Fiscal 2019 CSR Activity Report - Occupational Safety and Accident Prevention Activities

Occupational Safety and Accident Prevention Activities

Environment

Toray Group pursues its own safety activities using occupational health and safety management systems (such as OHSAS 18001 and ISO 45001). In addition, officers and other employees audit all group companies and plants every year and evaluate and seek improvements in the status of their management of safety and health, accident prevention and environment from a standardized perspective. In addition, best practices are shared at sites throughout the Group to enhance the entire Group’s performance. Employees are key stakeholders of 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, Toray Group creates a group-wide safety slogan. In fiscal 2019, the Group used the unique keyword of “Anzen Koh-Doh”1 to remind employees worldwide to take thoughtful safety actions. 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 potentially serious impact of an accident not only within the company but on surrounding communities, the Group acts with strong determination to prevent accidents such as fires and explosions, making accident prevention a top priority. Toray Group sets up safety and health committees and works to ensure the safety and health of its employees through united efforts of labor and management, based on occupational health and safety laws in the countries in which it operations. These efforts help to ensure a pleasant working environment.

  1. 1 This refers to thinking about and acting on the basics of safety in order to enhance personal hazard sensitivity, identify hazards in the workplace, and ensure one’s own safety.

2019 Safety Slogan

AP-G 2019
We Should Achieve “Zero Accidents”. Each of us does “Anzen Koh-Doh”!
—“Seriousness,” “Motivation,” “Awareness”

Every year, company presidents and plant managers from Toray Industries and its group companies around the world meet at the Toray Group Safety Meeting. At the meeting, safety action policies and main activities are shared to set a common course, activities at worksites are reported, and safety awards are given 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, on-site safety lecture by Toray Industries 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.

  • 2019 Toray Group Safety Meeting in Toray Human Resources Development Center2019 Toray Group Safety Meeting in Toray Human Resources Development Center
  • Safety Summit of Toray Group Companies in the AmericasSafety Summit of Toray Group Companies in the Americas

Toray Group Safety Record

Number of major accidents

■Reporting scope
Toray Group
■Target in 2019 (calendar year)
0

Result in 2019

0

Number of fire and explosion accidents

■Reporting scope
Toray Group
■Target in 2019 (calendar year)
0

Result in 2019

2

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
■Target in 2019 (calendar year)
No more than 0.05

Result in 2019 (calendar year)

0.34

A safety meeting with the participation of unit heads at Aichi Plant (Toray Industries, Inc.)A safety meeting with the participation of unit heads at Aichi Plant (Toray Industries, Inc.)

Toray Industries has collected data on all occupational accidents since 1980, and for Toray Group since 1990. 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.
The frequency rate for occupational accidents resulting in lost work time for Toray Group overall in 2019 was 0.34. Although this is a positive result compared with that of Japan’s manufacturing industry (1.20), it fell far short of the target of 0.05 or lower. One reason for this is that group companies had many accidents resulting in lost work time. Accordingly, the Group is working to strengthen safety management at those group companies with support and guidance from Toray’s main plant in Japan.
Toray Group will continue to identify the root cause of each accident to prevent reoccurrence, and avoid similar accidents based on the lessons learned in these accidents. Additionally, the Group will raise employee awareness of the need to practice safety first at all times.
To ensure familiarity with “Anzen Koh-Doh” practices, unit heads in charge of work on the front line will take the leading role at Toray Industries and its group companies in Japan in reforming safety awareness and actions in their own workplaces. Since 2015, unit heads have been meeting to share and discuss their safety activities, encouraging each other to work hard to ensure safety.

Furthermore, Toray Group has designated that an organized workplace is crucial to safety, as one of its safety principles under the Group’s basic safety rules. In 2019, the Group stressed the basics of safety by emphasizing the comprehensive implementation of 5S—seiri (sort), seiton (set in order), seiso (shine), seiketsu (standardize) and shitsuke (sustain). The Group endeavors to foster 5S practice leading to Anzen-Koh-Doh, through repeated practice of seiri, seiton, and seiso in workplaces, so that all employees adopt seiketsu and shitsuke. Seiketsu fosters employees' motivation to keep the workplace standardized and clean, and shitsuke raises employees' awareness to adhere to the rules. To further energize these activities, employees visit Group companies and plants whose initiatives are models of excellence. This enables employees to learn about tools such as visualizing overload, unevenness, and waste in worksites and optimizing workflow to create space, which they implement at their own companies.

In terms of fire and explosion accidents, small-scale fires occurred at one group company in Japan and one group company outside Japan, but these accidents did not cause human damage nor did either affect any area outside of plant premises. One fire was caused by sparks emitted from hot work and the other fire traced to sediment from a duct or chimney. To prevent a recurrence of these fires, the Group has implemented stricter management of hot work and improved the duct sediment inspection and cleanup. In an effort to eliminate similar fire-related accidents, the Group has a system to enable Group companies to rapidly share critical information on fire-related accidents. The Group uses knowledge gained from previous accidents to adopt effective fire prevention strategies and implement unified accident prevention management standards.

