Production Shut-down Checklist
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About this production shut-down checklist
A production shut-down is where guesswork causes the most damage: missed isolations, unclear WIP status, and handovers that leave the next team to figure it out. This production shut-down checklist gives operations teams a consistent sequence for preparation, in-process checks, escalation, and close-out — so the line stops safely and restarts with fewer surprises.
What this production shut-down checklist covers
Use it for planned stops (maintenance, changeovers, end-of-run) and for unplanned downtime where you need structure fast. It helps you:
- confirm authorisation, comms, and permits before anyone starts
- protect product and traceability by capturing WIP status and quality holds
- follow a controlled stop sequence and verify isolations (not just apply them)
- spot escalation triggers early, before downtime or risk spreads
- complete a clean, accountable handover with open actions clearly listed
Who it is for
This checklist fits frontline operations teams in manufacturing and safety-critical environments — shift leaders, line leads, maintenance coordinators, and anyone responsible for stopping equipment and leaving it in a known, safe state.
How to use it on shift
Run the checklist in real time as the shut-down happens. If you hit an escalation trigger (safety incident, isolation cannot be verified, quality risk, suspected damage, or downtime beyond your threshold), pause and escalate immediately. The goal is simple: replace “I think it’s fine” with a recorded, shared view of what is true.
Why standardising shut-downs improves performance
Most shut-down losses are not caused by the stop itself — they come from inconsistency: different sequences by different people, missing evidence, and handovers that hide risk. Standard checks create a repeatable baseline, make issues visible early, and reduce rework during restart.
Run this checklist in Ocasta
With Ocasta, teams complete shut-down checks on mobile, capture notes at the point of work, and create a clear audit trail without chasing paperwork. You get a live view of what is complete, what is blocked, and where escalation is needed — across every site.
Disclaimer: This checklist is for general guidance only and does not constitute legal, regulatory, health and safety, or professional advice. You are responsible for ensuring compliance with applicable laws, standards, and internal policies.
Included questions
Here's what's included in this production shut-down checklist:
Before you start (7)
Confirm the shut-down is planned, safe, and properly authorised — so you do not rely on memory under pressure.
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Dropdown
What is the reason for the shut-down?
Choose the closest match. If it is unplanned, use the escalation section immediately.
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Person
Who authorised the shut-down?
Record the accountable person (shift manager, maintenance lead, production manager).
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Text
When was the shut-down communicated to affected teams?
Include who was notified (production, maintenance, quality, warehouse, HSE).
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Yes/No
Is the work area clear of non-essential people and hazards?
Remove trip hazards, clear access routes, and confirm safe egress.
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Yes/No
Is the correct PPE being worn for the shut-down tasks?
Match PPE to the task (e.g. cut-resistant gloves, eye protection, hearing protection).
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Yes/No
Are permits required for any work during the shut-down?
Examples: lockout/tagout, hot works, confined space, working at height.
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Yes/No
If permits are required, have they been issued and briefed to the team?
Do not proceed until permits are approved and understood.
Preparation checks (7)
Reduce waste and rework by stabilising the process, protecting product, and getting the right people ready.
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Yes/No
Has new material feed been stopped at the agreed point?
Prevent half-processed stock and reduce scrap.
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Dropdown
What is the status of work-in-progress (WIP)?
Choose the current state and capture details in notes if needed.
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Yes/No
Is all WIP clearly labelled and stored in the correct location?
Include batch/lot, time stopped, and disposition (hold/quarantine/scrap).
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Yes/No
Is a quality hold required?
Use if the shut-down is linked to a quality concern, drift, or out-of-spec result.
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Yes/No
Has maintenance been notified and scheduled (if needed)?
Confirm who is attending and the expected start time.
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Yes/No
Are required tools, spares, and consumables available before shut-down work begins?
Avoid extending downtime while someone searches for parts.
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Yes/No
Have critical logs or system data been captured before powering down?
Examples: PLC alarms, trend data, batch records, counters, printouts.
In-process shut-down steps (9)
Follow a consistent sequence to protect people, equipment, and product. Capture anything unusual as you go.
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Yes/No
Was a controlled stop completed according to the standard sequence?
Use the documented stop sequence for the line or machine (not local habit).
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Yes/No
Have all energy sources been identified for isolation?
Electrical, pneumatic, hydraulic, steam, gas, gravity, stored energy.
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Yes/No
Has lockout/tagout been applied where required?
Use the correct locks and tags, and record isolations per site rules.
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Yes/No
Has stored energy been released or made safe?
Bleed lines, discharge capacitors, secure suspended loads, block moving parts.
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Yes/No
Has isolation been verified (try-start / test for dead) as required?
Verification is the step people skip — make it explicit.
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Yes/No
Has product been removed from the line to prevent spoilage or contamination?
Include hoppers, conveyors, chutes, feeders, and packaging stations.
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Yes/No
Has waste and scrap been segregated and disposed of correctly?
Follow site segregation rules (rework, scrap, hazardous waste, recycling).
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Dropdown
What level of clean-down has been completed?
Choose the level that matches the standard for this type of stop.
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Yes/No
Are guards, covers, and access panels replaced or secured after work?
If removed for maintenance, confirm they are reinstated or the area is controlled.
Escalation criteria (6)
Stop guessing. If any of these apply, escalate immediately and record what you saw.
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Yes/No
Has there been a safety incident or near miss linked to this shut-down?
Escalate to the duty manager and HSE as per site procedure.
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Yes/No
Is any equipment unable to be isolated or verified safely?
Do not proceed. Escalate to maintenance lead and shift manager.
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Yes/No
Is there a quality risk to any product already produced or in WIP?
Examples: out-of-spec, contamination risk, label or traceability concern.
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Yes/No
Is critical equipment damage suspected?
Examples: overheating, burning smell, unusual vibration, leaks, repeated trips.
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Number
Expected downtime (minutes)
If it exceeds your site threshold, escalate and update the plan.
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Text
Escalation notes
What happened, what you observed, and what action is needed next.
Close-out and handover (7)
Leave the site and the next shift with clarity: what is safe, what is pending, and what happens next.
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Yes/No
Has the shut-down status been updated for visibility?
Update the agreed system: board, digital log, downtime tracker, or handover note.
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Text
What actions are still open?
List outstanding tasks, owners, and deadlines (e.g. parts to order, inspections to complete).
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Yes/No
Is the area left safe and secure?
Tools removed, spillages cleaned, barriers/signage in place, access controlled.
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Yes/No
Are materials and chemicals stored correctly and labelled?
Include cleaning chemicals, lubricants, and any decanted containers.
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Yes/No
Has a handover been completed with the next responsible person or shift?
Cover isolations in place, WIP status, quality holds, and restart prerequisites.
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Person
Who was the shut-down handed over to?
Record the person taking responsibility from this point.
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Signature
Final sign-off
Confirms the shut-down steps are complete and the current state is accurately recorded.