Occupational Safety and Accident Prevention Activities

Materiality Focus

Employees are key stakeholders of the Toray Group. Needless to say, ensuring their safety is the prerequisite to their capacity to make the most of their potential. Officers and employees work together to implement persistent safety initiatives with the goal of zero accidents, out of respect for humanity and the sanctity of life.
To raise the awareness, every year, the Toray Group creates a group-wide safety slogan. In fiscal 2016, the Group urged employees worldwide to always think carefully before acting in conducting their work, through the unique keyword of "Anzen Koh-Doh" ("thoughtful safety action"). The Toray Group is working hard to ensure that the message reaches all of its employees including those at group companies outside of Japan.

Due to the potential impact of an accident not only within the company but on surrounding communities, the Group places the highest priority on accident prevention.

 

2016 Safety Slogan

AP-G 2016
We Should Achieve "Zero Accidents". Each of us does "Anzen Koh-Doh"!
~ "Seriousness" "Motivation" "Awareness" ~

Every year, company presidents and plant managers from Toray and its group companies around the world meet at the Toray Group Safety Meeting. At the meeting, presentations on safety action policies and main activities, lectures by external experts, and activity reports from worksites are offered to raise awareness of safety. The Group's employees are all united under the leadership of top management in working on safety activities with the aim of achieving zero accidents.

Furthermore, the Safety Summit, safety lectures by Toray's directors, and other events are held on a national and regional basis, and at each group company and plant of the Group. These efforts promote a common awareness of the Toray Group safety slogan, policies, and main activities, enabling centralized management of safety activities across the Group.

 

  • 2016 Toray Group Safety Meeting in Toray Human Resources Development Center2016 Toray Group Safety Meeting in Toray Human Resources Development Center
  • Toray Group Safety Summit in IndonesiaToray Group Safety Summit in Indonesia

Toray Group Safety Record

Number of major accidents

Reporting scope: Toray Group

Fiscal 2016 target:
0 accidents

Result:
0 accidents

Number of fire and explosion accidents

Reporting scope: Toray Group

Fiscal 2016 target:
0 accidents

Result:
1 accident

Achieve world's best standard for safety management (not exceeding 0.05 frequency rate for occupational accidents resulting in lost work time)

Reporting scope: Toray Group

Fiscal 2016 target:
No more than 0.05

Result:
0.33

Based on keywords, employees take action to prevent the occurrence of similar accidents (No. 3 Plant, Toyo Jitsugyo Co., Ltd.). Based on keywords, employees take action to prevent the occurrence of similar accidents (No. 3 Plant, Toyo Jitsugyo Co., Ltd.).

In 2016, no major accidents occurred at the Toray Group, but there was one fire at a Group company outside Japan that caused some facilities damage. The Group responds to accidents by dispatching internal accident prevention experts to the affected site to investigate the cause and ensure that measures are put in place to prevent future accidents. The knowledge they gain in the process is then circulated within the Group.
The Group investigates the root cause of accidents and implements measures to prevent recurrence with the continued goal of achieving zero accidents, making safety its highest priority.

Toray has collected data on all occupational accidents since 1980, and for the Toray Group since 1990. Information on past accidents is used by all group companies as valuable data for implementing preventative measures. Both the number of occupational accidents and frequency of occupational accidents resulting in lost work time have declined, compared with when the data was first collected.

Meanwhile, the frequency rate for occupational accidents resulting in lost work time for the Toray Group overall in 2016 increased by 0.19 points to 0.33. Although this is a positive result compared with that of Japan's manufacturing industry (1.15), it fell far short of the target of 0.05 or lower.

One reason for this result was that the definition of an occupational accident was partially revised in December 2015. The Group acknowledges that there is room for improvement, and it is striving to further raise the level of safety. It works to eliminate accidents by investigating the root causes of each accident, implementing preventative measures, and further educating employees to think carefully before acting.

Number of Occupational Accidents: Toray Group (Lost work time and non-lost work time)

Number of Occupational Accidents: Toray Group (Lost work time and non-lost work time)

Occupational Accident Frequency Rate1: Toray Group

Occupational Accident Frequency Rate 1: Toray Group

  1. 1 Occupational accident frequency rate: The number of fatalities and injuries at worksites per one million cumulative working hours

Enhancing Safety and Accident-Prevention Training

As part of their safety and accident prevention training, Toray Group companies and plants provide workshops and hands-on simulations to sensitize employees to dangers and hazards. Safety devices are used to simulate dangers such as getting caught up in rollers, electrocution, and residual pressure. In the area of accident prevention, the Group conducts simulation training to teach employees about the risk of fires and explosions, and provides training on the fundamentals of accident prevention.

Additionally, the Group publishes articles on safety and accident prevention in its in-house newsletter, People. In 2016, the newsletter published a feature that examined the basics of fires and explosions.

  • Demonstrating the danger of fires and explosions at Toray School of Technology and BusinessDemonstrating the danger of fires and explosions at Toray School of Technology and Business
  • Accident-prevention training room at Toray's Tokai PlantAccident-prevention training room at Toray's Tokai Plant

VOICEMessage from a Trainer

Implementing safety training and workshops for construction employees and subcontractor personnel

I work for the Project Management Section of the Plant Business Department. We implement the following training for construction site managers, construction leaders, and foremen employed by subcontractors, and we also encouraged them to attend external workshops.

  1. Occupational health and safety training (two days each year, held on first Monday and Tuesday in June)
  2. Safety simulation training (once annually between July to September)
  3. Safety training mandated under Industrial Safety and Health Act (as needed)
  4. Workshops for operators of four-wheeled vehicles (four times per year, organized by Tokyo Metropolitan Police Department)

This training serves the common purpose of preventing occupational accidents at Suido Kiko, and raising the knowledge, skills, and awareness of front line employees. We sought to create a curriculum that is both practical and effective, by combining group classroom education with hands-on simulation training that enables participants to experience the dangers first-hand.