Number of Occupational Accidents2: 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 Rate3: Toray Group
Occupational Accident Frequency Rate3: Toray Group
  1. 2 Data for Japan includes non-regular employees (part-time employees, contract employees, casual part-timers, and dispatched workers). Data from outside of Japan does not include temporary staff.
  2. 3 Occupational accident frequency rate: The number of fatalities and injuries at worksites per one million cumulative working hours.

Identifying Danger (Hazards), Evaluating Risk, and Accident Surveys

1. Identifying danger (hazards) and evaluating risk

Toray Group has a system whereby employees report any potential risks in the workplace to managers and the managers provide feedback on countermeasures and improvements. Before starting work, hazard prediction information, near miss reports, and safety proposals are shared with employees to confirm and mitigate risks.
Company inspectors also carry out audits to review the system for preventing occupational accidents and the status of the implementation of countermeasures. If there are any problems, the inspectors give instructions for improvements.

2. Accident investigation

In the event of an occupational accident, the emergency response review meeting and the countermeasure meeting are convened to clarify the chain of events leading up to the accident, identify the cause, and decide on and execute countermeasures. In addition, information about the accident is shared throughout the Group and measures taken to prevent a reoccurrence.

3. Prioritized risk reduction activities

The Group analyzed the factors involved in occupational accidents at Group companies in 2019, which indicated that floors, passageways or mounting/installation hardware were the leading cause of accidents at 24%, followed by rotating equipment at 20%. Many of the accidents relating to floors, passageways or mounting/installation hardware involved falls during everyday movement, which is seen as a risk to everyone who works at Toray Group worksites. To mitigate this risk, the Group has comprehensively implemented 3S and 5S at its worksites, to secure passageways and working space. The Group is also working to raise the safety awareness of all employees to ensure they practice safety first.
Accidents involving rotating equipment and sharp-edged objects can lead to significant injury and are considered major risk factors. All work involving rotating equipment and sharp-edged objects is subject to an annual risk assessment and classified based on the degree of risk, so that safety measures can be implemented according to the risk level. The Group implements risk management using plan-do-check-action (PDCA) cycles to reduce risks.

Causes of Occupational Accidents (Both Requiring and Not Requiring Work Absence) at Toray Group in 2019

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 simulators enable workers to experience the dangers of electrocution, residual pressure, and getting caught in rollers. Virtual reality (VR) technology is also used to realistically simulate accidents at worksites. 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 on familiar topics regarding safety and accident prevention in its in-house magazine, People. Starting in 2019, the magazine has been publishing features on the fundamentals of accident prevention.

  • Simulation training at Mishima Plant (Toray Industries, Inc.)Simulation training at Mishima Plant (Toray Industries, Inc.)
  • Simulation training at Nagoya Plant (Toray Industries, Inc.) Virtual reality simulation of actual worksite, involving collision with a forkliftSimulation training at Nagoya Plant (Toray Industries, Inc.)
    Virtual reality simulation of actual worksite, involving collision with a forklift
  • Demonstrating the danger of fires and explosions at Gifu Plant (Toray Industries, Inc.)Demonstrating the danger of fires and explosions at Gifu Plant (Toray Industries, Inc.)

Implementing Safety Management Together with Subcontractors

On-site monitoring of actual work (Meinan Service Inc.)On-site monitoring of actual work (Meinan Service Inc.)

Toray Industries implements uniform safety activities for its own work as well as subcontracted work that is subcontracted to on-site Toray affiliates4 and Group companies. Monthly occupational health and safety committees and regular safety and liaison meetings are used to discuss the implementation status of safety activities and enhance communication with subcontractors, to ensure that all parties are aligned in the implementation of safety activities. Employees conduct on-site monitoring of operations in practice such as those involving forklifts and sharp-edged objects, and use the results to generate recommendations for necessary improvements that enhance safety and ease of work. Subcontractors also submit their requests for work and equipment improvements, to increase physical safety.

  1. 4 Toray affiliates: Toray Industries’ subsidiaries that provide ancillary services for plant operations

Safety Management Implemented by Subcontractors

Safety meeting at Tokai Plant (Toray Industries, Inc.)Safety meeting at Tokai Plant (Toray Industries, Inc.)

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. Regular safety and liaison meetings are conducted to gain input from subcontractors, and are used to communicate the Group's policies and measures. At plants, Toray and subcontractors work together on safety initiatives, including safety posters, slogan contests and safety suggestions.

