Pre and Post Shutdown Activity Forms and Checklists

TABLE OF CONTENTS
Title Page 1 of 11 (Start here, fill in shutdown dates and team members)
Shutdown Audit 2 of 11
Involve the affected departments as necessary to complete their sections

Meet regularly beginning 6 - 8 weeks before shutdown to revise and review
Distribute this document within your organization for full understanding

Save this document in the applicable shutdown-start up binder/folder for review of lessons learned after startup
Review this document as a starting point for the next shutdown period
Master contact list (by department) 3 of 11
Backup Support: The following sections are used to support the "Required Documentation". Alternate formats are also acceptable.
Shutdown FMEA 4 of 11
Shutdown Team Meeting Schedule 5 of 11
Production Plan (with Customer Requirements) 6 of 11
Employee Information (Who is working when) 7 of 11
Shutdown Checklist 8 of 11
Maintenance Plan (for shutdown period) 9 of 11
Startup Checklist 10 of 11
Facility Checklist 11 of 11
Form #: 75132
Revision #:1
Table of Contents
SHUTDOWN PLAN / AUDIT FOR: Modatek Systems
Customers Shutdown Period Starts (Date Only) Company Address: 400 Chisholm Drive
Customers Shutdown Period Ends (Date Only) Milton, ON, L9T-5V6
mm/dd/yy
DUNS Code or
Issue Date: customer code
Last Updated: (name) (telephone)
Plant Manager
Created By: Quality Manager
(Team Names) Production Manager
Production Manager
Production Manager
Shipping Manager
Purchasing Manager
DISTRIBUTION :
Customer:
Form #: 75132
Revision #: 1
Page 1 of 11
SHUTDOWN PLAN / AUDIT FOR: Modatek Systems
Customers Shutdown Period Starts (Date Only) Company Address:

Customers Shutdown Period Ends (Date Only)
mm/dd/yy
DUNS Code or
Issue Date: customer code
Last Updated: (name) (telephone)
Plant Manager
Created By: Quality Manager
(Team Names) Production Manager
Production Manager
Production Manager
Shipping Manager
Purchasing Manager
DISTRIBUTION :
Customer:
Form #: 75132
Revision #: 1
Page 1 of 11
SUPPLIER EXTENDED SHUTDOWN AUDIT
Section Name:
DATE
Line / Location:
Yes No N/A Score Status Audit Completed by (Name):
53 2 0 96% G Customers contact name:

G
Management
Item # YES NO N/A COMMENTS
Does Management have a documented Shutdown/Startup Plan with timing for each
1
major department/area that will protect the customer, tooling, machinery, and facilities? x
Has Management reviewed all Customers Bulletins on their website and incorporated
2
them into the Shutdown/Startup Plan.
x
3 Has a high risk list been generated by management identifying areas of major concern? x
Does the Management Team formally review the status of these plans at timely intervals
4
before the shutdown?
x
5 Does Management do a documented floor walk to review details of plan? x

Have specific people been designated to perform a final check in each area at the stop
6
of operations? x
Have specific people been designated to check each area, as well as the overall facility
7
during the shutdown? x
If any manufacturing or maintenance is planned during the shutdown, is salaried/hourly

8
staffing certified to perform required functions?
x
Has Management taken the initiative to restrict personnel moves the week prior to and
9
after the startup?
x
If personnel moves can't be restricted, has a training plan been incorporated for initial
10
startup, including reduced production rates, until quality and proficiency are validated?
x
If there are significant changes to tools, machinery, processes, or new additions for
11
startup, is there a documented approval plan?
x
Is there a documented communication distribution of significant product and process

12
changes to all departments?
x
Is there a published and distributed contact list in case of emergency during the
13
shutdown period?
x
14 Have champions been designated to perform pre-startup activities? x
Red=<75%, Yellow = 76%-90%, Green= 91%-100% Form #: 75132 Audit 4 of 4
Revision # 1
Page 2 of 11
Is there a "Lessons Learned" review conducted after startup to drive change to the
15
Shutdown/Startup Plan?
x
Score 15 0 0
QUALITY
Are plans in place for increased in-process quality checks the week that shutdown
1
occurs and during the week of startup? x
Is enhanced inspection planned during the week of startup for any new parts, parts with
2 changes, parts that have had customer issues, or major disruptions in the past 12 x
months?
If manufacturing is scheduled during the shutdown, has salaried/hourly staffing been

3 audited to ensure that certified personnel are scheduled, including the quality x
department and support organizations?
If any significant tooling, machinery, or process changes are to be made, is there a plan
4
for PPAP approval and part try outs? x
Has the Quality Department championed a recent cross functional PFMEA review of the
5
shutdown/startup process on product quality? x
Score 5 0 0
Materials
1 Are raw materials and purchased parts at the required inventory levels? x
2 If not, what is the a plan to get up to schedule? x
Are raw material and purchased parts stored to prevent damage/deterioration during the
3
shutdown?
x
Is in-process material stored to protect it from the environment and stacking distortion
4
during the shutdown?
x
Are process materials and wet chemicals stored to protect them during the shutdown
5
and is shelf life checked?
x
Are raw materials, process materials, in-process stock, and partial packs of finished
6
goods checked at shutdown for identification of each container?
x
Has the Materials Department participated in a shutdown/startup PFMEA contemplating

7
impact on materials? x
Have you verified that your tiered suppliers have shutdown/startup plans in place to
8
support your schedule x
Revision # 1
Page 2 of 11
Score 8 0 0
Machinery/Tooling
If PM is scheduled for Tooling, Machinery, or Processes during the shutdown, is there a

