Safety, Health, and Disaster Prevention Activities

Safety, health, and disaster prevention management system

At the Toyo Tires Group, the Safety, Health and Disaster Prevention Subcommittee of the Safety and Environment Committee discusses and formulates a mid-term plan and annual policy for safety, health and disaster prevention, and defines priority measures based on them. The mid-term plan, annual policy and priority measures are disseminated throughout the Group via the working group for each business segment. The Committee, Subcommittee and the working groups include labor union members to ensure that both labor and management work together in safety, health, and disaster prevention activities.

The Subcommittee conducts its activities every two months, including checking of the implementation status of the policy at each the working group and business site, follow-ups of accident recurrence prevention activities, and checking of improvement activities. The top management and senior officers of the labor union visit all business sites each year to inspect the implementation status of the policy and measures first-hand.

Safety, health, and disaster prevention management system

Safety, Health, and Disaster Prevention Management System

Fiscal 2015 safety, health, and disaster prevention management policy, and targets and results

Theme Policy Target Results
Overall policy Achieve zero accidents Steady reduction of work-related accidents No. of lost-time accidents: 11
No. of non-lost time accidents: 13
No. of minor accidents: 18
Safety management Take thorough measures to prevent recurrence of major accidents* Frequency rate: 0.5 or below Frequency rate: 1.77
Major accident: zero
Health management Reduce number of employees on sick leave Sick leave rate: 0.5% or below Sick leave rate: 0.71%
Disaster prevention management Enhance disaster prevention management, and improve disaster preparedness and disaster response training Improved evacuation areas to be used in the event of a disaster, and conducted nighttime evaluation drills
Traffic safety management Improve driving manners to reduce traffic accidents, while taking into account social responsibility Implemented safety education using information recorded on the event data recorders installed in company-owned cars
  • * Major accident: Accident resulting in death or disability (disability grade 7 or above)

Creating safe workplaces

We are working to create safe workplaces from the three perspectives of “equipment,” “personnel,” and “management system development.”

In fiscal 2015, as in the previous year, we achieved zero major accidents. The lost-time accident rate improved a little from the previous year, but the safety management target of reducing the frequency rate to 0.5% or below was not achieved. As a result of a trend analysis of accidents, it has been found that accidents involving employees with work experience of less than two years accounted for 39% of the total, that accidents occurred in a wide range of age groups, that the number of accidents caused by equipment failures was halved from the previous fiscal year, and that an increased number of accidents occurred in offices of the sales companies. We concluded that the major causes for these trends were the following: 1) employees’ lack of understanding and failure to use various safety management methods effectively, which have been introduced based on examples from other companies, and 2) a decrease in employee awareness of observing the basic rules: “stop, call and wait” and “stop and fix.”

Based on these reflections, in fiscal 2016 we will narrow down and determine priority action items, focusing on personnel aspects, and strive to further raise safety awareness in each individual employee.

Lost-time accident rate*1

  • *1 Lost-time accident rate: Number of lost-time accidents per million hours worked.
  • *2 Manufacturing industry, rubber product manufacturing industry: Data based on the Survey on Industrial Accidents (preliminary data) by the Ministry of Health, Labour and Welfare.
  • *3 The Toyo Tires Group: Data for 16 business sites, including affiliated companies (for fiscal 2012, data from April to December).

Enhancement of safety training program

In addition to “stop, call and wait” activities and point & call checks, we are vigorously promoting hazard prediction (KY) activities so that they will take root throughout the organization as small group-based voluntary initiatives.

Each of our business sites conducts safety training, in line with the grade-specific safety education system. Our safety training focuses on hazard prediction training and hands-on experience. A Safety Hazard Prediction Training Hall was opened at the Kuwana Plant in May 2013. Since then, Training Halls have been opened sequentially in Japan—at the Sendai Plant, Fukushima Rubber Co., Ltd. and Hyogo Manufacturing Complex. In fiscal 2015, the first overseas Safety Hazard Prediction Training Hall was established in Malaysia to provide hazard prediction training for local employees. In fiscal 2016, we plan to establish a training hall at a plant in China.

From fiscal 2016, we will work to enhance safety education programs. Specific planned activities include the following: analyzing the trends in accidents at each business site based on the data of past accidents and minor incidents; developing and implementing effective measures and training programs; and re-educating certified troubleshooters. For equipment planning and design departments, we will start a safety assessor* training program to develop certified safety assessors.

  • * Experts with comprehensive capability to perform validation, and with the knowledge and ability needed to evaluate the safety of machinery

Efforts to ensure thorough observance of the basic rules

In fiscal 2016, to raise employee awareness of observance of the basic rules, we will implement various activities, including having production workers identify tasks that may lead to nonobservance of the rules and develop improvement measures, and educating them, through OJT, about possible consequences arising from rule violation.

