When a line stops unexpectedly, the first move is to make the machine safe, not to look for the fault. It is also what gets the repair done faster: an isolated machine, symptoms written down and the right specialist called at the right time. This article covers unplanned breakdowns; a planned maintenance shutdown follows a different logic. Here are the six steps to take in the first hour, in order.
Key takeaways
- Before entering the hazardous zone of a machine, lock it out or apply an equivalent energy-control method, according to the plant's written procedure.
- Write down right away what operators saw, heard and read on the screen, then classify the fault: mechanical, electrical, pneumatic or product-related.
- Decide in advance how long to wait before calling an emergency service, and have the equipment model and nameplate at hand.
- When restarting, remove the locks according to the procedure, check the guards and restart empty.
1. Make the equipment safe before looking for the cause
Before touching the machine, stop it safely and control its energy sources. In Quebec, the employer must lock out or, failing that, apply an energy-control method offering equivalent safety before any work in the hazardous zone of a machine, whether adjusting, inspecting, unjamming, cleaning, repairing or maintaining it (section 196 of the RSST). Looking for the cause of a breakdown often means inspecting or unjamming, two tasks covered by this rule.
Lockout or an equivalent method: what the regulation says
Lockout means placing a uniquely keyed padlock on an energy-isolating device, which keeps all energy sources in a safe state for the duration of the work. The regulation also allows other methods. Simply unplugging is permitted in some cases, for example when the machine has a single energy source, the plug is within reach and the energy is truly absent once unplugged. For any other method, the employer must first analyze the machine and the risks to show that the method reduces the risk effectively.
Written procedure, equipment, training: who does what
The procedure belongs to the employer. The employer must write the lockout procedures, supply the equipment, train workers and coordinate the work. When several people enter the hazardous zone, each one applies their own lock. The stakes go beyond personal safety: in case of non-compliance, a CNESST inspector can order work stopped, close a workplace or seal a machine. If no procedure covers the machine involved, do not improvise: contact your health and safety lead.
One special case is worth knowing. When a diagnosis requires running the machine with a guard moved or a device disabled, the regulation requires a specific control mode (section 188 of the RSST). It is not something an operator improvises.
2. Write down what happened, right away
Note the symptoms before memories fade, because this information shortens the diagnosis. The operators on site saw or heard something: a noise, a smell, an indicator light, product jamming. Write it down, along with the error codes shown on the screen.
If plant policy allows it, take photos. In food plants, phones are often restricted: a sketch or a written note is enough.
3. Isolate the problem: mechanical, electrical, pneumatic or product
Putting the fault in the right category avoids calling the wrong person. A motor that will not start, a slipping conveyor or a sensor that detects nothing point to different specialists.
Ask three simple questions: what changed just before the stop (product, setting, recent work)? Does the problem affect one machine or the whole line? Do the indicator lights or error codes point to a specific component? Pass the answers on to the technician as is.
4. Check spare parts
Part availability can decide whether the stoppage lasts a few hours or a few days. Check whether the belt, bearing, motor or sensor involved is in stock.
Note the model number and the equipment nameplate. The technician can then order the part before even arriving, which often avoids a second trip. If the part no longer exists, it can often be remade to measure in our shop.
5. Call early, not after three attempts
Every unsuccessful attempt costs time and can make the damage worse. A technician who arrives with a diagnosis already started leaves sooner, which is why it pays to call before you have tried everything.
Set a maximum delay in advance
The right reflex is to decide on the delay before the breakdown, not during it, when the pressure pushes you to “try one more time”. For example, a plant might set 30 minutes for a critical line and longer for secondary equipment. This figure is only an example: each plant sets it according to how critical the line is.
What to prepare before calling
- the model and nameplate of the equipment;
- the symptoms observed and the error codes;
- what changed recently (product, setting, previous work);
- access to the machine, already made safe, and a contact person on site.
6. Plan the restart
The restart follows the plant procedure, which must cover lock removal and start-up. The regulation requires procedures to include removing locks and restarting the machine safely, and the CNESST guide has a section on lock removal (section 206 of the RSST).
In practice: remove the locks according to the procedure, put the guards back, check that nobody is in the hazardous zone and restart empty before feeding product again. Take the opportunity to note the cause of the breakdown. It is the basis of a preventive maintenance program that turns emergencies into planned work. For conveyors, see our conveyor preventive maintenance schedule.
FAQ: production stoppages in plants
Do you always have to lock out to repair a machine?
Before working in the hazardous zone of a machine, you must lock out or apply an energy-control method that provides equivalent safety. In some specific cases, such as a machine with a single energy source whose plug is within reach, simply unplugging is permitted.
Who must write the lockout procedure?
The employer, who must also supply the equipment, train workers and coordinate the work.
When should you call an emergency service?
When the delay set in advance has passed, or when the cause is still unknown and the part is not in stock. The earlier the call, the more the technician can prepare parts and tools.
What information should you give the technician on the phone?
The equipment model and nameplate, the symptoms, the error codes, what changed recently and the contact on site.
What is the difference between a planned and an unplanned production stoppage?
A planned shutdown is on the calendar: parts, labour and the execution plan are ready in advance. An unplanned stoppage happens without warning, which is why a checklist and a call delay decided in advance matter. For extra hands during a shutdown, see our industrial staffing.
How can you reduce unplanned stoppages?
By recording the cause of every breakdown and planning preventive maintenance. A maintenance log shows which parts wear fastest and which to keep in stock.
A production stoppage right now?
Alliance Maintenance Industrielle offers a 24/7 emergency service everywhere in Quebec, with qualified mechanics and a mobile team. If the breakdown requires welding, our welders also work directly at your site: see our industrial welding. Call 438-357-8800, day or night.
Sources
- CNESST — Exposure to hazardous zones of a machine (in French)
- Quebec Regulation respecting occupational health and safety (RSST), chapter S-2.1, r. 13
- CNESST — Guide on lockout and other energy control methods (in French)
Photo: Alliance Maintenance Industrielle. This article is for information only: the regulations, your plant's procedure and the manufacturer's recommendations take precedence. For a specific case, consult your prevention advisor or the CNESST.