1. Guideline
Minimum requirements regarding
contingency plans and their creation

2. Change History Guideline
Minimum requirements regarding contingency plans and their creation
Change History
Index 02
Reason 5.8 for change
Pt 5.8 time span changed on demand XXX.XXX
Date
Index 03
Reason 5.2 for change
Pt 5.2 Assessment changed on demand XXX.XXX
Date

3. Guideline
Minimum requirements regarding contingency plans and their creation
1. Introduction I
The standard ISO TS requires in chapter for events like
Power supply interruptions
Manpower shortages
Failure of important operating means
Field complaints
contingency plans so as to be able to fulfill the requirements of the customer also in such cases.

4. 1. Introduction II Basically a difference needs to be made between
Guideline
Minimum requirements regarding contingency plans and their creation
1. Introduction II
Basically a difference needs to be made between
contingency plans demanded by the authorities
contingency plans demanded by the ISO TS 16949
In the first case the objective chiefly focuses on limiting damage to
Man
Environment
Infrastructure
In the second case the objective chiefly focuses on
fulfilling our delivery commitments with regard to our customers.

5. 2. Target of this guideline
Minimum requirements regarding contingency plans and their creation
2. Target of this guideline
Supplying our customers with products on schedule
is one of the foremost targets of all plants belonging to COMPANY. In order to put us in a position where we can fulfill our delivery commitments also in contingencies,
each plant must create a contingency plan in line with this guideline

6. 3. Contingency in the sense of this guideline
Minimum requirements regarding contingency plans and their creation
3. Contingency in the sense of this guideline
A contingency in the sense of this guideline will be present when the following production factors are available only on a limited basis or not at all
Machines & tools
Plants
Buildings
Transportation means
Telephone
Electronic data-processing / network
Purchased production materials
Electric power
Water
Gas
Fuel oil and other combustibles
Manpower
Field complaints (recalls) will result in increased delivery commitments and must, in the sense of this guideline, be also treated as a contingency.

7. 4. Responsibilities The plant manager is responsible as to presence,
Guideline
Minimum requirements regarding contingency plans and their creation
4. Responsibilities
The plant manager is responsible as to
presence,
maintaining and
operating
of the contingency plan.
The contingency plan needs to be
verified and
validated
by the plant manager through suitable measures (if required, dummy runs).

8. 5. Approach & risk assessment
Guideline
Minimum requirements regarding contingency plans and their creation
5. Approach & risk assessment
Approach
For every event which potentially can result in a contingency in the sense of this guideline, a risk assessment needs to be run first.
Risk assessment
The risk assessment is run - preferably using Excel - corresponding the following schematic:
Event (5.1)
Assessment (5.2)
Production factor (5.4)
Consequences (5.3)
Significance (5.5)
Action (5.6)
Responsibility (5.7)
Time need (5.8)
Risk priority number (5.9)

9. Guideline
Minimum requirements regarding contingency plans and their creation
5.1 Events
Events are such processes which potentially result in the contingency in the sense of this guideline. Such events can be, for example
Acts of god like
Lightning strike
Hail
Storms
Snowstorms
Sandstorms
Hurricanes
Tornadoes
Storm tides
Earthquakes …
Epidemics
Flu
Pestilence …
Others
Acts of terrorism
Acts of war
Strikes
Accidents
Plane crashes …
This list is to be taken as an example and by no means it claims to be complete!
Lightning

10. Guideline
Minimum requirements regarding contingency plans and their creation
5.2 Assessment
The assessment of one and the same event is dependent on the geographic location of a plant, the political conditions prevailing there and other factors, and may for this reason differ widely from plant to plant!
The assessment in each case relates to a single event. The assessment is performed as follows:
1 = very unlikely
1 is assigned to events which based on experience cannot occur, or to date have not occurred.
2 = unlikely
2 is assigned to events which occurred already during the past 10 years
3 = possible
3 is assigned to events which occurred already during the past 5 years.
4 = likely
4 is assigned to events which occurred already during the past 2 years.
5 = very likely
5 is assigned to events which based on experience have in the past years occurred already several times or which occur regurarly.
Lightning 3

11. Guideline
Minimum requirements regarding contingency plans and their creation
5.3 Production factor
Here the affected production factors in accordance with section 3 are stated:
Machines & tools
Plants
Buildings
Transportation means
Telephone
Electronic data-processing / network
Purchased production materials
Electric power
Water
Gas
Fuel oil and other combustibles
Manpower
If necessary production factors could be specified more detailed, e. g. drilling machine No. 4711
Lightning 3
Electric power

12. Guideline
Minimum requirements regarding contingency plans and their creation
5.4 Consequences
The consequence of an event results in a contingency in the sense of this guideline, i. e.
restricted production factors or
unavailability of production factors
Lightning 3
Electric power
unavailable

13. Guideline
Minimum requirements regarding contingency plans and their creation
5.5 Significance
The significance always relates to a consequence and is assessed as follow:
1 = no influence on the quality of the product or the ability to deliver
3 = can have an influence on quality or the ability to deliver
5 = has an influence on quality or the ability to deliver
Lightning 3
Electric power
unavailable 5

14. Guideline
Minimum requirements regarding contingency plans and their creation
5.6 Action
The action relates to the contingency described under “Consequences” and its target at remedying it. The action must be described briefly and precisely, for example
“Start up spare compressor”
“Start up emergency power supply”
“activate supplier xyz for …”
Lightning 3
Electric power
unavailable 5
Start up

15. Guideline
Minimum requirements regarding contingency plans and their creation
5.7 Responsibility
Here the department must be specified which is responsible for introducing the measure for remedying the contingency.
Lightning 3
Electric power
unavailable 5
Start up
maintenance

16. Guideline
Minimum requirements regarding contingency plans and their creation
5.8 Time needed
Here the time needed until the measure for remedying the contingency becomes effective must be stated as follows.
1 = less than 8 hours
2 = more than 8 hours, however less than 5 days
3 = more than 5 days, however less than 10 days
4 = more than 10 days, however less than 14 days
5 = over 14 days
Lightning 3
Electric power
unavailable 5
Start up
maintenance 1

17. 5.9 Risk priority number (RPN)
Guideline
Minimum requirements regarding contingency plans and their creation
5.9 Risk priority number (RPN)
The risk priority number is the product of assessment figure, significance figure and time needed, with a
minimum of 1
maximum of 125
Lightning 3
Electric power
unavailable 5
Start up
maintenance 1 15

18. 6. Conclusions Sort the RPN’s in descending order
Guideline
Minimum requirements regarding contingency plans and their creation
6. Conclusions
Sort the RPN’s in descending order
define or try to improve the actions for the high RPN issues
try to minimize the consequences, e. g. by redundant production factors …
The method described in this guideline allows us to evaluate in a demonstrable way any imaginable event.
Lightning 3
Electric power
unavailable 5
Start up
maintenance 1 15