1
plan with defined requirements and validation steps for checking the PM?
x
2 Are spare parts at the required inventory levels? x
Is there additional validation required on startup of the above that has been
3
communicated to the quality department and manufacturing personnel?
x
4 Is there a plan to tryout other high risk machinery, tooling, or processes? x
Is there a published list of do's and don'ts for protection of tools and equipment during
5
the down period, such as lubrication or preservatives?
x
If the environment will change during the shutdown (heat/cold), is there a plan to
6
normalize the tooling/equipment prior to startup? x
Do you have a written plan to recalibrate and verify proper operation of all automated
7
checks? (ie - Electrical verification station, part presence probes)
x
Torque Specific - Do you have a written plan to recalibrate all torque monitoring systems
8
after extended shutdown period?
x
Welding Specific - Do you have a written plan to verify weld integrity after extended
9
shutdown period?
x
Score 9 0 0
Facilities
Have significant facility/layout changes been reviewed with all departments to prevent
1
disruption at startup? x
Have guidelines been established for safe shutdown and startup of of heating, cooling,
2
and/or water flow for all the facility, with a list of do's and don'ts? x
3 Is there a champion identified to check the facility daily during the shutdown? x

Revision # 1
Page 2 of 11
4 Is an early startup of normalized heating and cooling planned? x
Score 4 0 0
Major Changes
If you plan any tooling and/or equipment rebuilds, replacements, relocations, or new
startups for this period, proceed with this section.
x
Has this information been shared with GM purchasing, Supplier Quality, and the affected
1
assembly plants?
x
Have sufficient banks been built with appropriate safety stock and appropriate level of
2
audit depending on the risk? x
Have bank quantities been reviewed with GM Purchasing, Supplier Quality, and the
3
affected assembly plants? x
4 Is there an acceleration plan that contemplates minor problems? x
Is there a contingency plan developed in event of a failure of the plan, with appropriate
5
levels of immediate communication to the customer?
x
6 Is there a well defined part approval plan? x

Has the responsible PPAP SQE been contacted to define if PPAP is required with the
7
level and timing of submission?
x
Has the supplier contacted The Engineer at the assembly plant to determine if try out
8
parts are required?
x
Is an extended enhanced inspection plan communicated, understood, and organized for
9
flawless execution?
x
Is feedback from the enhanced inspection planned to be driven upstream for immediate
10
countermeasures?
x
Have alarms been established at the enhanced inspection to trigger an additional level
11
of containment for customer protection?
x
Tier 2/3 Impact - Are there any plans related to tool moves or supplier changes at the
12
tier 2/3 supplier level?
x

Revision # 1
Page 2 of 11
Has this information been shared with customers purchasing, Supplier Quality, and the
13
affected assembly plants?
x
Have plans for PPAP and part try outs been developed and communicated to the
14
appropriate customer personnel?
x
Score 12 2 0

Revision # 1
Page 2 of 11
Section Name:
DATE
Line / Location:
Yes No N/A Score Status Audit Completed by (Name):
36 1 18 97% G Customers contact name:

G
Management
Does Management have a documented Shutdown/Startup Plan with timing for each
1
major department/area that will protect the customer, tooling, machinery, and facilities? x
Plan and timing in place
Has Management reviewed all Customers Bulletins on their website and incorporated
2
them into the Shutdown/Startup Plan.
x
Bulletins reviwed on daily basis
3 Has a high risk list been generated by management identifying areas of major concern? x
Does the Management Team formally review the status of these plans at timely intervals
4
before the shutdown?
x
5 Does Management do a documented floor walk to review details of plan? x

Have specific people been designated to perform a final check in each area at the stop
6
of operations? x
Have specific people been designated to check each area, as well as the overall facility
7
during the shutdown? x
Various teams will be on the premises
If any manufacturing or maintenance is planned during the shutdown, is salaried/hourly

8
staffing certified to perform required functions?
x
Has Management taken the initiative to restrict personnel moves the week prior to and
9
after the startup?
x
If personnel moves can't be restricted, has a training plan been incorporated for initial
10
startup, including reduced production rates, until quality and proficiency are validated?
x
Team Members are trained prior to new work assignments
If there are significant changes to tools, machinery, processes, or new additions for
11
startup, is there a documented approval plan?
x
Done according to the GM requirements (PPAP)
Is there a documented communication distribution of significant product and process
12
changes to all departments?
x
Is there a published and distributed contact list in case of emergency during the
13
shutdown period?
x
Contact list available in the office area
14 Have champions been designated to perform pre-startup activities? x

Revision #: 1
Page 2 of 11
Is there a "Lessons Learned" review conducted after startup to drive change to the
15
Shutdown/Startup Plan?
x
Issues reviewed in th eproduction meeting
Score 15 0 0
QUALITY
Are plans in place for increased in-process quality checks the week that shutdown
1
occurs and during the week of startup? x
Is enhanced inspection planned during the week of startup for any new parts, parts with
2 changes, parts that have had customer issues, or major disruptions in the past 12 x
months?
If manufacturing is scheduled during the shutdown, has salaried/hourly staffing been

3 audited to ensure that certified personnel are scheduled, including the quality x
department and support organizations?
Work is assigned according to skill and ability matrix
If any significant tooling, machinery, or process changes are to be made, is there a plan
4
for PPAP approval and part try outs? x
Crossmember engineering change
Has the Quality Department championed a recent cross functional PFMEA review of the
5
shutdown/startup process on product quality? x
Score 5 0 0
Materials
1 Are raw materials and purchased parts at the required inventory levels? x
2 If not, what is the a plan to get up to schedule? x
Are raw material and purchased parts stored to prevent damage/deterioration during the
3
shutdown?
x
Is in-process material stored to protect it from the environment and stacking distortion
4
during the shutdown?
x
Are process materials and wet chemicals stored to protect them during the shutdown
5
and is shelf life checked?
x
Are raw materials, process materials, in-process stock, and partial packs of finished
6
goods checked at shutdown for identification of each container?
x
Has the Materials Department participated in a shutdown/startup PFMEA contemplating

7
impact on materials? x
Have you verified that your tiered suppliers have shutdown/startup plans in place to
8
support your schedule x
Revision #: 1
Page 2 of 11
Score 7 0 1
Machinery/Tooling
If PM is scheduled for Tooling, Machinery, or Processes during the shutdown, is there a

