The document provides guidance for safely restarting factory operations after a lockdown. It outlines procedures that must be followed across various departments, including adhering to government guidelines, ensuring employee safety, reviewing work-in-progress, checking equipment and supplies, and communicating with stakeholders. Departments covered include office, HR, purchasing, stores, receiving inspection, production planning, foundry, heat treatment, machine shop, final inspection, packing, and development. The goal is to safely restart operations while addressing any backlogs or issues that arose during the lockdown period.

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