Factory Restart Checklist

Are you ready to restart your Factory?

Before you do, here’s a quick checklist to see if you are ready to restart manufacturing facilities after lock down.
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Pre-Restart Checklist

Please fill up all the response for getting a consolidated list

1 / 69

Category: Workers

Do you have processes to ensure that no sharing of workstations take place?

2 / 69

Category: Workers

Do you have processes to ensure that no sharing of tools  take place between the workers?

3 / 69

Category: Workers

Are there processes to ensure that physical distancing is followed in the work floor and dining facilities ?

4 / 69

Category: Workers

Do you have  adequate stock of hand sanitizer to provide all employees?

5 / 69

Category: Workers

Do you have adequate stock of PPEs to provide  all employees?

6 / 69

Category: Workers

Do you  have adequate stock of face protective shields to provide all employees?

7 / 69

Category: Workers

Do you have adequate  stock of masks to provide all employees?

8 / 69

Category: Workers

Do you have adequate stock of gloves to provide all employees?

9 / 69

Category: Workers

Do you have processes in place to conduct temperature checks of all employees twice a  day?

10 / 69

Category: Workers

Do you have processes to educate staff on safety steps to take from entry to exit in the factory?

11 / 69

Category: Workers

Do you have processes in place to educate staff on measures to take precautions at personal level?

12 / 69

Category: Storage of products

Is there any damage or wear and tear in the storage facilities/silos?

13 / 69

Category: Manufacturing processes

If there are any difficulties in managing crucial backward linkages for safe functioning, did you approach local district administration for assistance?

14 / 69

Category: Manufacturing processes

Are all equipment inspected as per safety protocol of the equipment?

15 / 69

Category: Manufacturing processes

Did you carry out a trial test before resuming full fledged production?

16 / 69

Category: Manufacturing processes

Were leakages if any, in other equipment's tagged?

17 / 69

Category: Manufacturing processes

Were other equipment's checked for leakages?

18 / 69

Category: Manufacturing processes

Were leakages if any, in the instruments tagged?

19 / 69

Category: Manufacturing processes

Were all instruments in the vacuum system checked for leakages?

20 / 69

Category: Manufacturing processes

Were leakages if any, in the fittings tagged?

21 / 69

Category: Manufacturing processes

Were all fittings in the vacuum system checked for leakages?

22 / 69

Category: Manufacturing processes

Were leakages if any, in the valves tagged?

23 / 69

Category: Manufacturing processes

Were all valves in the vacuum system checked for leakages?

24 / 69

Category: Manufacturing processes

Were leakages if any, in the flanges tagged?

25 / 69

Category: Manufacturing processes

Were all flanges in the vacuum system checked for leakages?

26 / 69

Category: Manufacturing processes

Were leakages if any, in the vacuum system tagged?

27 / 69

Category: Manufacturing processes

Were all vacuum systems tested for leakages?

28 / 69

Category: Manufacturing processes

Have you performed service test for leakages in equipment?

29 / 69

Category: Manufacturing processes

Have you performed service test for leakages in steam piping?

30 / 69

Category: Manufacturing processes

Have you performed service test for leakages in compressed air piping?

31 / 69

Category: Manufacturing processes

Have you performed service test for checking leakages in water piping?

[The service test needs to be performed by treating with normal operating fluid]

32 / 69

Category: Manufacturing processes

Did you perform the tightness test for your plant?

33 / 69

Category: Manufacturing processes

Are the temperature gauges functional?

34 / 69

Category: Manufacturing processes

Are the pressure gauges functional?

35 / 69

Category: Manufacturing processes

Are the valves operating at proper pressure levels?

36 / 69

Category: Manufacturing processes

Is there any obstruction in the valves?

37 / 69

Category: Manufacturing processes

Are the pipelines operating at proper pressure levels?

38 / 69

Category: Manufacturing processes

Is there any obstruction in the pipelines?

39 / 69

Category: Manufacturing processes

Is there any residual material or wear and tear in the conveyor belts?

40 / 69

Category: Manufacturing processes

Is there any residual material or wear and tear in the valves?

