5.3 Outage / Disaster Recovery Playbooks + Test Schedule

Disaster recovery is not about "hope"; it is about Mean Time to Recovery (MTTR). In a crisis, adrenaline lowers cognitive function. If the recovery process relies on improvisation, the facility will fail. We replace panic with pre-engineered logic paths known as Playbooks. These are not broad policy documents; they are executable scripts that dictate specific mechanical and digital actions to restore stability.

The Playbook Architecture

A Playbook must be binary. It does not ask "What do you think?"; it commands "Do X, then Check Y."

Scenario A: Total Grid Loss (Blackout)

• Trigger: Utility feed = 0V.
• Action 1: Verify Generator Start within 10 seconds.
• Action 2: If Generator Fails -> Then Initiate "Load Shedding Protocol." Cut all HVAC and Compressed Air to preserve UPS battery for the Server Room.
• Action 3: Manually isolate sensitive SMT equipment breakers to prevent voltage spike damage upon grid restoration.

Scenario B: IT Infrastructure Collapse (Ransomware/Server Failure)

• Trigger: MES (Manufacturing Execution System) offline.
• Action: Switch to "Paper Buffer" Mode.
• Constraint: Production continues using physical travelers for up to 4 hours. If > 4 hours, initiate Controlled Shutdown to prevent data reconciliation nightmares.

Scenario C: Environmental Breach (Flood/Hazmat)

• Trigger: Water/Chemical alarm.
• Action: Kill main power to affected zone immediately to prevent electrocution. Deploy containment dikes before calling external emergency services.

Pro-Tip: Laminate these Playbooks and zip-tie them to the relevant equipment (e.g., the Generator Transfer Switch). When the lights go out, nobody can find the file on the server.

The Testing Schedule (Drills)

A plan that is not drilled is a hallucination. Testing validates two things: the hardware capability and the human response time.

Tabletop Simulation (Quarterly)

• Scope: Management Team only.
• Method: Throw a curveball scenario (e.g., "Fire in Chemical Store + Sprinkler Failure"). Analyze the decision gaps in communication and authority.

Functional Drill (Bi-Annual)

• Scope: Specific Department (e.g., Maintenance).
• Method: Physically cut power to a non-critical distribution board. Measure the time to diagnose, isolate, and restore.

Full Scale Evacuation (Annual)

• Scope: Entire Facility.
• Method: Trigger alarms. Measure headcount accountability speed.
• Metric: Target < 3 minutes for 100% accountability.

Communication & Chain of Command

Chaos stems from ambiguity in leadership. Define the "Incident Commander" explicitly.

• If Incident Occurs -> Then The Shift Supervisor is Incident Commander until relieved by the Facility Manager.
• If Media/External Agencies contact facility -> Then strictly "No Comment." Refer to Legal/PR immediately.
  • Risk: Misinformation leaks cause stock price volatility and liability admissions.

Final Checklist