1
plan with defined requirements and validation steps for checking the PM?
x
2 Are spare parts at the required inventory levels? x
Is there additional validation required on startup of the above that has been
3
communicated to the quality department and manufacturing personnel?
x
4 Is there a plan to tryout other high risk machinery, tooling, or processes? x
Is there a published list of do's and don'ts for protection of tools and equipment during
5
the down period, such as lubrication or preservatives?
x
If the environment will change during the shutdown (heat/cold), is there a plan to
6
normalize the tooling/equipment prior to startup? x
Do you have a written plan to recalibrate and verify proper operation of all automated
7
checks? (ie - Electrical verification station, part presence probes)
x
Poke Yoke samples are in place
Torque Specific - Do you have a written plan to recalibrate all torque monitoring systems
8
after extended shutdown period?
x Torque verification is in place as part of our current manufactturing
process.
Welding Specific - Do you have a written plan to verify weld integrity after extended
9
shutdown period?
x
Weld destruct is done according to the existing validation process
Score 7 1 1
Facilities
Have significant facility/layout changes been reviewed with all departments to prevent
1
disruption at startup? x
No facility changes planned during shutdown
Have guidelines been established for safe shutdown and startup of of heating, cooling,
2
and/or water flow for all the facility, with a list of do's and don'ts? x
3 Is there a champion identified to check the facility daily during the shutdown? x Various Team Members will be on the premises;facility will not be
completely shut down

Revision #: 1
Page 2 of 11
4 Is an early startup of normalized heating and cooling planned? x
Score 2 0 2
Major Changes
If you plan any tooling and/or equipment rebuilds, replacements, relocations, or new
startups for this period, proceed with this section.
x
Has this information been shared with GM purchasing, Supplier Quality, and the affected
1
assembly plants?
x
Have sufficient banks been built with appropriate safety stock and appropriate level of
2
audit depending on the risk? x
Have bank quantities been reviewed with GM Purchasing, Supplier Quality, and the
3
affected assembly plants? x
4 Is there an acceleration plan that contemplates minor problems? x
Is there a contingency plan developed in event of a failure of the plan, with appropriate
5
levels of immediate communication to the customer?
x
6 Is there a well defined part approval plan? x

Has the responsible PPAP SQE been contacted to define if PPAP is required with the
7
level and timing of submission?
x
Has the supplier contacted The Engineer at the assembly plant to determine if try out
8
parts are required?
x
Is an extended enhanced inspection plan communicated, understood, and organized for
9
flawless execution?
x
Is feedback from the enhanced inspection planned to be driven upstream for immediate
10
countermeasures?
x
Have alarms been established at the enhanced inspection to trigger an additional level
11
of containment for customer protection?
x
Tier 2/3 Impact - Are there any plans related to tool moves or supplier changes at the
12
tier 2/3 supplier level?
x

Revision #: 1
Page 2 of 11
Has this information been shared with customers purchasing, Supplier Quality, and the
13
affected assembly plants?
x
Have plans for PPAP and part try outs been developed and communicated to the
14
appropriate customer personnel?
x
Score 0 0 14

Revision #: 1
Page 2 of 11
Shutdown Contacts and Support Plan
Instructions: Enter the Name and Contact Telephone Number for the assigned department manager for each day of shutdown
Date
Senior Management
Quality
Production
Shipping
Scheduling
Purchasing
IT (incl EDI support)
Engineering
Maintenance
Tooling
Finance
Human Resources
Customer Service
Other (Specify)
Other (Specify)
Date
Senior Management
Form #: 75132
Revision #: 1
Page 3 of 11
Quality
Production
Shipping
Scheduling
Purchasing
Engineering
Maintenance
Tooling
Finance
Human Resources
Customer Service
Other (Specify)
Other (Specify)
Form #: 75132
Revision #: 1
Page 3 of 11
Shutdown Contacts and Support Plan
Instructions: Enter the Name and Contact Telephone Number for the assigned department manager for each day of shutdown
Date 23-Oct-22 24-Oct-22 25-Oct-22 26-Oct-22 27-Oct-22
Senior Management
Quality
Production
Shipping
Scheduling
Purchasing
Engineering
Maintenance
Tooling
Form #: 75132
Revision #: 1
Page 3 of 11
Finance
Human Resources
Customer Service
Other (Specify)
Other (Specify)
Date
Senior Management
Quality
Production
Shipping
Scheduling
Purchasing
Engineering
Maintenance
Tooling
Finance
Human Resources
Customer Service
Other (Specify)
Other (Specify)
Form #: 75132
Revision #: 1
Page 3 of 11
Shutdown FMEA
Instructions: Insert your Shutdown FMEA on this page. It should be formatted to AIAG standards with RPN's assigned compliant with Rev 3 requirements. Note: this is an EVENT FMEA, specific to the activities and risks
associated with shutting down and starting up equipment, not a part FMEA. Your "backup", "recovery" or "prevention" plan should be described for each risk element in the "Actions Taken" section of the FMEA. Use the
information included in the other pages of this workbook, especially the maintenance items, to determine your risk elements.
POTENTIAL
FAILURE MODE AND EFFECTS ANALYSIS
Print # NA Rev. NA (PROCESS FMEA) FMEA Number:
Item: NA Process Responsibility: Prepared by:
Model Year(s)/Vehicle(s) Key Date N/A Date (Orig.) 20-Oct-22
Team: Date (Rev.)
C Potential O D
Process Potential Potential S l Cause(s)/ c Current e R. Recommended Responsibility Action Results
Function/ Failure Effect(s) of e a Mechanism(s) c Process t P. Actions & Target Actions S O D R.
Require- Mode Failure v s of Failure u Controls e N. Date Taken e c e P.
ments s r Prevention Detection c v c t N.
Excessive inventory of components Develop rust Poor E-Coating 6 Poor Scheduling 1 Releases done according to the Min/Max and Physical Inventory done on regular 5 30
customer requirements basis; bar code scanning ensures
automatic inventory update
Physical Inventory done on regular