41 / 69

Category: Manufacturing processes

Is there any residual material or wear and tear in the supply pipelines?

42 / 69

Category: Manufacturing processes

Are there any signs of wear and tear in the heat exchangers?

43 / 69

Category: Manufacturing processes

Are there any signs of wear and tear in the furnace?

44 / 69

Category: Manufacturing processes

Are there any signs of wear and tear in the boilers?

45 / 69

Category: Manufacturing processes

Was there a run in of rotatory equipment under proper supervision?

46 / 69

Category: Manufacturing processes

Was the cleaning process followed by air/water/ chemical cleaning?

47 / 69

Category: Manufacturing processes

Are discharge lines in your factory mechanically cleaned?

48 / 69

Category: Manufacturing processes

Was the cleaning process followed by air/water/ chemical cleaning?

49 / 69

Category: Manufacturing processes

Are equipments in your factory mechanically cleaned?

50 / 69

Category: Manufacturing processes

Was the cleaning process followed by air/water/ chemical cleaning?

51 / 69

Category: Manufacturing processes

Are the pipelines in your factory mechanically cleaned?

52 / 69

Category: Manufacturing processes

Was the report forwarded within 30 days of completion of the Audit?

53 / 69

Category: Manufacturing processes

Was the audit report with the comments of the expert, forwarded to the concerned authority?

54 / 69

Category: Manufacturing processes

Was the audit conducted by an independent expert, not associated with such industrial activities carried on by you?

55 / 69

Category: Manufacturing processes

Has the Safety Audit been carried out?

56 / 69

Category: Manufacturing processes

Do you have process in place to conduct safety audit prior to restarting?

[This is in accordance with Rule 10 of the Manufacture, Storage and Import of Hazardous Chemicals Rules, 1989].

57 / 69

Category: Storage of raw material

Is there any distress or damage in the roof of the storage building?

58 / 69

Category: Storage of raw material

Did you check if there are any damage/ wear & tear in the supply pipelines/valves/conveyor belts?

59 / 69

Category: Storage of raw material

Have you checked for any smoke in your storage areas?

60 / 69

Category: Storage of raw material

Have you checked for any leaks in your storage areas?

61 / 69

Category: Storage of raw material

Have you checked for any exposed wires in your storage areas?

62 / 69

Category: Storage of raw material

Have you checked for any abnormalities like strange smell in your storage areas?

63 / 69

Category: Storage of raw material

Have you checked for any abnormalities like strange sound storage areas?

64 / 69

Category: Storage of raw material

Is there proper lighting in the storage areas?

65 / 69

Category: Storage of raw material

Is there proper ventilation in the storage areas?

66 / 69

Category: Storage of raw material

Have you checked for chemical stability of the HAZMAT chemicals in storage before using them for any process?

[While the term is not defined in the guidelines, usually HAZMAT Chemicals signifies Hazardous Material Chemicals. HAZMATs include such substances as toxic chemicals, fuels, nuclear waste products, etc. The guidelines here are talking specifically talking about Hazardous materials which are chemicals.]

67 / 69

Category: Storage of raw material

Did you check your open storage vessels/containers/ bags/ silos for possible oxidation/chemical reaction/ rusting /rotting etc.?

68 / 69

Category: Storage of raw material

Have you done an inspection of the storage facility in your factory to check for signs of wear and tear during the lockdown?

69 / 69

Category: Storage of raw material

Have you done an inspection of the storage facility in your factory to check for signs of spills during the lockdown?

Your score is

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Post Re-start Checklist

Please fill up all the response for getting a consolidated list

1 / 31

Category: Workers

Do you sanitize the accommodations provided to your workers regularly?

2 / 31

Category: Workers

Have you sensitized your employees about raising an alarm in case of abnormalities like strange sounds or smell, exposed wires, vibrations, leaks, smoke, abnormal wobbling, irregular grinding or other potentially hazardous signs?

3 / 31

Category: Workers

If you deal with hazardous materials in your unit, are the workers who are dealing with hazardous materials skilled and experienced to deal with such materials?

