Creating Safe Workplaces

Creating Safe Workplaces

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

In FY 2016, as in the previous year, we had no major accidents and dramatically lowered the lost-time accident rate*1 compared to the previous fiscal year. We were unable, however, to achieve the goal of cutting the “frequency rate”, one of the safety management goals, in half (0.86 or less) compared to the previous fiscal year. A trend analysis of accidents reveals that accidents involving employees with less than two years of work experience account for 41.5% of all accidents, that accidents occur for a wide range of age groups, that the number of accidents caused by equipment increased from the previous fiscal year, and that cuts/scraps were the most common type of accident, accounting for 32%. This is probably because while continual efforts to make improvements related to machines has prevented major accidents, we are overlooking the environment in which small accidents can readily occur because of insufficient consideration of hidden risks around people.

Based on these reflections, in FY 2017, we will not only recheck items that should be improved on at each business site and narrow down priority issues but also work to create a safer work environment and raise safety awareness of each individual employee.

Lost-time accident rate

Lost-time accident rate

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

Efforts to Ensure thorough Compliance with Basic Rules

In FY 2016, frontline employees moved forward with efforts to find operations that could lead to not fully complying with safety rules and to revise work standards to make it possible to thoroughly comply with safety rules by making improvements to how the work is done. Through these efforts, accidents due to causes such as not fully complying with the “TYM”* rule and diverging from safety rules fell compared to the previous fiscal year.

  • * TYM: “TOMERU, YOBU, MATSU” (in Japanese) rule refers to stopping, calling, and waiting when there is a malfunction with machinery.

Composition of accidents by cause

Composition of Accidents by Cause

Enhancing Safety Training Program

In addition to “stop, call, and wait” (TYM) 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 efforts.

Each of our business sites conducts safety training in line with the grade-specific safety education system. Our safety training focuses on “KY” training and hands-on education. We are moving forward with establishing “Safety KY Training Halls”, where employees learn the importance of conducting work in line with rules by experiencing the dangers that machinery entails through hands-on educational equipment. A “Safety KY Training Hall” was opened at the Kuwana Plant in FY 2013. Since then, training halls have been opened one after another in Japan—at the Sendai Plant, Fukushima Rubber Co. Ltd., and Hyogo Manufacturing Complex—and we have started to train local employees by creating halls in the plants in Malaysia and China (China has two plants).

From FY 2016, we have been working to further enhance safety education programs. In addition to analyzing trends in accidents at each business site based on the data of past accidents and minor incidents and developing and implementing effective measures and training programs, we are strengthening the education of certified troubleshooters. For equipment planning and design departments, we started a Safety Assessor* training program to develop certified safety assessors, and as of April 1, 2017, 36 people have been certified as safety assessors.

  • * Employees who possess the knowledge and skills needed to evaluate the safety of machinery and the overall ability to judge its appropriateness.

Hands-on education in China (Zhangjiagang plant)

Hands-on education in China(Zhucheng)

Hands-on education in China (Zhangjiagang plant [left]; Zhucheng [right])

Number of Certified Safety Assessors and Safety Basic-Assessors

Certified Safety Assessors and Safety Basic-Assessors Parties Subject to Ministry of Health, Labour and Welfare Education Notification Certified Employees in the Company
Safety Lead Assessor (SLA) Can Evaluate Appropriateness as Equipment Safety Third Party Design engineer, Production Engineer Manager -
Safety Assessor (SA) Can Design Equipment Safety 1
Safety Sub-Assessor (SSA) Production Engineer Manager 4
Safety Basic-Accessor (SBA) Safe Equipment Operation Can Operate Equipment Safely Foreman, work leader, various staff responsible for safety 14
Safe Operation of Explosion-Proof Electric Equipment 17

Continuous Improvements through the Safety Management System

Since FY 2013, our business sites have been working to obtain OSHMS*1 certification or to be registered as a “Good Safety Company”*2. As of the end of FY 2016, twelve plants and offices in Japan operate a safety management system. We will move forward with efforts to raise employee awareness of safety management and create a safe working environment by working hard to run through the improvement activity cycle to reduce risks in the workplace.

  • *1 Safety and health management system certification 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.
Efforts Business Site When Acquired/Registered
Acquired JISHA OSHMS Certification Sendai Plant Recertified November 2016
Kuwana Plant January 2016
Fukushima Rubber Co. Ltd. November 2014
Hyogo Manufacturing Complex Akashi Plant June 2015
Toyo Soflan Co. Ltd. Examining becoming ISO45001 certified
Registered as “Good Safety Company” 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

Traffic Safety Efforts

In FY 2014, with the aim of improving traffic safety and encouraging courteous driving, we started to introduce and operate driving recorders in company-owned cars. Driving recorders are installed in all company-owned cars other than sales cars. As for sales cars, about 30.5% have driving recorders, including those driven by new drivers (new employees with less than one year of service), which are required to have driving recorders. More advance driving monitoring systems are also being introduced in sales cars.

Since FY 2015, we have worked to control accident rates* for company-owned cars. In addition to this, we have strengthened traffic safety measures and provide various types of training, including that to improve driving manners and prevent accidents using video of accidents recorded by driving recorders, which also includes accident prevention education. In FY 2016, the accident rate or new employees fell to 9% from 18% because of special training, such as safe driving courses for new drivers at independent training facilities. However, the overall accident rate for sales cars increased to 8.9%, and in FY 2017, we will not only continue to work to provide practical safe driving and hazard detection training using information from driving recorders and to improve driving manners and but also strive to eliminate traffic accidents.

  • * Accident rate = number of accidents/vehicles

Response to Asbestos Issues

At the Toyo Tires Group, two employees have thus far been recognized as suffering from a work-related illness associated with asbestos, and seven people have been issued with personal health records.
We will continue to conduct special health examinations of people who engaged in work that involved handling asbestos in the past.