Insufficient inventory of components Short ship Customer downtime 9 Poor Scheduling 1 Releases done according to the Min/Max and basis; bar code scanning ensures 5 30
customer requirements automatic inventory update
Expired Shelf life (lube) Sticky lube Difficulty in assembly 2 Poor stock rotation 1 FI/FO 7 14
Equipment malfunctioning Line down Customer downtime 9 Poor maintenance 1 Preventative maintenance 4 36
Power failure PM Action Plan Support personnel on the
premises during the summer
shutdown; warm up line prior to
going back to regular production
Manpower Insufficient Manpower to address production Manufacturing difficulties/Quality Poor planning Review vacation plan with all departments to Daily monitoring
needs over shutdown Issues ensure enough personnel is available to
7 1 support required activities. 3 21
Customer contacted to ensure requirements

are understood
Check GM Bulletins
Un-trained Manpower running equipment Manufacturing difficulties/Quality Poor Planning Training plan in place; training matrix captures Layered audits;
over shutdown Issues status of training by station. Work is assigned
7 1 based on Skill and Ability 4 28
Conveyor Change Cannot Transfer Parts Manufacturing difficulties/ Quality Poor Planning Review plans, timeline for implementation of First run of new conveyor
Issues 7 1 conveyor to ensure that it is working properly verification. Team buyoff at 4 28
integrators.
Wrong Conveyor Verification of conveyor system to ensure Verification of OEM capability to

7 1 compliance to current system. replacement. 4
28
Difficulty In Welding Manufacturing difficulties/ Quality Loose Cables Verification of welds by weld technician after Visual/cut and etch analysis.
Issues 7 1 change of cables. First/Last Off 4
Ground Cable Changes (Welding System) 28
Wrong Cables Verification of cables with OEM blue prints to Visual/cut and etch analysis.
7 1 ensure conformity. First/Last Off 4
28
Robot Program Lost Manufacturing difficulties/ Quality Connectivity Issue After PM complete, robot is verified for correct Visual
Issues 7 1 program, TCP, and weld path. 7
Robot Preventative Maintenance 49
Form #: 75132
Revision #:1
Page 4 of 11
POTENTIAL
Team: Date (Rev.)
C Potential O D
Logic Issues Manufacturing difficulties/ Quality Poor Planning Verification of electrical system through Verification to schematic drawings.
Issues 7 1 panels. Logic verification. 4 28
Electrical PM
Form #: 75132
Revision #:1
Page 4 of 11
POTENTIAL
Team: Date (Rev.)
C Potential O D
Form #: 75132
Revision #:1
Page 4 of 11
Shutdown Team Planning Meetings
Meeting 1- Kick Off: 6 to 8 weeks prior to scheduled shutdown.
Meeting 2- Updates- Scheduled as required
(if necessary)
Finalization Meeting: 2 weeks prior to shutdown.
Agenda
- review customer schedules
- review Shutdown plan forms for completion and acceptability
- review production needs / bank build status prior to shutdown
- review maintenace projects, timeline, contractors, skilled trade manning, service shutdowns
- review engineering projects, timelines, contractors, skilled trade manning, service shutdowns
Form #: 75132
Revision #:
Page 5 of 11
Shutdown Production Plan As of (Date):
mm/dd/yy
Enter all of your customers part numbers, names and destination locations in Column B in the appropriate section. Enter a new line for each of multiple destinations. These will be copied to the enhanced ispection matrix sheet found in this workbook. Insert rows as needed
to include all of your customers parts. Include Tier 2 parts
Instructions Based on current releases and plant memos, fill in the requirements and past due information as of the date shown above. Update this information weekly or as required by your customer contact.
Fill in whether your current production schedule reflects extra production for any parts for which you do not have a bank meeting the shutdown requirements; add details (ie extra shift scheduled, added daily production) of how you will meet the delivery requirements
Complete the column Yes or No for whether you intend at this time to run production for these parts during the customers shutdown period.
Bank build
Requirements Past due Running during
Inventory on plan on
Part Number Part Description Destination Plant during Shutdown today Shutdown? (Yes Comments
hand (Today) Schedule?
(pieces) (pieces) / No)
(Yes / No)
New Parts
Carryover parts with

Engineering /
Process changes /
New customer
destination plants
All Other customer

parts including
Service orders
Form #: 75132
Revision #: 1
Page 6 of 11
Form #: 75132
Revision #: 1
Page 6 of 11
Shutdown Production Plan As of (Date):
mm/dd/yy
Enter all of your customers part numbers, names and destination locations in Column B in the appropriate section. Enter a new line for each of multiple destinations. These will be copied to the enhanced ispection matrix sheet found in this workbook. Include Tier 2 parts.
Instructions Based on current releases and plant memos, fill in the requirements and past due information as of the date shown above. Update this information weekly or as required by your customer contact.
Fill in whether your current production schedule reflects extra production for any parts for which you do not have a bank meeting the shutdown requirements; add details (ie extra shift scheduled, added daily production) of how you will meet the delivery requirements.
Complete the column Yes or No for whether you intend at this time to run production for these parts during the customers shutdown period.
Bank build
Requirements Past due Running during
Inventory on plan on
Part Number Part Description Destination Plant during Shutdown today Shutdown? (Yes Comments
hand (Today) Schedule?
(pieces) (pieces) / No)
(Yes / No)
New Parts
Carryover parts with

