Start up and shut down procedures

[Teri - 2011]

Start up/shut down procedures

One of our customers is demanding a start up/ shut down procedure to be in place. (we shut down for 2-3 weeks during the holidays). Anybody have one that they would care to share? Or a checklist of some sort that your company may be using? I have one started, however, I am having a total break down of the brain , I know I am missing items (it's friday!! )

Thanks!!

 

[Wes Bucey]

There are several reasons why a customer wants/needs to know about a supplier's shutdown/startup procedures. The primary thing is they want to know how it will affect them, their deliveries, and the product they buy from the supplier. Keeping this in mind, you simply outline the following:

1. reason for shutdown (inventory, retool, material shortage, vacation, etc.)
2. date and duration of shutdown
3. emergency contacts during shutdown
4. effect, if any, on shipments for existing orders
5. dealing with returns, billing issues
6. methodology to assure startup will be smooth and cause no change in product from previous
7. how supplier will deal with any backlog of orders sent during shutdown
8. anything else which can affect relationship with customer

 

[RosieA]

Hi Teri,

I'm not sure what business you're in, or whether your plant maintains environmental controls during a shut down, but here are a few thoughts on start-up:

1. machine start-up procedures: is there a step-by-step process to follow when restaring machinery? Do you need a warm-up period on machinery, is there pre-startup maintenance that needs to be done, do you need to "waste" some raw material to get machinery back up to pre shutdown efficiencies?
2. first article requirements for the first production after the shut-down;
3. refresher training for operators;
4. Beyond the first article, is there an enhanced level of vigilance or inspection needed until production is back to pre shutdown levels?
5. Do tools and fixtures need to be assessed for environmental issues like rust after sitting idle?
6. Has there been any raw material degradation?
7. Does any component material need cure time before use?

Best,
Rosie

 

[Bill Ryan - 2007]

We've had that "requirement" from most of our customers. A couple of them "demand" returning to the "Pre-Launch" Control Plan.When we do shut down for extended periods (a four day "weekend" or greater) we will follow the Pre-Launch CP until we're confident we are "back on track". If the customer is also in shutdown for an extended period, they will normally ask for some special type of documentation to go with each shipment for a prescribed period of time.

Rosie and Wes have a couple of nice lists which should be considered even if a customer didn't have the "Startup" requirement.