Continuous improvement through the implementation of the safety management system

Since fiscal 2013, our business sites have been working to obtain OSHMS*1 certification or to be registered as a “Good Safety Company.”*2 The implementation of the safety management system has been launched at our major production bases. In fiscal 2016, we will work to improve employee awareness of safety management and create a safe working environment by ensuring proper implementation of the safety management system throughout the Group and by activating continuous improvement activities to reduce risks in the workplace.

  • *1 Safety and Health Management System certification, accredited by the Japan Industrial Safety & Health Association
  • *2 Safety and health performance evaluation services offered by the Japan Industrial Safety & Health Association for enterprises with less than 300 employees
Target Business site Achievement time
Acquisition of JISHA OSHMS standards certification Sendai Plant November 2013
Kuwana Plant January 2016
Fukushima Rubber Co., Ltd. November 2014
Hyogo Manufacturing Complex Akashi Plant June 2015
Toyo Soflan Co., Ltd. Under considering the acquisition of ISO45001 certification instead of JISHA OSHMS.
Acquisition of “JISHA Good Safety Company” certification Ayabe Toyo Rubber Co., Ltd. March 2015
Soflan Wiz Co., Ltd. Iwaki Plant March 2015
Atsugi Plant October 2015
Akashi Plant February 2016
Orient Machinery Co., Ltd. Itami Plant December 2014
Kuwana Plant December 2014
Sendai Plant March 2015
  • * Toyo Soflan Co., Ltd. is considering the acquisition of ISO45001 certification (to be published in September 2016) instead of JISHA OSHMS.

Traffic safety efforts

In fiscal 2014, with the aim of improving traffic safety and encouraging safe driving manners, we started introduction/management of event data recorders in company-owned cars.

Company-owned cars other than sales cars have a 100% installation rate of event data recorders. As for sales cars, an event data recorder is installed in about 27% of sales cars, including cars driven by new drivers (new employees with less than one year of service), for which installation of an event data recorder is required.

From fiscal 2015, we have managed accident rates of company-owned cars. In addition to this, we have strengthened traffic safety measures by providing safe driving and hazard prediction training, training for improving driving manners through the use of images of accidents recorded by event data recorders, and accident prevention education. As a result, in fiscal 2015 the number of accidents involving sales cars decreased by 15% from fiscal 2014, and the accident rate (calculated by dividing the number of accidents by the number of company-owned cars) fell from 9.2% to 5.8%, the lowest level in the industry. In fiscal 2016, to achieve zero traffic accidents, we will continue to implement practical safe driving training and driving manners improvement activities at each business site, through the use of information recorded on the event data recorders.

Creating healthy and comfortable workplaces

Mental health care promotion

Mental health seminar held at a business siteMental health seminar held at a business site

Mental health problems are one of the major causes of long-term sickness absence. The Toyo Tires Group has held mental health care seminars for all employees from managers and supervisors to general staff.

In fiscal 2015, as part of efforts to prevent workplace mental health problems, stress check events were held at all business sites and subsidiaries in Japan, and a total of 3,280 people received stress checks. And, based on the check results of each organization, mental health care seminars were held at each business site.

Furthermore, we work to reduce long-term sickness absences by promoting early detection and intervention through individual guidance and consultation in cooperation with industrial health staff and Employee Assistance Program (EAP) companies. We also provide support for employees on long-term sickness absence to ensure a smooth return to work. We plan to review our return-to-work support measures so that we can provide appropriate support for each employee according to their physical and mental condition.

Implementation of the stress check program

Under the revised Industrial Safety and Health Law, which went into effect in December 2015, our Group holds stress check events at business sites with 50 employees or more, and provides guidance and consultation based on the check results.

By understanding their own mental health condition through stress checks, employees can take care of themselves in order not to let too much stress build up. If an employee is found to have high stress levels, he/she can request to consult a doctor to receive advice. Stress checks also enable our Group to take prompt measures for employees with high stress levels, such as reducing their workload and improving their working conditions and environment. We will work to prevent the development of mental health problems among employees by making use of the stress check program.

Measures against metabolic syndrome

Since fiscal 2008, to help prevent metabolic syndrome, we have conducted specific health examinations and specific health guidance. In fiscal 2015, the percentage of those assessed as requiring health guidance decreased slightly by 0.6% from the previous year. However, the rate of receiving health guidance among employees assessed as needing such guidance remains low.

The Company and the Health Insurance Society will work in collaboration to further increase health awareness among employees subject to specific health guidance and provide support to help them change their lifestyles and improve their health.

