What went wrong at the Kundli electronics plant
On July 10 a sudden blaze erupted in a mid‑size electronics assembly unit in Kundli Industrial Area. Workers reported a thick black smoke plume rising from the soldering bay, where multiple soldering irons and reflow ovens were operating unattended. The fire spread quickly through stored printed‑circuit board (PCB) pallets that were stacked against a wall without any separation, and the fire alarm failed to sound beyond the immediate workshop, leaving the night shift unaware until flames breached the fire‑rated partition.
An investigation later revealed three glaring lapses: first, the absence of a dedicated hot‑work permit system, meaning operators could start welding or soldering without a supervisor’s sign‑off. Second, the electrical distribution board was overloaded; several branch circuits shared a single feeder, and the circuit breakers showed visible wear but were never replaced. Third, the fire‑extinguishing equipment—two CO₂ extinguishers—had expired tags and were mounted too low for the height of the equipment rows, rendering them ineffective when the fire broke out.
These failures are not unique to Kundli; many small‑to‑medium manufacturers in Haryana keep legacy wiring, ignore routine inspection tags, and store combustible inventory in fire‑hazard zones. The result is a perfect storm where a minor spark can ignite a full‑scale loss, jeopardising production, employee safety, and the mandatory fire NOC. Understanding exactly where the breakdown occurred guides the checklist that follows.
Immediate actions before the next shift starts
Begin every shift with a visual walk‑around of the hot‑work area. Verify that all soldering stations have functional temperature controls, that cords are intact, and that no flammable material sits within a two‑metre radius. A simple checklist on the shop floor, signed by the shift supervisor, creates accountability and catches missing safety gear before work resumes.
Next, test the fire alarm audibility by pulling the test switch on the central panel. The sound should be clearly audible at the farthest point of the production floor, the break‑room, and the administrative office. If the alarm is muffled, check for obstructed speaker grills or dead batteries in the backup unit. Document the test result in the logbook; the record will be requested during the next fire NOC renewal.
Finally, ensure that portable extinguishers are visible, properly mounted, and have up‑to‑date pressure gauges. For electronics work, a clean‑agent extinguisher (CO₂ or dry‑chemical) should be within arm’s reach of each soldering line. Replace any unit with a cracked body or expired tag immediately, and record the replacement date. This three‑step routine can be completed in under ten minutes but dramatically reduces the chance of a small spark becoming a disaster.
- Check hot‑work area for combustible clutter
- Verify fire alarm test and audibility
- Inspect portable extinguishers for tag date and pressure
Electrical distribution and load management
A common root cause of industrial fires is an overloaded distribution board. Conduct a load audit by listing each major machine—reflow oven, pick‑and‑place robot, testing rigs—and noting their rated amperage. Compare the sum against the rating of the incoming feeder and the capacity of each circuit breaker. If the total exceeds 80 % of the breaker rating, you must re‑route circuits or install a dedicated feeder for high‑draw equipment.
During the audit, look for signs of overheating: discoloured wiring, melted insulation, or a faint smell of burnt plastic near terminal blocks. These are early warnings that the conductors are carrying more current than designed. Replace any compromised cable with BIS‑marked, flame‑retardant wiring appropriate for industrial use, and ensure that all connections are tightened to the correct torque.
Zed‑King Fire & Safety can perform a detailed electrical safety audit as part of its fire NOC preparation service. The team brings portable clamp meters and thermal imaging cameras to pinpoint hidden hot spots, then issues a compliance report that satisfies the local fire department’s documentation requirements.
Storage layout and housekeeping for combustible inventory
Electronics components—especially packaged PCBs, solder paste trays, and insulated wires—are classified as combustible because of the polymer resins they contain. Store these items on metal racks at least one metre away from heat‑generating equipment. Keep aisles clear so that a fire crew can move a wheeled fire extinguisher or a hose reel without obstruction; a minimum width of 1.2 metres is a practical rule of thumb for most Haryana factories.
Implement a first‑in‑first‑out (FIFO) system for raw material pallets. Older pallets should not sit stacked against walls for months, as dust accumulation creates a secondary fuel source. Conduct a weekly housekeeping audit: sweep floors, wipe down surfaces, and remove any stray packaging material that could act as tinder. Record the audit in a visible log; auditors appreciate a documented routine.
When hazardous chemicals such as solvents or cleaning agents are used, store them in a fire‑rated cabinet with proper ventilation. Labels must be legible, and the cabinet should be secured to the floor to prevent tipping during an earthquake or a minor impact. This practice not only protects the inventory but also satisfies the fire department’s requirement for safe chemical storage.
- Maintain 1 metre clearance from heat sources
- Keep aisles at least 1.2 metres wide
- Use FIFO for PCB pallets and conduct weekly housekeeping
Documentation, training and NOC renewal checklist
The fire NOC renewal process in Haryana asks for a set of documents that many factories keep in scattered folders. Consolidate them into a single fire safety binder: the latest fire alarm test report, extinguisher service certificates, electrical inspection reports, and a signed hot‑work permit register. The binder should be kept in the office near the main entrance where the fire officer can inspect it without delay.
Train all staff, including contract workers, on the location and operation of fire‑extinguishing equipment. Conduct a short drill every quarter where a mock alarm is sounded and employees must evacuate to the designated assembly point within two minutes. Record attendance and any observations about bottlenecks; these records become part of the compliance evidence for the NOC.
A final tip for the renewal audit is to appoint a fire safety officer—usually the senior shift supervisor—who signs off on each checklist item before the fire department’s visit. This person acts as the point of contact for any queries, ensuring that the auditor sees a single, accountable voice rather than a collection of disparate signatures.
- Create a single binder with all fire safety records
- Run quarterly evacuation drills and log results
- Assign a fire safety officer to sign off checklist items
Putting the checklist into daily practice
The true value of a checklist lies in habit. Post the three‑step start‑of‑shift routine on the wall near the main entry, using colour‑coded symbols for each task. Encourage supervisors to review the board during the daily brief and to tick off each item on a laminated sheet that can survive the factory environment. Over time, the visual cue becomes a part of the work culture, reducing reliance on memory alone.
Periodically review the checklist against any changes in plant layout or equipment upgrades. If a new CNC machine is installed, add a specific line to verify its cooling system and emergency stop function. Likewise, when the fire alarm system is upgraded, update the audibility test procedure to include the new speaker locations. This dynamic approach keeps the safety plan relevant and prevents it from becoming a static document.
For a practical next step, contact Zed‑King Fire & Safety to arrange a free site survey. Their engineers will walk the floor, compare your current practices with the checklist, and suggest any missing controls before the next NOC inspection. A short visit today can save weeks of rework and costly downtime tomorrow.