Engineering /
Process changes /
New customer
destination plants
25776302 GMX001 RR FE1 NON ABS Rear Twist Axle GM Lordstown 0 0 1 Day Inventory No No
25776301 GMX001 RR FE1 ABS Rear Twist Axle GM Lordstown 0 0 1 Day Inventory No No
25776300 GMX001 RR FE1-5 LUG Rear Twist Axle GM Lordstown 0 0 1 Day Inventory No No
25776303 GMX001 RR FE3 Rear Twist Axle GM Lordstown 0 0 1 Day Inventory No No
25793738 GMX001 RR SS ABS Rear Twist Axle GM Lordstown 0 0 1 Day Inventory No No
15918778 GMX001 FRT FE1 Front Engine Cradle GM Lordstown 0 0 1 Day Inventory No No
15918779 GMX001 FRT FE3 Front Engine Cradle GM Lordstown 0 0 1 Day Inventory No No
25796153 GMX001 FRT SS Front Engine Cradle GM Lordstown 0 0 1 Day Inventory No No
15917891 GMT001 FRT WLD Front Engine Cradle GM Ramos 0 0 1 Day Inventory No No
All Other customer 25861148 GMT966/967/968 Base Level Frame Asm- Drivetrain & Frt Susp GM Lansing Delta Township 0 0 1 Day Inventory No No
parts including 25861149 GMT966/967/968 Up Level Frame Asm- Drivetrain & Frt Susp GM Lansing Delta Township 0 0 1 Day Inventory No No
Service orders 25876169 GMT966/967/968 Steering Gear Package (non-variable effort) GM Lansing Delta Township 0 0 1 Day Inventory No No
25876166 GMT966/967/968 Gear Asm - Strg (variable effort) GM Lansing Delta Township 0 0 1 Day Inventory No No
25876168 GMT966/967/968 Steering Gear Package (variable effort) GM Lansing Delta Township 0 0 1 Day Inventory No No
25876167 GMT966/967/968 Gear Asm - Strg (non variable ratio) GM Lansing Delta Township 0 0 1 Day Inventory No No
25857752 GMT966/967/968 PWR Train MNT Package- Switchable GM Lansing Delta Township 0 0 1 Day Inventory No No
25857745 GMT966/967/968 PWR Train MNT Package GM Lansing Delta Township 0 0 1 Day Inventory No No
Form #: 75132
Revision #: 1
Page 6 of 11
Form #: 75132
Revision #: 1
Page 6 of 11
SHUTDOWN CHECK LIST
Instructions: Identify all Shutdown Activities and
detail them on this sheet
Systems Champion Timing Initial Comments
Maintenance Champion Timing Initial Comments
Quality Champion Timing Initial Comments
Materials Champion Timing Initial Comments
Form #: 75132
Revision #: 1
Page 8 of 11
Note: Bold items must be executed
Form #: 75132
Revision #: 1
Page 8 of 11
Production Champion Timing Initial Comments
Form #: 75132
Revision #: 1
Page 8 of 11
SHUTDOWN CHECK LIST
Instructions: Identify all Shutdown Activities and
detail them on this sheet

Server Tape Backups Daily MT IT will be on the premises for system maintenance
User and system support Daily
Perform upgrades and maintenance

Shut Down 001 Line and Isolate
Shut Down Twist Bolt On and Isolate
Shut Down 001 BO and isolate
Shut Down 300 series and isolate
Shut Down 001 Weld and Isolate
Shut Down Scrubber
Shut Down E-Coat
Shut Down Lambda Front and Isolate
Shut Down Lambda Rear and isolate
Shut Down 310 and 210 series and isolate
Shut Down Lambda bolt on and Isolate
Shut Down Scrubber
Shut Down Lambda Bushing Press and Isolate
Initiate GP-12 Training December 21, 2007

Communicate shutdown and start-up
dates as per 862 and 830 releases
Customers that are NOT shutting down

verify Bank Builds
Ensure manpower & Supervision to
ship to customers
Form #: 75132
Revision #:1
Page 8 of 11
Form #: 75132
Revision #:1
Page 8 of 11
Empty twist bolt on production line of all
product.Each station will be stocked with current
level parts ready for next production run as per
schedule
Empty 001 bolt on production line of all
product.Each station will be stocked with current
schedule
Empty sub cell 310 of all finished product.All
stations will be emptied.
Empty 001 & 357 weld line of all finished

weldments, all finished product will be sent to E coat
Empty all 001 weld line sub stations of all current

level production parts and put into stock;stations 2-
120/130,2-140,2-145,2-160
Empty all 200 series weld stations of finished
LCA's,all finished product will be sent to E coat
Empty all 200 series sub stations of all current level

production parts and put into stock;stations 2-25,2-2-
20 line 1,2-2-20 line 2, 2-2-30 line 1, 2-2-30 line 2.

Empty Lambda Front weld line of all finished
weldments, all finished product will be sent to E coat
once through GP-12
Empty all Lambda Rear Line of all finished
weldments, all finished product will be sent to E-Coat
once through GP-12
Empty Lambda Bolt on line of all product. All
product to go through GP-12 and put into stock
Empty Lambda Bushing Press of all finished
product. Each station will be stocked with current
schedule.
Form #: 75132
Revision #:1
Page 8 of 11
Maintenance Shutdown Plan
Item (ie PM, Move, Clean, Replace, Overhaul,

Machine / Equipment Department Plan Start Date Plan Finish Date On FMEA? RPN Comments
Install New Equipment)
Form #: 75132
Revision #: 1
Page 9 of 11

Form #: 75132
Revision #: 1
Page 9 of 11

Form #: 75132
Revision #: 1
Page 9 of 11

Delta Twist (Not Working

Twist Axle Weldline Axle/Ian Smith Stn 10 C&D-Tool Inspection/Modifications 22-Dec-07 23-Dec-07 N/A N/A December 24,
D/L 25, 26, 2006)

Twist Axle Weldline Axle/Ian Smith Twist stn 30 & 60 Welker Inspections Ln 1 22-Dec-07 23-Dec-07 N/A N/A December 24,
D/L 25, 26, 2006)

Twist Axle Weldline Axle/Ian Smith Stn 50 Cylinder Coupling Blocks 22-Dec-07 22-Dec-07 N/A N/A December 24,
D/L 25, 26, 2006)
Twist Axle Weldline Axle/Ian Smith Twist stn 30 & 60 Welker Inspections Ln 2 22-Dec-07 22-Dec-07 N/A N/A December 24,
D/L 25, 26, 2006)
Twist Axle Weldline Axle/Ian Smith Twist 150 overhaul 22-Dec-07 27-Dec-07 N/A N/A December 24,
D/L 25, 26, 2006)
Twist Axle Weldline Axle/Ian Smith Stn 10 Ln 2 Shotpin Ground 27-Dec-07 27-Dec-07 N/A N/A December 24,
D/L 25, 26, 2006)

