CSR Guidelines & Activity Reports - Safety, Accident Prevention, and Environmental Preservation

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 2018, 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, safety lectures 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.

  • 2018 Toray Group Safety Meeting in Toray Human Resources Development Center2018 Toray Group Safety Meeting in Toray Human Resources Development Center
  • Toray Group Safety Summit in ChinaToray Group Safety Summit in China

Toray Group Safety Record

Number of major accidents

■Reporting scope
Toray Group
■Target in 2018 (calendar year)
0

Result in 2018

0

Number of fire and explosion accidents

■Reporting scope
Toray Group
■Target in 2018 (calendar year)
0

Result in 2018

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 2018 (calendar year)
No more than 0.05

Result in 2018 (calendar year)

0.28

A safety meeting with the participation of unit heads at Tokai Plant (Toray Industries, Inc.)A safety meeting with the participation of unit heads at Tokai 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 2018 improved by 0.11 points to 0.28. 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 outside Japan that recently joined Toray Group 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, while taking “Anzen Koh-Doh” even further. To ensure familiarity with “Anzen Koh-Doh” practices, unit heads in charge of work sites will take the leading role at Toray Industries and its group companies in Japan in reforming safety awareness and actions in their own workplaces. Toray Industries has held report meetings for discussion of safety, in which unit heads meet to share and discuss their activities, since 2015.
In terms of fire prevention, small-scale fires occurred at Toray Industries 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 accident involved a fire in a vehicle parked in the employee parking lot, and the other a fire on the lawn caused by a spark from the neighboring company’s construction sites; neither involved fire in a Toray plant itself.

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 Rate2: Toray Group
Occupational Accident Frequency Rate: Toray Group
  1. 2 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 inspections to determine whether there are any problems with 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 surveys

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 countermeasures. In addition, information about the accident is shared throughout the Group and measures taken to prevent a reoccurrence.

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 on familiar topics regarding safety and accident prevention in its in-house newsletter, People. In 2018, as in the previous year, the newsletter focused on the basics of fires and explosions.

  • Simulation training at Okazaki Plant (Toray Industries, Inc.)Simulation training at Okazaki Plant (Toray Industries, Inc.)
  • Training using accident case studies at  Nagoya Plant (Toray Industries, Inc.)Training using accident case studies at Nagoya Plant (Toray Industries, Inc.)
  • Demonstrating the danger of fires and explosions at Nasu Plant (Toray Industries, Inc.)Demonstrating the danger of fires and explosions at Nasu Plant (Toray Industries, Inc.)

Implementing Safety Management Together with Subcontractors

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

Mutual Safety Inspections by Toray Affiliates on Premises of Toray Plants

Mutual safety inspection (Tsuchiura Shokusan Inc.)Mutual safety inspection
(Tsuchiura Shokusan Inc.)

Toray Industries had the presidents of Toray affiliates that provide ancillary services for plant operations participate in annual mutual safety inspections of their facilities in order to verify the progress of safety initiatives. In 2018, the monitoring of hazardous work included work with sharp blades and heavy load transport. Personnel advised each other on areas needing improvement and monitored the progress of improvements.

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

  • Safety confirmation team during an evacuation drill (Du Pont-Toray Co., Ltd.)Safety confirmation team during an evacuation drill (Du Pont-Toray Co., Ltd.)
  • Firefighting training (Toray Textiles, Inc.)Firefighting training (Toray Textiles, Inc.)

Initiatives for Improving Fire-Prevention Capabilities

In 2018, Toray Group outlined four key tasks (see below) to strengthen fire prevention at Toray Group. 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.
In earthquake preparedness measures, Toray places the highest priority on employee safety and has strengthened its earthquake response by implementing evacuation drills using its employee safety verification system. Additionally, the Group conducts business continuity planning in order to meet its social responsibility to keep supply lines open in the event of a large-scale earthquake.

Four Tasks

Tasks Results of 2018 activities
Effectively use fire-prevention checklists
  1. Revised fire-prevention checklists
    Revised checklists to reflect knowledge and lessons learned from recent near-misses at Toray Group and began using them
Enhance fire-prevention training
  1. Provided fire-prevention training for engineers, etc., company-wide (elementary and intermediate levels)
  2. Prepared plant education for entire group and carried out on a trial basis
  3. Provided fire-prevention training for operators at plants (younger operators and leader courses)
Enhance change management
  1. Operated manufacturing process change standards on manufacturing conditions, work contents, workers and equipment.
  2. Applied these standards at group companies outside Japan guided by Toray’s main plant
Build a safety management system for hot work
  1. Supported and guided companies and plants to appropriately operate the framework (in Japan)
  2. Rolled out the initiative to 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.

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 health effects on former and current Toray Group employees as of March 31, 2019 are described below.

Certified occupational accidents arising from handling asbestos (Toray Group): 104 (77)
Certified health victims based on Japan's Act on Asbestos Health Damage Relief (Toray Group): 8 (7)
Medical examination recipients involving asbestos (Toray Group): 4,022

  • Note: Figures in parentheses refer to fatalities.