As the manufacturing sector evolves, maintaining competitiveness increasingly demands more than incremental advancements—it requires strategic overhauls that provide long-term gains. One such strategy, ‘lift and shift,’ involves taking assets offline, relocating them, or upgrading equipment to better suit the shifting needs of the operation. While this can significantly improve business performance, it also presents challenges that must be addressed with careful planning and execution to minimise disruptions to productivity.
What is Manufacturing Lift and Shift?
Lift and shift is a versatile term used across industries, particularly in manufacturing, to describe the process of moving, upgrading, or replacing machinery and equipment. The scope of these projects can vary widely. For some manufacturers, it might involve something as simple as installing a new machine. For others, it could mean relocating an entire factory, a process that requires meticulous planning and execution.
Fundamentally, lift and shift is about taking a piece of equipment or a whole system offline to transfer it to a different location or replace it with cutting-edge technology. This process can include dismantling equipment, transporting it, and reinstalling it at the new location. In cases of full factory relocations, additional steps such as cleaning, refurbishing, and even reconfiguring production lines may be necessary. For instance, moving a food production facility would likely require disconnecting and sanitising conveyor belts and other equipment to meet strict hygiene standards.
Why Relocate Your Manufacturing?
At first glance, lift and shift services might seem necessary only when problems arise, such as equipment failure or space constraints. However, proactive manufacturers understand that relocating part or all of their operations can offer numerous strategic advantages. Below are some of the key reasons why a business might consider a lift and shift project:
- Better Facility
As a business grows, the needs of its manufacturing facility can change dramatically. Over time, incremental improvements might no longer suffice, and the best decision for the business may be to move to a new facility altogether. This could be driven by several factors, including the need for more space, improved energy efficiency, or the desire to install new, larger machinery that the current facility cannot accommodate. A new facility might also offer better infrastructure, access to advanced technologies, or compliance with more stringent regulatory requirements.
- Favourable Location
Location is a critical factor in manufacturing efficiency. Being closer to suppliers, customers, or essential resources can result in significant cost savings and operational efficiencies. For example, a food and drink manufacturer located near its primary suppliers can reduce transportation costs and improve supply chain reliability. Additionally, relocating to a region with lower labour costs or more favourable tax conditions can also provide financial advantages. In some cases, moving to a new location may open up access to new markets, enabling the business to grow and reach new customers.
- Expansion
One of the primary goals of any manufacturer is to expand—whether that means increasing production capacity, improving product quality, adopting new technologies, or all three. Lift and shift projects can be a vital part of this expansion strategy. By relocating or upgrading equipment, a manufacturer can increase its operational capacity with minimal disruption to ongoing processes. This flexibility allows the business to scale up or down as needed, responding quickly to market demands and opportunities.
- Replacing Machinery
In the fast-paced world of manufacturing, staying ahead of the competition often requires adopting the latest technologies. New machinery and equipment can offer significant improvements in efficiency, quality, and cost-effectiveness. However, integrating these technologies into an existing production line can be challenging. Lift and shift provide a solution by allowing businesses to replace outdated machinery with minimal disruption. By upgrading to the latest equipment, manufacturers can maintain their competitive edge and continue to meet customer demands efficiently.
How to Effectively Manage Lift and Shift Projects
While the benefits of lift and shift are clear, these projects can be complex and require careful planning and execution. Here are some strategies to ensure a successful lift and shift operation:
- Detailed Planning: Start with a comprehensive plan that outlines every step of the process, from taking equipment offline to reinstalling it at the new location. Consider all logistical challenges, including transportation, permits, and safety regulations.
- Minimising Downtime: One of the biggest concerns with lift and shift projects is the potential for downtime. To mitigate this, plan the relocation during periods of low production or consider using temporary equipment to maintain operations.
- Engage Expert Support: Given the complexity of these projects, it is often beneficial to work with experienced professionals who specialise in industrial relocations. They can provide the expertise and resources needed to ensure a smooth transition.
- Communication: Keep all stakeholders informed throughout the process. This includes employees, suppliers, and customers. Clear communication can help manage expectations and prevent misunderstandings.
Lift and shift projects offer manufacturers a powerful tool for enhancing their operations, improving efficiency, and staying competitive in a rapidly changing industry. Whether it is relocating to a better facility, moving closer to key suppliers, expanding capacity, or upgrading machinery, the benefits can be substantial.
