Work to be done after resuming on work after long shut down or lock down

1. Startup of Factory After Lockdown
Process Wise Startup – First & Most important thing is to
adhere Guidelines issued by Ministry of Home affairs.
safety norms required as per factories act, guidelines ,
Government regulations , EOHS compliance & applicable
regulations in the regions where the location is.

2. Process Wise Startup -Office
 Ensure seating arrangement is cleaned properly.
 Ensure wiring of computer system is proper.
 Update/inline the system with server /Erp after
consultation with superiors.
 Download mails & arrange properly pending works .
 Reply each & every mail .
 Make list of work which was in progress when
lockdown started & start working on them
 Make list of work which was planned in following days
from lockdown starts & start working on them.

3.  Ensure Sufficient manpower is available in plant.
 Pl communicate with Employees .
 Make sure availability of PPE for COVID 19 & applicable PPE for
processes.
 Skill matrix & available employees to be reviewed.
 Communicate with department heads & arrange retraining of
employees incase of new process or new employee & wherever
required.
 Review the statutory & regulatory pending works during lockdown &
take on priority.
Process Wise Startup – HR

4.  Ensure availability of material which is supposed to received
during lockdown period.
 Review pending purchase requirements & po. Make action plan.
 Communicate with suppliers for availability of required material &
inventory at them.
 Review supplier evaluation & rating is completed after lockdown.
 Review if there any material which is need to be returned or
replaced.
 Review ISO / IATF/EOHS certification of suppliers are valid.
 Make sure that GRN are not pending & bills of accepted material
are
booked in the system.
Process Wise Startup – Purchase

5.  Tally stock of Raw material , Consumable & Maintenance related
material .
 Ensure shelf life of material is valid.
 Ensure there was no mix up in materials.
 Ensure all material is in good condition.
 Notify to Purchase for Material with less inventory .
 Status of material which was in transit when Lockdown started.
 Circulate Inventory sheet.
 Ensure Weighing balance working properly by self calibration.
 Ensure Material issue system & bar code is working properly.
 Ensure there is identification on every material
 Get checked first few charge before issue from Metallurgy
department
Process Wise Startup – Stores

6.  Material receipt during lock down is checked & ok for
use.
 Status of GRN pl complete pending GRN.
 Ensure Calibration of Instruments otherwise Notify to
calibration dept.
 Ensure Shelf life of chemicals prepared for testing.
 Check Sand for HTS & lump formation once again.
Process Wise Startup – Receiving Inspection

7.  Make schedules considering backlogs & customer demand.
 Communicate with Marketing for acceptance of schedules.
 Communicate dispatch dates of materials which is not packed to
marketing considering all situations happened due to lockdown.
 Plan number of resources required to complete the schedule in
agreement with production team.
Process Wise Startup – PPC

8.  Ensure availability of quality sand.
 Ensure machine condition ,air supply , Oiling & Lubrication of
machine.
 Check sand quality in Hoppers.
 Check heaters .
 Ensure pattern number as per plan & start production.
 Check shells for scratch hardness.
Process Wise Startup – Foundry
1) Shell Molding

9. Process Wise Startup – Foundry
1) Melting & Pouring
• Ensure availability of proper water pressure & Temp.
• Ensure Furnace Lining quality.
• Ensure weighing balance calibration.
• Ensure Temp stick working properly.
• Ensure Hydraulics of furnace working good.
• Ensure availability of trolleys.
• Ensure Vibrator is working
• Ensure all cranes are working.
• Ensure Centrifugal machines are running.
• Ensure availability of Laddles.
• Ensure availability of Fire Extinguishers, check there pressure
gauge.
• Check status of material produced during lock down start date.
Complet route card & production registers.

10.  Ensure Air pressure.
 Ensure Alumina sand level
 Ensure Quenching oil level.
 Ensure all temp indicators are working.
 Ensure heating is not abnormal.
 Ensure cooling towers working.
 Ensure availability of binding wire & hooks, rods & fitures.
 Ensure crane is working.
 Ensure availability of Fire extinguishers.
 Ensure alarms & poka yoke are working.
 Check status of material heat treated during lockdown start,
check quality of material & if ok complete route card.
Process Wise Startup – Heat Treatment

11.  Check spectro, Microscope wiring.
 Ensure AC is working.
 Ensure availability of Argon gas cylinder.
 Start spectro with standard operating procedure.
 Ensure spectro & Micro polishing machine is working.
 Ensure quality of hardness testing ,check masters & if
ok offer for inspection.
 Ensure heat treated lots during Lock down start date
are checked for Hardness & micro.
Process Wise Startup – Metallurgy Lab

12.  Ensure Lubrication & oiling of machine is done.
 Ensure tools & grinding wheels ,grinding segments are properly fitted.
 Check auto feeder working before starting production.
 Ensure coolant level & concentration is correct.
 Ensure all required gauges & instruments are in good condition & calibrated before
use.
 Ensure control plans & family sheet is available on machine.
 Start machine as per guidelines in Work instruction.
 Check & then Fill up the machine checklist
 Ensure machine slides & guide ways are free.
 Ensure all pressure gauges are working.
 Ensure oil in Hydraulic system.
 In first off check 5 parts instead of 1 for first startup.
 If any abnormal noise or vibration is observed immediately stop the machine & inform
to supervisor & maintenance.
 Ensure status of WIP( parts on machine or for machining during lockdown start
.Check for quality involve quality person , if ok then only offer for process.
 Ensure Route cards are available & filled .
 Ensure ERP & Bar coding system functioning correctly.
Process Wise Startup – Machine Shop

13.  Ensure all Lights are illuminating properly.
 Ensure all Non confirming material is recorded & disposed off.
 Ensure MPI machines working properly.
 Check Media concentration of MPI , validate pie gauge & if shown ok then
start the inspection.
 Check shelf life & condition of Zyglo chemicals. Stir well before use.
 Recheck the Material in process during lock down.
 Ensure all gauges & instruments are in good condition & calibrated before
use.
 Recheck the material which was pending for packing during lockdown starts.
 Ensure Air dryer is working properly.
 Recheck unidentified parts & then take action accordingly.
 Ensure computer & UPS connections are proper before starting machine.
 Ensure calibration status of instruments & Gauges.
 Ensure AC working & humidity before starting inspection activity.
 Ensure UPS & computer connections of laser marking are proper.
Process Wise Startup – Final Inspection & Gauge Room

14.  Check status of material at laser marking .
 Ensure packed material in sample for good condition.
 Material proven for rust check with large sample size for
good condition.
 Check material which was in progress during lockdown for
rust & mix up.
 Check incomplete boxes for mix up.
 Ensure Packaging standard is followed as per customer
agreement on packed material during lock down starts &
startup after lockdown end.
Process Wise Startup – Oiling & Packing

15.  Review list of development parts.
 Categories the parts as per different stages during lockdown starts.
 Make a list of activities which are in progress when lockdown starts
or planned in the week & till Ist week of May.
 Review the above list & make action plan with responsibility & Target
date.
 Recheck & confirm the suitability of parts in development WIP for
further use.
 Make sure availability of Tooling & Gauges which are supposed to
come during lock down period.
 Update plans accordingly with new dates.
 Communicate with customer for samples which are due in lockdown
period & feedback of supplied parts which is to be received durig
lockdown.
Process Wise Startup – Development