01
Challenge
The client was moving its entire packaging production line from Cikarang to a new plant in the Makassar Industrial Estate. Every day the line stood still, customer orders slipped.
Management set the target: production in Makassar had to restart within 14 days of the first machine being dismantled.
- Heaviest machine 18 tonnesNeeded a lowbed and a 50-tonne crane at both ends.
- Precision componentsExcess vibration could throw the calibration off.
- Limited sailingsOnly two vessels could take flat racks that week.
02
Solution
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1
Survey and lift plan
The team measured every machine, its centre of gravity and the access at both plants. The client's engineer approved the rigging plan seven days ahead.
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2
Anti-vibration packing
Precision components were removed, crated in timber with dampers and fitted with shock sensors.
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3
Two shipping waves
Heavy machines went on 6 flat racks and 4 × 40 ft FCLs, split across two vessels so the schedule never relied on a single sailing.
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4
Unloading and placement on foundations
The same crane was mobilised to Makassar. Machines went straight onto their foundations according to the new plant layout.
03
Results
- days from the first dismantling to production restart, against a 14-day target
- 11
- machines damaged or needing major recalibration
- 0
- production days saved compared with the client's original estimate
- 3
Shock sensor data and the signed handover reports are available for review if your procurement team needs them.
Project photos
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Lifting the 18-tonne machine at the original plant. -
PHOTO: timber crate with dampers and shock sensors
Packing the precision components. -
PHOTO: flat rack loaded onto a vessel at Tanjung Priok
First wave, 6 flat racks. -
PHOTO: machine placed on its foundation at the new KIMA plant
Placement at the destination plant.
“We set aside three days for recalibration. We never needed them. The first line was in production on day eleven.”