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Aspects of Shutdown - Pre & Post Audit

Now that we have seen all the key factors/phases for a successful shutdown such as the scoping, kick off, identification, safety and procurement. A successful execution of shutdown should start with an audit and should be followed by an audit. Let us dive deep now.


The aim of this audit is to ensure that all the ingredients (as discussed in my previous blog) required for conducting a successful shutdown are available. We will be looking into some of the key ingredients.

Maintenance & Repair Inventory: The materials required to carry out the shutdown are procured and stored in the storeroom/staging area. And also the materials are to be pre-tested for the required standards, as this may hamper/delay the entire process.

Manpower: The personnel with the right skillset & training are assigned to carry out the job at hand for each of the activities.

Inventory Reconciliation: Any work in progress/raw material type of materials should not be present in the shop floor, these could prove to be a hazard.

Rental Equipment: Ensure the availability of the rental equipment and also timely return of the materials as this may increase the cost of shutdown.

Health, Safety & Environment Audit: This will be conducted by the safety team, they should ensure that the aspects of the safety are in place w.r.t environment and health of humans working.


Operational Area: As part of this we are revisiting the first pillar of TPM (Total Preventive Maintenance) i.e. Jishushozen, which when applied are

  • Audit each of the assets that was a part of the maintenance exercise and ensure that it is in complete working condition viz. check for any leakage, noise, insulation.

  • Audit the floor and ensure that none of material/equipment that are left over from maintenance are lying around the shop floor.

  • Housekeeping again becomes a key aspect i.e. the floor should be completely conducive to initiate work viz. not slippery, etc.

  • Ensure that precaution/notice/signage are placed AS IS to avoid any confusion.

Inventory perspective: Return any additional material/equipment, inventory that was left unconsumed. Return rental equipment.

Statutory Compliance: Ensure that any statutory compliance related certifications are renewed. Also identify equipment which needs to be inspected by competent/ government authority.

Safety: Log any accidents/mishappenings that happened during the shutdown, this would act as a precursor for future operations and shutdown planning's. Ensure that the permits like zero permit, vessel entry, work at height, cold & hot permit cycles are duly adhered to and completed in all sense.

Vendor Analysis: List down all the third party vendors involved in the process and then grade their performance against expectation. Some of the key factors to be considered would be delivery, quality, payment, flexibility, etc.

Finance Audit: An analysis with respect to the actual cost incurred versus the initially planned shutdown budget is prepared. Based on the outcome of this report, remedial actions need to be planned for future shutdown.


Rollout is a mini value stream map created during the process of shutdown, as you know the job of a value stream map is to identify value adding, enabling & non-value adding activities and then removing the non-value adding activities as much as possible. All the non-value adding activities are duly recorded for future purpose and value adding activities can be inculcated (Wherever possible & plausible) as part of regular maintenance, this could bring the shutdown timings to a huge extent.

The above discussed aspects for a successful shutdown planning is a gist. There are many other factors that can and should be considered depending on the industry.


Great information! Thanks for sharing these wonderful tips in how to handle shutdown in the pre and post audit stages.

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