Collaboration with the Health Insurance Society

Collaboration with the Health Insurance Society is essential to implementing employee health management/improvement activities effectively and efficiently. In conjunction with the Data Health Plan,* formulated by the Health Insurance Society, we will promote data-driven health activities. Specifically, we will analyze the data on disease and health status of our Group employees by region and by business site, and compare such data with those of other companies in the same industry to identify the characteristics and problems of our Group. Based on the findings, we will develop measures to improve employees’ health.

  • * Plan for health activities to maintain and improve the health of society members, formulated on the basis of analysis of various data, including itemized statements of medical expenses

First-aid and life-saving training

DVDs of a first-aid and life-saving training sessionDVDs of a first-aid and life-saving training session

We distribute to all business sites DVD recordings of a first-aid and life-saving training session held at the Kuwana Plant representing our major manufacturing sites, to ensure that all of our employees acquire basic first-aid and life-saving knowledge and skills.

The installation of automatic external defibrillators (AEDs) has been completed at all business sites of the Toyo Tires Group in Japan. We also inform local residents that AEDs installed at our plants are available for their use.

Chemical risk assessment

Under the revised Industrial Safety and Health Law, from June 1, 2016 companies manufacturing or handling the specified chemical substances are obliged to perform risk assessments for the 640 chemical substances which have been confirmed as having a certain degree of hazardousness and/or toxicity.

All of the Group’s business sites completed risk assessments in our Group by the end of May 2016. Based on the results of the risk assessments, we will develop and implement risk reduction measures so as to protect employees from danger and prevent them from developing health problems.

Creating disaster resistant workplaces

Fire prevention efforts

Since fiscal 2014, voluntary inspections have been carried out using thermography to prevent fires caused by electrical facilities/equipment or wiring.

The plan for fiscal 2016 is to further strengthen preventive management against fire risks. Specifically, we will work to reduce or eliminate not only tangible fire risks, but also potential fire risks, by using the Voluntary Fire Prevention Inspection Guidelines (in the format of a checklist), which outlines the key points for the inspection of electrical facilities/equipment and wiring, etc. To this end, we have classified fire risks in the plants and research facilities and identified places with fire hazards.

  • Risks by area (including work areas, equipment and facilities) within the plant and research facility
  • Risks inherent in the work performed by humans
  • Risks in places where combustible vapor/gas accumulates
  • Risks in places where the above three conditions overlap

Earthquake and disaster drills

In Japan, huge earthquakes are expected to occur in the near future, such as a Nankai Trough earthquake and an earthquake directly under the Tokyo metropolitan area. In preparation for large earthquakes, we have installed earthquake early-warning systems at all business sites and subsidiaries in Japan. Other preparedness activities include stockpiling emergency foods and supplies, conducting evacuation drills, and devising measures for employees who cannot return home (routes to return home on foot, etc.).

In fiscal 2015, to reinforce our commitment to protecting human life and safety, we held nighttime emergency drills at all business sites and subsidiaries in preparation for a major earthquake occurring at night. At the Kuwana Plant, 20 temporary shelters are installed in the event of tire racks toppling over in the distribution warehouse.

In fiscal 2016, to provide more practical training, we plan to conduct blind-type disaster drills at some business sites. Unlike ordinary drills in which scenarios are communicated to participants beforehand, in a blind-type disaster drill, participants are required to cope with the situation on the spot.

In-house fire brigade (Fundamental Technology Center)In-house fire brigade (Fundamental Technology Center)

Drill on handling leaks of hazardous substances (F.C.C Co., Ltd. [Fukushima Plant])Drill on handling leaks of hazardous substances (F.C.C Co., Ltd. [Fukushima Plant])

Temporary shelter for use in the event of an earthquake   (Kuwana Distribution Warehouse)Temporary shelter for use in the event of an earthquake (Kuwana Distribution Warehouse)

Safety confirmation training in the event of a disaster

The Toyo Tires Group has introduced an external safety confirmation system that covers all business sites and employees, and holds a Group-wide simultaneous disaster simulation drill four times a year based on a scenario in which a special emergency warning has been issued. Training on telephone safety confirmation procedures (in accordance with the contact network prepared by each department) is also conducted to ensure that the safety of employees is checked, not only by the safety confirmation system, but also by actually telephoning each other.

Response to asbestos issues

At the Toyo Tires Group, one employee has thus far been recognized as suffering from a work-related illness associated with asbestos. At present, seven people have been issued with personal health records (Kenko Kanri Techo). We will continue to conduct special health examinations for people who may have come into contact with asbestos in the past.