In creating a safer workplace, it is essential that each and every employee remains aware of health and safety issues and be on a constant lookout for potential dangers lurking in each work situation. In FY2009 - FY2012, we created a mechanism to allow health and safety training to continue to be held. During this period, we repeatedly held training for managers and equipment designers/developers on hazardous and dangerous work. Furthermore, in FY2012, we deployed our "declaration of five points to personally protect ourselves" in order to raise individual's safety awareness in addition to our annual activities. We promoted this scheme through morning meetings and similar events. In the future, we will continue to improve this mechanism.
Efforts and Status
Training personnel to anticipate hazards
(1) Conducting maintenance to prevent breakdowns
To prevent accidents from occurring while responding to equipment troubles or short stoppages, it is necessary to prevent the underlying cause-equipment failure. In FY2009 - FY2012, we strived to minimize equipment failure through the use of mechanical monitoring and analysis in each stage of production. This allowed us to identify equipment areas that require inspection and maintenance, which were then put on a regular schedule of maintenance. In the future, we will continue to work toward reducing and eliminating equipment trouble and short stoppages.
(2) Maintaining and satisfying safety standards for individual equipment
We have been enacting and applying facility safety standards that establish common risk measures for production equipment since FY2005 with the aim of promoting inherently safe designs by evaluating risks and incorporating appropriate countermeasures from the design and development stages of new production facilities. In FY2009 - FY2012, we additionally created safety standards by facility that establish risk measures for specific equipment and started to apply these. When manufacturing and remodeling new production equipment, three checks are performed by the designer, the person in charge of the department where the equipment will be used and the person in charge of the Safety and Environment Department. Since then, we have been complying with these standards.
(1) Installing and maintaining appropriate ventilation devices
We continue to improve operating methods and other measures to prevent workers from coming into contact with chemicals or to minimize that likelihood. We also verify the capacity of local ventilation systems, making refinements as necessary. New ventilation systems we introduced in FY2009 - FY2012 after discussions and investigations between the appropriate parties were appropriate and took into account operability and ventilation efficiency. Moreover, we reviewed the shape of the hoods of the existing ventilation systems and made improvements, such as reducing the area of the opening of the intake duct.
(2) Reducing fire and explosion potential
We take a comprehensive approach to preventing chemical fires through such measures as managing humidity, making facilities explosion-proof, and removing static electricity from jigs and personnel. In FY2009 - FY2012, we placed emphasis on static electricity measures and equipment explosion-proof measures in areas where chemical substances are used and stored. We verified the static electricity measures taken at each site in our audits and completed the implementation of measures for the deficiencies that were discovered. We also quantified the usage control standards for equipment explosion-proof measures.
Creating and observing procedures ensuring safety when safety devices are disabled
To prevent unsafe behavior by workers, Taiyo Yuden has drawn up operating procedures for both normal and irregular tasks and standardized key points requiring strict observance for health and safety reasons. In FY2009 - FY2012, we objectively checked and evaluated the maintenance and management situation for each work site risk. As part of this effort, we completed the check of the compliance with the procedures to ensure safety when safety equipment has been disabled.
Building and exploiting an accident database
When an accident occurs, it is essential to prevent similar accidents from occurring at other sites. In FY2009 - FY2012, we created an accident database and so it became possible to search and check the details, types, causes and more of accidents. We now have an environment where it is possible to share information. Moreover, we are continuing to appropriately collect and review the needs of users in order to improve the database and make it even more user-friendly. Our accident database is used by the health and safety committee at each site to provide accident updates, explain causes, provide training on accident prevention, and set up safety measures when designing facilities.
Countering Major Risks
Earthquake preparation measures to protect lives now in place
Since FY2008, we have been promoting measures to protect lives in the event of an earthquake. These measures are focused on four areas: (1) Ensuring evacuation routes; (2) Keeping objects from falling; (3) Preventing secondary accidents; and (4) Earthquake-proofing buildings (at the time of renovations). We completed these measures during FY2012. To ensure evacuation routes, we created evacuation route maps and installed evacuation equipment. To keep objects from falling, we took measures to prevent objects such as lights and window glass from dispersing and falling, and to prevent objects such as pipes and ducts from falling. To prevent secondary accidents, we created cut-off procedures for high voltage power supplies and took measures to prevent combustibles and chemical substances from spilling.
(1) Maintaining low incidence ratio for mental health problems
We have introduced a mental health care system - Primary prevention: Self-care, such as stress checks of all employees; Secondary prevention: Internal staff care, such as line care and counseling for all managers and supervisors; Tertiary prevention: External care and internal staff care, such as leaves of absence and return to work support. In FY2012, we set up an environment in which it is possible for employees to freely take a stress check whenever they want by introducing a simple occupational stress questionnaire web system. It should be noted that the incidence rate for mental health problems (see G1.) declined to 0.2% in FY2012. Going forward, we will continue to promote self-realization and treatment of stress, reaching out when managers notice changes in the people working for them and appropriate support for those in need as soon as possible. We aim to further enhance our mental health care support so that it is possible for each and every one of our employees to work in good health.
Mental Healthcare System
G1: Incidence Rate
(2) Keeping down abnormal checkup findings
In order to keep down abnormal checkup findings, we are continuing to promote efforts toward the prevention and improvement of lifestyle diseases, centering on nurses and public health nurses at each site. We have established and are running a health improvement program for those who have been identified as in need of health guidance from the results of regular health checks. This has been leading to improvements to the lifestyles of our workers. In FY2012, we set up salad bars for hands-on nutritional guidance and our employees learned about the importance of ingesting vegetables, the amount of vegetables necessary every day and the best way to eat vegetables. In the future, we will continue to promote activities that focus on preventing and improving lifestyle diseases so that it is possible for our employees to work in good health.