When a plant shuts down, whether for a planned shutdown, preventive maintenance, or a technical stop, the restart must be thoroughly prepared. A poorly cleaned or poorly inspected environment can trigger equipment failures, contaminate production, slow operations, or even put workers at risk.
This checklist compiles the essential steps to restart any production area safely, efficiently, and in compliance with industry standards.
Why a Restart Checklist Is Essential
Reduce the Risk of Incidents
After a shutdown, contaminants, dust, deposits, grease, or maintenance residues can accumulate. Without strict control, these can lead to:
- slips or OHS incidents;
- mechanical malfunctions;
- sensor errors;
- overheating or abnormal friction;
- loss of final product quality.
Ensure Compliance and Hygiene
Certain industries—food, pharmaceutical, processing—are subject to strict standards. A restart checklist helps prevent:
- regulatory non-compliance;
- cross-contamination;
- loss of certifications;
- batch rejection.
Optimize Performance From the First Minutes
A poorly prepared line creates:
- slow startup;
- high scrap rates;
- micro-stoppages;
- reduced throughput.
A clean and inspected environment ensures a stable and productive restart.
General Site Inspection
Before any cleaning, a detailed assessment is required.
Key Checks
- Accumulation of dust, particles, or shavings.
- Presence of oils, lubricants, or liquid residues.
- Visible contaminants: organic matter, polymers, chemical deposits.
- Areas overlooked during shutdown: beams, structures, under conveyors.
- Abnormal odors (humidity, burning, solvents).
- Floor condition (cracks, slipping hazards, debris).
Thorough Cleaning of Critical Areas
Every production environment includes high-risk zones that must be addressed first.
Floors and Circulation Areas
- Removal of fine dust (explosion risk in certain industries).
- Removal of liquids or oils.
- Verification of anti-slip conditions.
- Full cleaning of drains and grates.
Conveyors and Mechanical Systems
- Deposits on conveyor belts.
- Grease accumulation on bearings and motors.
- Residues under feed points.
- Precise cleaning of rollers, shafts, supports.
Production Equipment
- Production heads, molds, extruders, mixers.
- Buildup in heating zones.
- Dusty or misaligned sensors.
- Robotic arms, tooling, nozzles, guides.
Invisible but Critical Zones
- Ceilings, beams, lighting fixtures.
- Behind electrical panels (no water).
- Ventilation/extraction ducts.
- Metal structures and platforms.
Note: These areas are often missed by internal teams, making professional cleaning highly valuable.
Mechanical and OHS (SST) Checks
After cleaning, technical validation is required.
Elements to Inspect
- Tightening of screws and fasteners.
- Mobility of parts (no friction).
- Lubrication system verification.
- Testing of emergency stop buttons.
- LO/TO (lockout/tagout) verification before re-energizing equipment.
- Inspection of pressurized systems.
- Verification of guards, shields, and protective covers.
Electrical and Electronic Checks
Shutdowns often involve electrical interventions—making verification essential.
Electronic Checklist
- Dust removal from sensors and detectors.
- Clean and calibrated optical detection.
- Electrical panels closed, dry, and unobstructed.
- Inspection of connectors, cables, and conduits.
- Basic functional testing.
Hygiene Validation (Regulated Industries)
For food, pharmaceutical, or cosmetic environments:
- Contact surfaces free of micro-residue.
- No organic contaminants.
- ATP testing if applicable.
- Inspection of mold-risk zones.
- Sanitation according to HACCP or internal protocols.
Progressive Startup and Quality Control
Once cleaning and checks are complete, the line should be restarted gradually.
Recommended Steps
- Initial “dry run” to monitor behavior.
- Measure speed, belt tension, and detect abnormal noise.
- Test sensors in real conditions.
- Produce a pilot batch.
- Quality control of the batch (weight, dimensions, texture, consistency, etc.).
- Final adjustments before full restart.
A Safe Restart Depends on Thorough Preparation
Professional cleaning combined with a rigorous checklist ensures:
- a safe restart;
- stable production from the first minutes;
- reduced risk of breakdowns;
- better final product quality;
- an environment compliant with industrial standards.
Proper maintenance isn’t just an obligation. It’s a strategic tool to extend equipment lifespan and safeguard overall plant performance.