Twist Axle Weldline Axle/Ian Smith Buffer Rack P/P Verification 27-Dec-07 28-Dec-07 N/A N/A December 24,
D/L 25, 26, 2006)

Twist Axle Weldline Axle/Ian Smith Station 30 Welker I/O Removal 27-Dec-07 27-Dec-07 N/A N/A December 24,
D/L 25, 26, 2006)

Twist Axle Weldline Axle/Ian Smith Robot Base Limit Switch/ Robot Enabling Device 27-Dec-07 29-Dec-07 N/A N/A December 24,
D/L 25, 26, 2006)
Twist Axle Weldline Axle/Ian Smith Station 10 Ln2 2 Shotpin Ground 27-Dec-07 28-Dec-07 N/A N/A December 24,
D/L 25, 26, 2006)
T-Model Hard Stop Tear Down / Inspection Line 1 &
Twist Axle Weldline Axle/Ian Smith 27-Dec-07 28-Dec-07 N/A N/A December 24,
2
D/L 25, 26, 2006)
Twist Axle Weldline Axle/Ian Smith Twist Axle Station 150 Overhaul 22-Dec-07 27-Dec-07 N/A N/A December 24,
D/L 25, 26, 2006)
Twist Axle Weldline Axle/Ian Smith Install Platforms Twist Axle Weldline 28-Dec-07 28-Dec-07 N/A N/A December 24,
D/L 25, 26, 2006)
(Not Working
E-Coat/Rob
E-Coat Area Crane Oil Change 22-Dec-07 29-Dec-07 N/A N/A December 24,
Cazabon
25, 26, 2006)
(Not Working
E-Coat/Rob
E-Coat Area PM Tank/Flowmeters 22-Dec-07 22-Dec-07 N/A N/A December 24,
Cazabon
25, 26, 2006)
(Not Working
E-Coat/Rob
E-Coat Area Clean & Isolate Ufs 22-Dec-07 23-Dec-07 N/A N/A December 24,
Cazabon
25, 26, 2006)
(Not Working
E-Coat/Rob
E-Coat Area Repair Stage Piping 23-Dec-07 23-Dec-07 N/A N/A December 24,
Cazabon
25, 26, 2006)
(Not Working
E-Coat/Rob
E-Coat Area PM Coalescer/Screens 23-Dec-07 23-Dec-07 N/A N/A December 24,
Cazabon
25, 26, 2006)
(Not Working
E-Coat/Rob
E-Coat Area PM Waste Water Clarifiyers 28-Dec-07 28-Dec-07 N/A N/A December 24,
Cazabon
25, 26, 2006)
(Not Working
E-Coat/Rob
E-Coat Area Repair Piping Stages 29-Dec-07 31-Dec-07 N/A N/A December 24,
Cazabon
25, 26, 2006)
(Not Working
E-Coat/Rob
E-Coat Area Permeate Piping 29-Dec-07 30-Dec-07 N/A N/A December 24,
Cazabon
25, 26, 2006)
(Not Working
E-Coat/Rob
E-Coat Area Clean Screens / Holding Tanks 28-Dec-07 30-Dec-07 N/A N/A December 24,
Cazabon
25, 26, 2006)
Delta Cradle Weldment Delta (Not Working
001 and TABO verify/teach robot load/unload
/Bolt On & Twist Axle Assembly/ Rob 22-Dec-07 29-Dec-07 N/A N/A December 24,
positions
Bolt On Cazabon 25, 26, 2006)
/Bolt On & Twist Axle Assembly/ Rob 001 Bolt on Blue Part process overhaul 22-Dec-07 29-Dec-07 N/A N/A December 24,
Form #: 75132
Revision #: 1
Page 9 of 11


Examine all PLC Codes Regarding All Jumped Out
I/O's
/Bolt On & Twist Axle Assembly/ Rob Error Messages For PV2 001 Weld Poke Yoke 22-Dec-07 29-Dec-07 N/A N/A December 24,
TABO Sta 40 Panelview Screen To Display Reject
Rack JSN's
TABO sta40 PV Screen To Display JSN Tracking Of
Line (Same As Zone3)
/Bolt On & Twist Axle Assembly/ Rob 001 Bolt on Blue Part Process Overhaul 22-Dec-07 29-Dec-07 N/A N/A December 24,
/Bolt On & Twist Axle Assembly/ Rob Turn Table Limit Switches 22-Dec-07 29-Dec-07 N/A N/A December 24,
/Bolt On & Twist Axle Assembly/ Rob Re-Route 2-1-72 Cables Under Fixture. 22-Dec-07 29-Dec-07 N/A N/A December 24,
/Bolt On & Twist Axle Assembly/ Rob Maintenance All AC Units In Electrical Panels 22-Dec-07 29-Dec-07 N/A N/A December 24,
Silicone Fire Jackets/Kevlar Wrap After Dry Icing Of
Tools
001 Bolt-On Shipping Rack Palm Out, Relocate
To/On Post
/Bolt On & Twist Axle Assembly/ Rob 2-25/2-20/2-30 Multi Conductor Cable RE/RE *** 22-Dec-07 29-Dec-07 N/A N/A December 24,
2-1-90 Robot Pick/Place Positions After New End
Effector Install
/Bolt On & Twist Axle Assembly/ Rob Replace Robot Wrist Cover. 2-2-20 R1 22-Dec-07 29-Dec-07 N/A N/A December 24,
/Bolt On & Twist Axle Assembly/ Rob 001 BO Robot Program For Blue Part Check 22-Dec-07 29-Dec-07 N/A N/A December 24,
/Bolt On & Twist Axle Assembly/ Rob Turn Table Limit Switches 22-Dec-07 29-Dec-07 N/A N/A December 24,
/Bolt On & Twist Axle Assembly/ Rob 2-25/2-20/2-30 Multi Conductor Cable RE/RE *** 22-Dec-07 29-Dec-07 N/A N/A December 24,
/Bolt On & Twist Axle Assembly/ Rob 2-120/2-140 Multi Conductor Cable RE/RE *** 22-Dec-07 29-Dec-07 N/A N/A December 24,
Silicone Fire Jackets/Kevlar Wrap After Dry Icing Of
Tools
Overhaul 001 Weld Conveyors, Fix And Install
Damaged Pallets
001 Weldstation.71 R1 Connect Air To Robot
Controller
Overhaul 001 Weld Conveyors, Fix And Install
Damaged Pallets
/Bolt On & Twist Axle Assembly/ Rob Replace Conveyor Belt On 2-230 Conveyor 22-Dec-07 29-Dec-07 N/A N/A December 24,
/Bolt On & Twist Axle Assembly/ Rob Modify Pallets On 2-160 / 2-140 22-Dec-07 29-Dec-07 N/A N/A December 24,
Replace Bent Bolts On 001 Bolton Conveyor
Fixtures (Urethane Supports)
TABO Zone1 Repair Airbag Frame - E-Coat Rack
Lift Table
Form #: 75132
Revision #: 1
Page 9 of 11


