need to be covered, but it could also result in operational downtime that has ripple effects on your business’s broader reputation and ability to deliver according to promised timelines.
Damaged machinery has costly repercussions but can be avoided with thorough planning and specialist lifting and moving expertise.
How can AIS Vanguard help with factory relocation?
As experienced equipment movers, we understand the enormity of factory relocation projects for manufacturers and the need for a proven partner with the right skills to complete the job efficiently, safely and with minimal downtime.
Our factory relocation services include:
- Expert project management and coordination
To minimise downtime and ensure a careful and controlled approach to the move, our team of skilled factory removal engineers carry out rigorous planning at the outset of a project.
This involves visiting the factory, cataloguing the equipment, machinery and infrastructure to be moved and identifying any access issues and risks before a schedule of works is compiled.
The work schedule explains each phase of the factory removal, with a precise sequence of how all factory dismantling work will be delivered. This is especially critical for factories that intend to operate partially during the move.
The planning stage also establishes project objectives, introduces the moving team – including the project manager, sets out estimated timescales and identifies any downtime required during the move. This information will inform a comprehensive method statement and produce relevant and rigorous risk assessments.
- Customised solutions
Every factory is different, so every factory relocation is different, too. Variations in the scale of the operation, the nature of the equipment to be moved, and the distances factories are being moved all have to be considered.
As a result, the AIS vanguard team deploys a customised approach to meet each manufacturer’s circumstances and produces a bespoke personalised factory relocation plan for each move. There is no one-size-fits-all approach, so we don’t even consider trying to adopt one.
- State-of-the-art equipment and techniques
With our in-house fleet of specialist heavy lifting equipment, we always have the right equipment to ensure a safe and efficient factory relocation.
We can carry out heavy, complex and technical lifts and moves safely by using cranes, forklifts, hydraulic jacks, skates, slings and chains. This variety means we always have the most appropriate solution and can consider factors such as restricted access, high tonnages and the specific needs of sensitive equipment.
- A highly experienced team
We have vast experience relocating factories and machinery across the UK and within Europe via our sister business, AIS Eurelo. We pride ourselves on using the best lifting and moving techniques and having a highly skilled team, and our widespread presence across the country and mainland Europe means that we can rapidly respond to a range of operational requirements regardless of location.
All factory relocation projects are assigned a project manager to ensure complete operational control and regular communication with all parties. The project manager is supported by a specialist engineering team comprising SSSTS-trained forepersons, riggers, mechanical fitters, HGV drivers (Class 1 and 2), crane operators and M&E specialists. To ensure that all our heavy lifting and moving activities are delivered to the highest safety standards, we employ an in-house team of certified slingers, signallers, banksmen and appointed persons.
- Efficient and safe relocation of heavy machinery
The combination of our specialist in-house fleet of equipment and a highly skilled team guarantees the efficient and safe relocation of all factory and heavy machinery. The appropriate levels of safety shouldn’t have to come at the cost of delays, so we ensure that it doesn’t end up doing so in practice.
- Commitment to Health and Safety
Adherence to strict health and safety practices ensures a safe and efficient project. At AIS Vanguard, we are a safety-first business and pride ourselves on holding several trusted safety accreditations including ISO 9001, 14001 and 45001. We are also RoSPA and British Safety Council members and hold Safe Contractor SSIP, Safe Contractor Safe PQQ and Constructionline Gold accreditations, among others.
- Minimise downtime and disruption to operations
We understand just how important it is for manufacturers to minimise the impact of a factory relocation project and that lost time is lost revenue. That’s why reducing downtime is always a priority. We work closely with clients to understand their timescales and develop a customised plan that supports commercial and operational priorities. The method statement outlines estimated timescales for project completion and shows how much downtime will be required during the factory relocation.
- Expert dismantling and reassembly of equipment
All factory removal projects must begin with dismantling and moving equipment. Our project team ensures the safe disconnection and decommissioning of equipment ahead of any move. The team follows the process in the method statement, which considers the best way to complete the task with the most negligible impact on operations.
- Professional packaging and transportation services
We can provide complete logistics support for all factory relocations, including professional packaging and transportation. This can include building high-quality custom-made crates to fit machinery precisely to protect high-value assets and ensure machinery is not damaged in transit. Protection during transit is an integral part of our full-service factory relocation capabilities. Our specialist movers show the utmost respect and care for all assets at every stage.
The right support
A trusted and experienced factory relocation partner is vital to minimise operational downtime and move equipment safely and efficiently.
Contact us for specialist help with your next factory move project or to learn more about AIS Vanguard’s factory relocation expertise.