While this seems like a ton of things to include on one checklist, remember that the layoff process is stressful for everyone. In these stressful moments, it’s a lot easier to look at a checklist than try to remember everything in the heat of the moment. This step is all about what happens immediately after the manufacturing plant closure. For example, if the plant workers barely check their email accounts, don’t email it to them. Maybe you should, instead, include the letter with their check or have their manager pass them out.
If you’re the plant system engineer or the plant manager, it’s important to prepare for a plant shutdown at least a month, if not longer, before the scheduled shutdown date. You can customize a shutdown checklist by tailoring it to your facility’s specific equipment, processes, and safety requirements. Regularly update the checklist to reflect changes in operations or regulations, ensuring it remains relevant and effective for your particular needs. Implementing this checklist not only improves efficiency but also supports compliance with industry regulations, safeguarding your plant and personnel.
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This template ensures you handle every shutdown professionally, protecting your assets and personnel. The plant team should give everything one more look before restarting the plant or process. Even when every step is taken and every job plan is followed, stuff happens. A motor is bumped during work on another piece of equipment, causing misalignment. Housekeeping staff accidentally hits a piece of equipment.
- A manufacturing plant shutdown checklist helps you streamline workflows and ensures that all team members align with the shutdown process.
- Plant shutdowns are oftentimes a necessary aspect of operational maintenance, and typically happen at least once a year.
- Then analyze where/why overruns occurred and what you can do to avoid them this time.
Dedicate a member of the shutdown leader’s team to each contractor. They will ensure the contractors work is being completed to the degree laid out in their contract and on time. This person will also serve as a point of contact for contractors. Based on the list, generate a master timeline for the shutdown using a Gantt chart. Using the original list and Gantt chart, order necessary equipment and supplies.
Operations Order Template
Though standard, plant shutdowns aren’t always convenient. Between overtime, third party contractors, maintenance supplies, and new equipment or parts, the costs add up fast. A plant shutdown isn’t the most exciting gift you’ll plant shutdown checklist give this season, but it’s one that keeps on giving in many ways. A checklist helps you comply with regulatory requirements by ensuring that you complete all safety protocols and documentation accurately. During periods of low demand, a planned shutdown can optimize resource use and reduce operational costs. The time, money and effort devoted to planned shutdowns can be extreme.
Relieve any mep systems that are under pressure for testing. After you have completed step one and have a list of those being let go, you need to start planning the offboarding process. First, we recommend having all of the necessary resources to make the layoff event go smoothly. This guide will assume that your business has already done everything in its power to save a plant from closing.
Ensure that all replacement parts, accessories and rebuilt equipment are in stock before the shutdown. The last thing any team needs is to have staff on hand to conduct maintenance, replacements and new installations only to be held up waiting for rebuilt equipment to return from a shop. That’s why you need a checklist to avoid forgetting important safety considerations during the plant shut down. This way you get a complete picture and are less likely to overlook factors that could derail progress during the shutdown.
Collision Avoidance Systems
A maintenance rep suggested replacing the packing and stayed on hand to make sure the packing was installed and seated correctly. This repacked digester operated successfully from January to April of that year, when an outage occurred. This saved the plant more than $98,000 during these four months. These are a few examples of problems that could occur after proper installation.
By following a detailed checklist, you reduce the risk of overlooking critical steps, which can lead to costly errors or safety hazards. Designate an emergency coordinator and emergency action team. It ensures that no essential maintenance steps are missed. A plant shutdown safety checklist will help you focus on safety better while carrying out the plant shutdown activities safely. It includes sections for a shutdown audit, master contact list, failure modes and effects analysis, meeting schedule,. It includes 31 items to ensure all necessary work is identified and reviewed by the turnaround team in a timely manner.
- In effect keeping your plant running efficiently until the next plant shutdown.
- Be sure to obtain competitive bids on contract work, and choose partners that have experience completing shutdowns efficiently, quickly, and successfully.
- It is because you have no plan at all and there may be hazards that you have never thought about.
- It’s a necessary evil, one that you can prepare for to maximize benefits and minimize cost and inconvenience.
At the same time, you need to make sure all of these moves follow regulations that protect workers, especially those over 40 years old. You should also make a list of goals that this event wants to accomplish. Then, consider how the event will play out in the court of public opinion and things of that nature. This section can be a bit all over the place, but the real takeaway here is that you need to thoroughly understand the event before it occurs. Read in-depth guides covering key topics related to this article. Steve Hall is the Southeast regional manager of SEPCO where he has worked for 21 years.
Other Important Things To Remember
Maintenance shutdowns include getting damaged or deteriorated parts of machinery repaired or replaced. To do this efficiently, you must prepare and order the necessary replacement parts several weeks in advance. Access a complete set of resources aimed at maximizing safety, quality, and operational excellence, including detailed guides, related templates, and real-world use cases. Partial shutdown maintenance can be a good way to keep the plant operational in some capacity. When a portion of the plant is operating as normal and maintenance is occurring in another part of the plant, miscommunication can be disastrous.
Following the steps outlined below will help ensure that a plant’s next outage will be successful. Properly shut down any nonessential equipment or systems (electric, water, gas) as. This document provides a template for planning a facility shutdown. Step three on your manufacturing plant closure checklist is all about actually downsizing the company. This involves sending notices, holding meetings, and extending benefits.
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Take more care against unexpected shutdowns rather than a planned shutdown. It is because you have no plan at all and there may be hazards that you have never thought about. Because of this risk, you have to focus on safety during plant shut down more than during normal plant operation. Be sure to obtain competitive bids on contract work, and choose partners that have experience completing shutdowns efficiently, quickly, and successfully. Brehob has a long history of helping our clients with shutdown service and repair for a wide range of equipment, including air compressors, cranes & hoists, and electric motors.