/Bolt On & Twist Axle Assembly/ Rob Modify Pallets On 2-160 / 2-140 22-Dec-07 29-Dec-07 N/A N/A December 24,
/Bolt On & Twist Axle Assembly/ Rob TABO Chain Tensioner Inspection And Replace 22-Dec-07 29-Dec-07 N/A N/A December 24,
TABO Zone1 Repair Airbag Frame - E-Coat Rack
Lift Table
/Bolt On & Twist Axle Assembly/ Rob Robot Greasing 22-Dec-07 29-Dec-07 N/A N/A December 24,
/Bolt On & Twist Axle Assembly/ Rob Change All Necessary Filters On All Lines (Air) 22-Dec-07 29-Dec-07 N/A N/A December 24,
/Bolt On & Twist Axle Assembly/ Rob Hydraulic Oil Tank Service (Filters) 22-Dec-07 29-Dec-07 N/A N/A December 24,
/Bolt On & Twist Axle Assembly/ Rob Weld Broken Support Under 320 Turn Table. 22-Dec-07 29-Dec-07 N/A N/A December 24,
Stn. 2-220 Check All 4-Way/2-Way Pins For Correct
Diameters And Change If Needed
Machine All Net Pads And Change Ground
Blocks/Isolators.
001 Mainline: Tool/Net Pads/Locating Pins/Ground
Blocks/Micarta Isolators
/Bolt On & Twist Axle Assembly/ Rob Ground Blocks, All Weld Cells 22-Dec-07 29-Dec-07 N/A N/A December 24,
001 Mainline: Tool/Net Pads/Locating Pins/Ground
001 Subs: Tool/Net Pads/Locating Pins/Ground
Make/Replace Worn Out UHMW E-Coat Protection
Strips On 001BO Robots
/Bolt On & Twist Axle Assembly/ Rob Robot Battery Change 22-Dec-07 29-Dec-07 N/A N/A December 24,
Replace 2-1-20 Tooling Error Proof Harting
Connectors
/Bolt On & Twist Axle Assembly/ Rob Inspect All Robot Wire Feeders 22-Dec-07 29-Dec-07 N/A N/A December 24,
Front Weld Line Lambda Tooling PM's 22-Dec 30-Dec N/A N/A
Rear Weld Line Lambda Tooling PM's 22-Dec 30-Dec N/A N/A
door is in
Rear Weld Line Lambda Install roll-up door at stn 80 22-Dec 28-Dec N/A N/A
house
all hyd tubing is

Bolt-On Line Lambda Relocate stn 90A 22-Dec 30-Dec N/A N/A
ready
Weld Line JS Tooling PM's 22-Dec 30-Dec N/A N/A
batteries are in
All robots Lambda / JS replace all backup batteries 22-Dec 28-Dec N/A N/A
house
Form #: 75132
Revision #: 1
Page 9 of 11
START- UP CHECK LIST
Instructions: Identify all pre-start up activities
and detail them on this sheet
Form #: 75132
Revision #: 1
Form #: 75132
Revision #: 1
START- UP CHECK LIST
Instructions: Identify all pre-start up activities
and detail them on this sheet

Resume support of returning staff AL

Start up 357 weld line, make cradle Geoff Mark 29-Dec GM
Start up 001 weld line, make cradle Chris Durkalec 29-Dec CD
Start up Twist Bolt On, make axle Bob Brown 29-Dec BB
Start up 001 Bolt on, make Cradle Chris Durkalec 29-Dec CD
Start up 300 series, assemble 2 LCA's Bob Brown 29-Dec BB
Start up 200 Series, make 4 LCA's Bob Brown 29-Dec BB
Start up Lambda Front weld line Randy Box 1-Jan RB
Start up Lambda Rear weld line Randy Box 1-Jan RB
Start up Lambda Bolt On line Randy Box 1-Jan RB
Start up JS weld line Randy Box 1-Jan RB

Initiate GP-12 Training December 21, 2007 Colin Stefanescu 2-Jan CS

Review / verify Customer releases Ken Krzewski Daily KK
Review & communicate NEW
schedules as required
Check for degradtion of process
materials and wet chemicals
Form #: 75132
Revision #: 1
Twist bolt on production line will run a All quality and productivity checks
minimium of one hour approx 80 axles to will be supported by QA and
Craig Ferrans 2-Jan CF
make sure line has no quality or productivity maintainance and once verified
issues normal production to follow
001 bolt on production line will run a All quality and productivity checks
minimium of one hour approx 60 cradles to will be supported by QA and
Craig Ferrans 2-Jan CF
make sure line has no quality or productivity maintainance and once verified
issues normal production to follow
All quality and productivity checks

Sub cells 310 and 320 will run a minimium of
will be supported by QA and
one hour approx 80 LCA's to make sure each Craig Ferrans 2-Jan CF
maintainance and once verified
station has no quality or productivity issues
normal production to follow

001 weld line will run a minimum of one hour
approx 60 cradles to make sure line has no Craig Ferrans 2-Jan CF
quality or productivity issues

357 weld line will run a minimum of one hour
approx 60 cradles to make sure line has no Craig Ferrans 2-Jan CF