Occupational health and safety training is implemented every year in June. We invite the director of the supervising labor standards bureau and occupational safety instructors to come and speak to the participants about the latest trends in occupational health and safety. We also implement safety simulation training, where participants experience hanging from a safety belt to learn first-hand about the dangers that exist.

Additionally, we implement safety training mandated under the Industrial Safety and Health Act for work that is potentially dangerous or hazardous. The training is implemented internally by employees who are certified as trainers, as we seek to continually increase our pool of employees who have received the training. We currently implement eight types of special training.

Seminar for plant formen and occupatinal health and safty managers
Seminar for plant formen and occupatinal health and safty managers

Shinobu IdeSection Manager, Project Management Section, Project Department, Suido Kiko Kaisha, Ltd.

Shinobu IdeSection Manager, Project Management Section, Project Department, Suido Kiko Kaisha, Ltd.

Implementing Safety Management Together with Subcontractors

The Toray Group recognizes its duty to ensure the safety of the many subcontractors working at its sites.

Occupational health and safety committees meet once a month with the participation of representative employees from subcontractors, to pursue safety activities with the mutual cooperation of everyone in the workplace. Regular safety and liaison meetings are conducted to gain input from subcontractors, and are used to communicate the Group's policies and measures.

In addition, Toray encourages its subcontractors to actively participate in general safety activities, such as by submitting ideas for safety posters and entering slogan contests.

In fiscal 2016, presidents of 10 Toray affiliates that provide ancillary services for plant operations cooperated to conduct mutual safety inspections of their facilities. The inspections served to verify the progress of safety initiatives, by monitoring hazardous work including forklift and packaging operations. Personnel advised each other on areas needing improvement and monitored the progress of improvements.

  • Safety meeting at Nagoya PlantSafety meeting at Nagoya Plant
  • Mutual safety inspection at Toyo Service Co., Ltd.Mutual safety inspection at Toyo Service Co., Ltd.

Preparing for Accidents through Fire-Prevention Drills

Fire-prevention drill at Ogaki Fuso Spinning Co., Ltd.Fire-prevention drill at Ogaki Fuso Spinning Co., Ltd.

All companies and plants in the Toray Group are making efforts to improve their accident-prevention capabilities by carrying out fire-fighting drills specifically intended for fires and explosions. These drills include practice using water hoses, rescuing the injured, responding to a chemical leak, and giving emergency notification to authorities and local residents.

Group plants that are next to the sea conduct evacuation drills in the event of a tsunami triggered by a large-scale earthquake.

Initiatives for Improving Fire-Prevention Capabilities

In 2016, the Toray Group outlined four key measures to strengthen fire prevention at the Toray Group and implemented fire prevention training for all Group companies. Plants in which fire related incidents occurred investigated the underlying cause based on onsite audits conducted by the Group's own accident prevention experts, and then developed countermeasures.

As a company that places the highest priority on employee safety, the Group has adopted an employee safety verification system and implemented evacuation drills to strengthen its earthquake response. Additionally, the Group conducted business continuity planning in order to meet its social responsibility to keep supply lines open in the event of a large-scale earthquake.

Four Key Measures Identified by Expert Committee and Activity Results

Key measures Details/objectives Results of 2016 activities
Utilize fire-prevention checklist Enhance and effectively utilize fire-prevention checklist
  1. Implemented fire-prevention checklist training for group companies outside Japan
  2. Established a system for trained staff to implement checklists (in Japan)
Enhance employee training Review and issue fire-prevention textbook; prepare and implement company-wide fire-prevention training system
  1. Established a training system for fire prevention, encompassing basic principles for fire prevention and skills training at the pilot plant
  2. Implemented fire prevention training for group companies outside Japan
Enhance management of manufacturing process change Standardize manufacturing conditions, work and equipment change procedures
  1. Developed workplace standards based on company-wide standards, prepared related documentation, and implemented the standards (in Japan)
  2. Established a framework for implementation at group companies outside Japan
Strengthen work security Standardize hot work rules and procedures
  1. Revised the hot work standards for companies and plants (in Japan), and checked the implementation status
  2. Established a framework for implementation at group companies outside Japan

Fire prevention training at Toray Human Resources Development Center for employees of group companies outside Japan
Fire prevention training at Toray Human Resources Development Center for employees of group companies outside Japan

Distribution Safety Initiatives

Toray is working to ensure safe distribution in its operations. In an effort to manage safety when transporting hazardous substances, Toray concludes security agreements with certain customers, raw material manufacturers, and shipping companies to designate their specific safety responsibilities and roles with regards to safety.

Health Effects and Response to Asbestos

The Toray Group has manufactured and imported building materials containing asbestos in the past. In addition, certain buildings and facilities were constructed using such materials and thermal insulation containing asbestos. Starting in 2005, when asbestos-related health hazards became a social concern in Japan, Toray took action to address the issue of its own asbestos-containing facilities. The health program offers medical examinations to current and former employees who handled even small amounts of asbestos and wish to undergo an examination. The Toray Group is working in good faith with individuals diagnosed with asbestos-related health issues by assisting with their applications for workers' compensation and providing an ongoing program of medical examinations. The Group has not been contacted about health issues by residents living near affected plants.

The health effects on former and current the Toray Group employees as of March 31, 2017 are described below.

⋅ Certified occupational accidents arising from handling asbestos (Toray Group): 83 (67)
⋅ Certified health victims based on Japan's Act on Asbestos Health Damage Relief (Toray Group): 9 (9)
⋅ Medical examination recipients involving asbestos (Toray Group): 3,981

Note: Figures in parentheses refer to fatalities.