Improve, upgrade or expand the plant you already run
A practical path for established operators: measure the losses, choose the smallest intervention that closes the gap, and buy it on a written requirement — not on a brochure.
Start with a loss baseline on the line you own, find the constraint, and test the cheapest fix first (method, maintenance, changeover). Only then compare retrofit, replacement and expansion on the same output target, total cost and shutdown risk. Our planning guides and tools are free to use; the project team prepares the RFQ and approaches suitable suppliers on your behalf for qualified projects.
Guides for existing operators
How to measure OEE losses on an existing line, separate availability, performance and quality, find the true constraint and size an upgrade only after the loss data is clear.
When to retrofit and when to replace production equipment: condition, controls obsolescence, safety re-assessment, lifetime cost comparison and a scoring table for existing plants.
How to plan a brownfield expansion at a running plant: tie-in register, shutdown windows, phased cut-over, utilities checks, safety controls and supplier responsibilities.
Machine builder, system integrator or in-house team? A buyer's comparison of factory automation companies for existing plants, with a scoring matrix and the questions that expose risk.
Who is asking — and what each role should check first
| Role | Their question | Start with |
|---|---|---|
| Owner / managing director | Is this worth the capital and the disruption risk? | Payback range, downside case, and what happens if we do nothing. |
| Operations / plant manager | Will this fix the losses I see every shift? | Loss baseline by category and the shutdown window the plant can afford. |
| Engineer / maintenance | Can it be integrated, maintained and made safe? | Interfaces, utilities, controls obsolescence and the safety re-assessment. |
| Purchasing | Are we comparing offers on the same scope? | One written requirement, a normalised scope matrix and acceptance terms. |
| Consultant / advisor | Is the business case built on measured data? | Data quality, assumptions register and sensitivity on the key drivers. |
The five questions, in the order to answer them
Diagnose first, decide second, buy third. Most avoidable upgrade spend comes from skipping the first step.
| Question | What you need | Where to go |
|---|---|---|
| Where is output really lost? | 4–8 weeks of stop, speed and reject data by cause | OEE loss analysis guide |
| Which step limits the whole line? | Cycle-time and queue data per step | Bottleneck guide |
| Retrofit or replace this asset? | Condition, obsolescence, spare-parts and safety status | Retrofit vs replace guide |
| How do we add capacity without stopping? | Tie-in list, shutdown window, cut-over plan | Brownfield expansion guide |
| Which step should we automate? | Labour hours, losses and control architecture per step | Factory automation systems guide |
| Which offer is actually better? | One URS, normalised scope, acceptance criteria | RFQ builder and quotation comparison |
Compare upgrade options on the same basis
Every option must be judged against the same output target, the same evaluation period and the same downtime cost.
| Option | Usual capital level | Disruption | Main risk |
|---|---|---|---|
| Method / maintenance / changeover fix | Low | Minimal | Gain fades without discipline |
| Targeted retrofit (controls, drives, tooling) | Low–medium | Planned stop | Hidden mechanical wear limits the gain |
| Bottleneck machine replacement | Medium | Planned stop + ramp-up | Constraint moves to the next step |
| Parallel line or extension | High | Tie-ins only, if planned | Utilities, space and permits |
| New site | Highest | Separate from current output | Long lead time; demand risk |
Tell us it is an existing operation
The upgrade request buttons on these pages open the RFQ builder marked as an operational upgrade or expansion, so the team reviews it as a brownfield project — current output, shutdown windows and existing equipment — rather than a new build. The project minimum for supplier outreach remains USD 250,000.
Frequently asked questions
Do you work with plants that only want to improve what they have?
Yes. Upgrade, retrofit, replacement and expansion projects at operating sites use the same free planning tools and the same managed RFQ process as new projects, subject to the USD 250,000 project minimum for supplier outreach.
What should I prepare before asking for an upgrade quote?
Current rated and actual output, a few weeks of stop and reject data, the product range, available shutdown windows, utilities and floor space, and the result you need after the upgrade.
Do you contact suppliers directly for me?
Yes, for qualified projects the project team prepares the RFQ and contacts suitable suppliers on your behalf, then helps you compare the offers. We do not sell buyer contact details to suppliers.
Request an upgrade assessment
Describe the line, the losses and the target. The team reviews it as an existing-operation project. Planning guides and calculators are free; supplier outreach applies to qualified projects of USD 250,000 or more.
Start the requestRelated guides and tools
- Factory automation systems for existing plants
- Industrial plant problems: symptom-to-cause guide
- Expand capacity or remove the bottleneck first?
- Fix, expand or build new — a CAPEX decision framework
- Upgrade vs expand vs new production line
- Phased automation upgrades: cost and downtime risk
- CAPEX/OPEX/ROI scenarios from your operating data
- ROI calculator
- Payback and IRR calculator
Sources and references
- ISO 22400-2:2014 — Defines manufacturing KPIs including OEE, availability, effectiveness and quality ratio.
- IEC 62402:2019 — Obsolescence management — basis for proactive spares and controls replacement planning.
- ISO 12100:2010 — Machinery safety risk assessment, relevant whenever an existing machine is modified.
Example figures are hypothetical and illustrate method only; they are not client results or price quotes.