A planned shutdown is expensive: every hour the line isn't producing is an hour lost. What makes the difference between a shutdown that finishes on time and one that runs over is almost always what was prepared beforehand. Here is the method we follow with our clients.

Two to three weeks before: lock in the work list

Gather the requests from production, maintenance and quality into a single list. For each job, note the equipment, what needs to be done, the estimated duration, the number of people and the parts required. Then freeze the list: a job added the day before is the leading cause of delays.

Order the parts and check them on receipt

Bearings, belts, chains, seals and custom stainless steel parts often have lead times. Order them as soon as the list is frozen, then check them on receipt: right model, right size, right quantity. A part that doesn't fit on the morning of the shutdown can hold up an entire crew.

Prepare lockout and permits

In Quebec, every machine being worked on must have a written lockout procedure (RSST, s. 188.1 to 188.13). Check that one exists and is up to date for each piece of equipment on the list, and plan enough personal padlocks for everyone involved.

Permits are also prepared in advance: hot work for welding and grinding, confined space entry for tanks and hoppers, and work at heights as needed. You will find our permit templates in PDF in the site map at the bottom of the page.

Build an hour-by-hour schedule

• Schedule the longest or riskiest jobs first.
• Avoid having two crews working in the same spot at the same time.
• Allow a margin for surprises discovered when equipment is opened up.
• Keep time at the end for cleanup, testing and restart.

On the day: a kickoff meeting and one lead per zone

A short safety meeting at the start of the shift lets everyone review the jobs, the risks and the permits. One lead per zone tracks progress and immediately reports any delay or discovery that changes the plan.

Before restarting

Count the tools and removed parts, put the guards back in place, clean the area and run tests with production. Lockout removal is done only once each person has removed their own padlock. A short report per piece of equipment (work done, parts replaced, points to watch) already sets up the next shutdown.

Need labour or a TIG welder for your next shutdown? Call us at 438-357-8800.

Sources

1. Regulation respecting occupational health and safety (RSST), CQLR, c. S-2.1, r. 13 — lockout, s. 188.1 to 188.13
2. APSAM — Lockout and other energy control methods: regulations
3. ASP Construction — Hot work permit (template, 2023)

Photo: Unsplash. This article provides general information; it does not replace the manufacturer's requirements or your facility's risk assessment.