4 / 31

Category: Workers

Do you have processes in place to manage the mandatory 14- day quarantine for employees who are positive and travelling employees?

5 / 31

Category: Workers

Do you have provisions to accommodate workers who need to be isolated in case of a positive case?

6 / 31

Category: Workers

Do you have adequate workstations for all personnel, such that sharing of workstation between the workers can be stopped?

7 / 31

Category: Workers

Do you have adequate tools for all personnel, such that sharing of tools between the workers can be stopped?

8 / 31

Category: Workers

Have you given priority to safety personnel in the selection of the staff for a particular shift?

9 / 31

Category: Workers

Are managerial and administrative staff working a shift at 33% capacity?

10 / 31

Category: Workers

If your plant/factory doesn’t require continuous operations and runs at full capacity, do you ensure that one hour gap provided between shifts?

11 / 31

Category: Workers

Are there physical barriers in place in the dining facilities to ensure physical distance?

12 / 31

Category: Workers

Are there physical barriers in place at work floors to ensure physical distance?

13 / 31

Category: Workers

Are you educating your staff on safety measures to be taken at a personal level?

14 / 31

Category: Workers

Have you provided every employee with hand sanitizer?

15 / 31

Category: Workers

Have you provided every employee with PPEs?

16 / 31

Category: Workers

Have you provided every employee with face protective shields ?

17 / 31

Category: Workers

Have you provided every employee with masks?

18 / 31

Category: Workers

Have you provided every employee with gloves?

19 / 31

Category: Workers

Do you allow employees showing symptoms or failing the temperature check to report to work?

20 / 31

Category: Workers

Do you conduct temperature checks of all employees twice a day?

21 / 31

Category: Workers

Do you sanitize the common areas that include lunch rooms and common tables every 2-3 hours and ensure that they are wiped clean with disinfectants after every single use?

22 / 31

Category: Workers

Do you maintain a sanitisation routine and ensure sanitisation is carried out every 2-3 hours?

23 / 31

Category: Storage of products

Do you isolate and sanitise finished goods?

24 / 31

Category: Storage of products

Do you sterilise boxes and wrappings brought into the factory premises?

25 / 31

Category: Manufacturing processes

Are the arrangement limited to dangerous goods transported by an installation only?

26 / 31

Category: Manufacturing processes

Do the MAH clusters have an extended coverage of 200km for reaching transport accidents spots?

27 / 31

Category: Manufacturing processes

Are there arrangements for round-the-clock emergency crews/ professional technical teams with MAH?

[While the term is not defined in the guidelines, usually MAH means Major Accident Hazard (MAH) According to point no. x on page 83 of the Guidelines on Chemical Disasters, 2007, "Round-the-clock emergency crews/professional technical teams provided with MAH and cluster of MAH should have an extended coverage of 200 km to reach transport accident spots for help. The arrangement would not be limited to dangerous goods transported by an installation only].

28 / 31

Category: Manufacturing processes

Do you have processes to deliver final goods in shifts?

29 / 31

Category: Manufacturing processes

If your establishment is not running for 24 hours, do you have lockout and tagout procedures and provisions in place?

30 / 31

Category: Manufacturing processes

Have you implemented processes in place to make sure safety protocols are followed?

31 / 31

Category: Manufacturing processes

Are safety protocols for all equipment’s in your factory in place?

Your score is

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Background

The safety protocols outlined by the National Disaster Management Authority (NDMA) come at the backdrop after several incidents which affected more than 5000 people and killed more that 11 people in the tragedy. Due to several weeks of lockdown and the closure of industrial units during the lockdown period, it is possible that some of the operators might not have followed the established SOP (standard operating procedure). As a result, some of the manufacturing facilities, pipelines, valves, etc. may have residual chemicals, which may pose risk. The same is true for the storage facilities with hazardous chemicals and flammable materials. In view of this, the NDMA has issued generic safety guidelines for industries and workers, as well as specific industry-based protocols such as product storage, manufacturing, and raw material storage.

Here’s a quick checklist to see if you are ready to restart manufacturing facilities after lock down.

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