IATF 16949 Clause 8.5.1.4 - Verification after Shutdown

[Peters]

I have next question:

8.5.1.4 Verification after shutdown
"The organization shall define and implement the necessary actions to ensure product compliance with requirements after a planned or unplanned production shutdown period"

What kind of shutdown do they mean? What is the problem with shutdown? Clause 8.5.1.3 is not enough?
Any ideas?

 

[Miner]

A planned shutdown could include a scheduled period of downtime due to low business volumes, or for a product line changeover (e.g., changing an assembly plant from producing cars to trucks). An unplanned shutdown could be due to a natural disaster (e.g., tsunami), breakdown of critical equipment that stops production, etc.

The problem that they are trying to address is the potential risks incurred from the extended length of time as well as the amount of changes that could occur during the shutdown. From my past experience in automotive, these are real risks that should be addressed.

 

[Peters]

OK. To sum up:
1. Night break is not shutdown.
In the case of the production stop for the night "8.5.1.3 Verification of job set-ups" is enaugh
2. Holiday break in August is the shutdown.
It may require a much more complex operations "8.5.1.4 Verification after shutdown" aiming to start production after a big stop (start-up of machinery, preparation/maintenance of the toolings, remove of preservation chemistry, replacement of the fluids, cleaning, start of the compressed air, trial run, comprehensive product testing etc.)
Is that it?

 

[Miner]

In general, yes. However, this is automotive, so you may have to justify it through a risk assessment.

I have worked with processes that you can shut down at night and restart with no issues. I have also worked with processes (e.g., hydrogen furnace) that you wanted to avoid shutting down because the cool down and restart processes were complex and the time required to reach steady state long.

 

[Peters]

Of course there are different processes.
I was looking for a general view.
In general for example in chemical processes often stop of the production is impossible. You can only completely shut down the chemical installation, drain the installation, and start the overhaul.
Thanks!

 

[Miner]

That is exactly what they are trying to encompass. They want controls in place to protect themselves from the risk that some company does not do what you describe.

 

[Eric C C]

We have a corporate internal work instruction for power outages (either a specific piece of equipment or a plant wide outage) which specifies what needs to happen both to the equipment and to the product effected by the power outage.
But we do not have a documented policy for a line that does not run over the weekend.
What defines a shutdown? Is it a power down? If we stop production for the weekend but we keep our lines powered up is that a shutdown? Obviously there are required procedures (which we do have documented) for the start up at each shift of operation.

If someone can share what the intention of IATF 16949 Clause 8.5.1.4 is I'd appreciate it very much. What would an IATF auditor be looking for as evidence of compliance?

Thanks

 

[bkirch]

Our approach was to first define what planned and unplanned shutdown was, and then we created a checklist for actions to do after an unplanned shutdown, and actions before and after a planned shutdown.

 

[Eric C C]

Thank you bkirch, have you been audited to the IATF standards yet?
Your approach seems very logical and simple.

 

[delorfra]

For your information, Ford & Renault have defined standard audit templates. You can find them on their portal.