All weld line sub stations for 357 and 001
will be run for minimum one hour to make sure Craig Ferrans 2-Jan CF
they have no quality or productivity issues

All 200 series weld stations will be run for
minimum one hour to make sure they have no Craig Ferrans 2-Jan CF

Fill sub cell 310 with product.All stations will
Rick Coulombe 30-Dec RC will be supported by QA and
be filled.
maintainance and materials
Fill sub cell 210 with product. All stations will
be filled.
Fill Lambda Front weld line with product.
Each station will be stocked with current level
parts ready for next production run as per
schedule.
Fill Lambda Rear Line with product. Each All quality and productivity checks
station will be stocked with current level parts Rick Coulombe 30-Dec RC will be supported by QA and
ready for next production run as per schedule. maintainance and materials
Fill Lambda Bolt on line with product. Each All quality and productivity checks
station will be stocked with current level parts Rick Coulombe 30-Dec RC will be supported by QA and
ready for nect production run as per schedule. maintainance and materials
Fill Lambda Bushing Press line with product.

Each station will be stocked with current level
parts ready for next production run as per
schedule.
Form #: 75132
Revision #: 1
Form #: 75132
Revision #: 1
Facility Check During Shutdown
Instructions: Identify all areas to be checked and list in Column A (Examples are given).
Identify person(s) responsible for checking these areas; they are to initial this sheet daily to verify that they have checked and all is OK.
After Pre Start-

Area
Last Shift Up
Form #: 75132
Revision #: 1
Page 11 of 11
Facility Check During Shutdown
Instructions: Identify all areas to be checked and list in Column A (Examples are given).
Identify person(s) responsible for checking these areas; they are to initial this sheet daily to verify that they have checked and all is OK.
After Pre Start-

Area
Last Shift Up
Facilities
Oil Storage Area A/L, T/L
Materials
Shipping - North A/L, T/L
Facilities
Waste Treatment A/L, T/L
E-Coat A/L,
E-coat Filter Pump T/L
E-Coat A/L,
E-coat Circulating Pump T/L
Materials
Shipping - South A/L, T/L
Facilities
Compressor Room - South A/L, T/L
Facilities
A/L, T/L
Lighting retrofit
Facilities
Repair grouting in office floor A/L, T/L
tiles
Snake out urinals in men's Facilities
washrooms A/L, T/L
Facilities
A/L, T/L
P M's
Form #: 75132
Revision #:1
Page 11 of 11

Pre and Post Shutdown Activity Forms and Checklists

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TABLE OF CONTENTS

Involve the affected departments as necessary to complete their sections

Distribute this document within your organization for full understanding

Master contact list (by department) 3 of 11

Shutdown Team Meeting Schedule 5 of 11

Production Plan (with Customer Requirements) 6 of 11

Employee Information (Who is working when) 7 of 11

Maintenance Plan (for shutdown period) 9 of 11

Customers Shutdown Period Starts (Date Only) Company Address:

53 2 0 96% G Customers contact name:

5 Does Management do a documented floor walk to review details of plan? x

If any manufacturing or maintenance is planned during the shutdown, is salaried/hourly

Is there a documented communication distribution of significant product and process

If manufacturing is scheduled during the shutdown, has salaried/hourly staffing been

Has the Materials Department participated in a shutdown/startup PFMEA contemplating

If PM is scheduled for Tooling, Machinery, or Processes during the shutdown, is there a

2 Are spare parts at the required inventory levels? x

4 Is there a plan to tryout other high risk machinery, tooling, or processes? x

Red=<75%, Yellow = 76%-90%, Green= 91%-100% Form #: 75132 Audit 6 of 4

4 Is there an acceleration plan that contemplates minor problems? x

6 Is there a well defined part approval plan? x

Red=<75%, Yellow = 76%-90%, Green= 91%-100% Form #: 75132 Audit 7 of 4

Red=<75%, Yellow = 76%-90%, Green= 91%-100% Form #: 75132 Audit 8 of 4

36 1 18 97% G Customers contact name:

5 Does Management do a documented floor walk to review details of plan? x

If any manufacturing or maintenance is planned during the shutdown, is salaried/hourly

14 Have champions been designated to perform pre-startup activities? x

If manufacturing is scheduled during the shutdown, has salaried/hourly staffing been

Has the Materials Department participated in a shutdown/startup PFMEA contemplating

If PM is scheduled for Tooling, Machinery, or Processes during the shutdown, is there a

2 Are spare parts at the required inventory levels? x

4 Is there a plan to tryout other high risk machinery, tooling, or processes? x

Red=<75%, Yellow = 76%-90%, Green= 91%-100% Form #: 75132 Audit 11 of 4

4 Is there an acceleration plan that contemplates minor problems? x

6 Is there a well defined part approval plan? x

Red=<75%, Yellow = 76%-90%, Green= 91%-100% Form #: 75132 Audit 12 of 4

Red=<75%, Yellow = 76%-90%, Green= 91%-100% Form #: 75132 Audit 13 of 4

IT (incl EDI support)

IT (incl EDI support)

Date 23-Oct-22 24-Oct-22 25-Oct-22 26-Oct-22 27-Oct-22

IT (incl EDI support)

IT (incl EDI support)

Physical Inventory done on regular

Customer contacted to ensure requirements

Wrong Conveyor Verification of conveyor system to ensure Verification of OEM capability to

- review customer schedules

- review Shutdown plan forms for completion and acceptability

- review production needs / bank build status prior to shutdown

Carryover parts with

All Other customer

Carryover parts with

Systems Champion Timing Initial Comments

Maintenance Champion Timing Initial Comments

Quality Champion Timing Initial Comments

Materials Champion Timing Initial Comments

Note: Bold items must be executed

Systems Champion Timing Initial Comments

Maintenance Champion Timing Initial Comments

Shut Down Lambda Bushing Press and Isolate

Quality Champion Timing Initial Comments

Initiate GP-12 Training December 21, 2007

Materials Champion Timing Initial Comments

Customers that are NOT shutting down