Preparing for Accidents through Fire-Prevention Drills

All companies and plants in 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.
Since 2012, Group companies and plants have been conducting drills toward establishing a company-wide emergency headquarters in response to a large-scale earthquake. The drills also involve checking on employees and monitoring facilities damage and supply chains. In 2019, the drills were expanded to encompass the response to subsequent earthquakes, which was appended to Japan’s Basic Plan for Measures against an Earthquake Disaster in the Nankai Trough by the Central Disaster Management Council. In addition to conducting drills for the initial response to a large-scale earthquake, Group plants in seaside locations conduct evacuation drills in case of a tsunami triggered by a large-scale earthquake.

  • Safety confirmation team during an evacuation drill (Toray Engineering Co., Ltd.)Safety confirmation team during an evacuation drill (Toray Engineering Co., Ltd.)
  • Firefighting training (Toray Plastics Precision Co.,Ltd.)Firefighting training (Toray Plastics Precision Co.,Ltd.)

Initiatives for Improving Fire-Prevention Capabilities

In 2019, Toray Group continued to implement Fire Prevention Project Part II to execute the four key tasks (see below) and entrench them into worksites in order to strengthen its fire prevention. The Toray Group’s internal accident prevention experts provided support and guidance in identifying the root cause and taking countermeasures to prevent reoccurrence of those fire accidents and near misses for which the experts decided onsite audits and investigations were necessary.
The Group’s earthquake measures seek to mitigate damage, while placing utmost priority on saving the lives of employees and preventing impacts on local communities. The Toray Group Business Continuity Plan (BCP) for a Large-Scale Earthquake outlines the emergency response to an earthquake and subsequent activities to maintain and restore business operations, as well as the Group’s duties and normal readiness. In particular, for critical products, the Group develops BCPs that encompass supply chains and continually works to reduce risks.

Four Tasks

Tasks Results of 2019 activities
Effectively use fire-prevention checklists
  1. Promoted use of revised fire-prevention checklists in and outside Japan
  2. Fostered leaders who can facilitate the use of fire-prevention checklists while giving instructions (in Japan)
  3. Fostered sub-leaders who actually use fire-prevention checklists at plants (in Japan)
Enhance fire-prevention training
  1. Provided fire-prevention training for engineers, etc., company-wide (elementary and intermediate levels)
  2. Conducted accident prevention training for workers of Group companies outside of Japan (enhancement of Group training based on fire cases)
  3. Provided fire-prevention training for operators at plants (younger operators and leader courses)
Enhance change management
  1. Conducted change management on manufacturing conditions, work contents, workers and equipment (in and outside Japan).
  2. Production engineering staff from Toray’s main plant provided operational guidance to Group companies outside of Japan
Build a safety management system for hot work
  1. Conducted hot work safety management at Group companies and plants (in and outside of Japan)
  2. Engineering staff from Toray Industries conducted inspections and provided guidance on hot work management at Group companies outside Japan
  • Fire-prevention training for engineers, etc., company-wide (Toray Human Resources Development Center)Fire-prevention training for engineers, etc., company-wide (Toray Human Resources Development Center)

Distribution Safety Initiatives

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

Initiatives to Reduce Health Effects of Chemical Substances on Employees

In consideration of the health risks to the Company’s employees and contract employees, Toray Industries is implementing the following initiatives for the handling of chemical substances.

  1. Study the actual handling of chemical substances
    Toray Group collects annual data on the volume of chemical substances handled by offices and plants of Group companies and volume in their possession. Furthermore, the Group clearly indicates the danger of mutagenicity for each chemical substance as stipulated in the Industrial Safety and Health Act, and discloses the risks.
  2. Implement chemical substance risk assessments
    Toray Group implements risk assessments using working environment measurements for the chemical substances that it handles, as well as using ECETIOC’s Targeted Risk Assessment (TRA) tool and control banding. The risk assessment results are used to protect the health of employees by implementing comprehensive measures to prevent worker exposure to organic solvents and dust where it is required.
  3. Conduct follow-up through internal audits
    Toray Group conducts an annual safety, health, accident prevention, and environmental audit, to objectively evaluate the methods for handling chemical substances and working conditions. The audit is used to identify any oversights or unattended issues and implement necessary improvements.
  4. Other
    Toray Group endeavors to maintain and improve working conditions by conducting working environment measurements and on-site monitoring of actual work in accordance with the risk level of handled substances. To prevent health issues among workers and continually follow-up on the health status of employees, the Group conducts medical checkups and training on the dangerousness of handled chemicals, and prepares and keeps records of the on-site monitoring of actual work.

Health Effects and Response to Asbestos

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. 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 cumulative health impacts on former and current Toray Group employees as of March 31, 2020 are as follows.

Certified occupational accidents arising from handling asbestos (Toray Group): 107 (90)
Certified health victims based on Japan's Act on Asbestos Health Damage Relief (Toray Group): 8 (8)
Medical examination recipients involving asbestos (Toray Group): 4,035

  • Note: Figures in parentheses refer to fatalities.