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Safety and Security

Targeting zero occupational accidents through risk reduction by all personnel, from top management to individual workplaces

Basic ConceptEach and every employee has the ability to identify dangerous situations

Five Pillars of Occupational health, Safety, and Accident-Prevention Activities

At the core of safety, it is important that each and every employee has the ability to identify dangerous situations and take appropriate steps to protect themselves and fellow employees. Even if equipment can be made completely safe, it is necessary to recognize that work and actions taken by individuals can have hidden risks. For this reason, we are making concerted efforts at safety education and raising sensitivity to risks, while following rules and creating a protective corporate culture.

At the same time, constructing a work environment in which employees can work with safety and security is our responsibility as a company and one of the most important priorities for management. The Sekisui Chemical Group is implementing total safety activities (i.e. zero occupational injuries, zero equipment-related accidents, zero commuting-related accidents, and zero extended sick leave) based on five themes*.


* Five themes:
Intrinsic safety of equipment, management using OHSMS, safety education of employees, risk prevention through risk detection activities and other initiatives, and auditing of health, safety, and accident prevention.

 

Occupational Safety Committee HeldManagement and labor work together to assess, research and propose solutions for occupational safety

At each business site of the Sekisui Chemical Group, the Occupational Safety Committee holds a meeting every month as mandated by law. In addition, the Central Occupational Safety Committee, consisting of members from corporate headquarters and labor unions, meets once a year. The Central Occupational Safety Committee is a labor and management organization that was created to assess, research and make strategic proposals related to occupational health and safety. Based on their deliberations, the Sekisui Chemical Group aims to strictly comply with laws and regulations, including the Industrial Safety and Health Act, ensure the safety and health of employees at work, and create a comfortable work environment. The Central Occupational Safety Committee and the Occupational Safety Committees at each business site assess workplace environments and safety devices, draw up and implement solutions to workplace problems, and decide rules covering various topics related to occupational safety and health.

 

Fiscal 2016 Results and OutlookImplemented educational programs for key persons in charge of safety activities

We develop human resources who put business activities into practice with a high awareness of safety and who can demonstrate this to their subordinates. In fiscal 2016, we moved beyond our company framework to bring together newly appointed top management, reconfirmed their preparedness and commitment to safety and planned and implemented the “Newly Appointed Business Site Top Manager Seminar” as a forum for the exchange of information.

Apart from disaster situations, for which the focus at Sekisui Chemical Group in particular is on prevention, we implement emergency response training in the core processes that covers the following scenarios: getting caught or entangled in machinery at a production facility; falling off equipment or falling over at a worksite; and a fire or explosion in a chemical process. Conducting “heads-up training” on each of the three scenarios at production sites and chemical processing sites, we also promote rigorous compliance with scaffolding work rules at construction sites.

General views of participants in a top management safety seminar taking the initiative during safety activities
Offering guidance on plant floor patrol Directing the response to a disaster during emergency training
General views of participants in a top management safety seminar taking the initiative during safety activities

Left:Plant floor patrol

Right:Disaster prevention drill


 

Safety AuditsSecond-party OHSMS certification at 36 business sites

Second-party certification of Occupational Health and Safety Management Systems (OHSMS) is being conducted at sites in Japan, with 36 sites having been certified as of March 2017. Since fiscal 2013, efforts have also been made to raise the level of safety throughout the Group as a whole by verifying, from a multifaceted approach, the results of the periodic self-auditing and assessment that began in fiscal 2010 through assessing them in headquarters auditing as well. Since the Company’s OHSMS are operated under internal certification, and the internal auditors’ skills might be called into question, Sekisui Chemical is focusing on improving those skills.

 

Review of Equipment Safety StandardsReviewing equipment safety standards in conjunction with conducting employee training

To prevent serious occupational injuries, we considered as essential the installation of safe equipment that is unlikely to cause accidents and conducted a review of our equipment safety design standards with regard to equipment safety.

In conjunction with this initiative, we provided training for those employees who are in charge of installing or maintaining equipment that explained the new standards in detail. The 290 employees who participated in the training deepened their understanding of the review content.

Employee training (Example of a standard)
Minimum space necessary to prevent accidental crushing
 

Early Detection of RisksTraining to improve ability to identify risks

In an effort to maintain a culture that gives safety top priority, instead of relying on specialists, we encourage plant floor supervisors and workers to train their eyes to better identify hazardous situations. To enhance each employee’s ability to identify risks, we began offering educational programs centered on patrolling plant floors in fiscal 2016.
In fiscal 2016, educational programs were held at Tokyo Sekisui Heim Industry Co., Ltd.’s Musashi Plant and Sekisui Chemical Co., Ltd.’s Shiga Ritto Plant, and attended by 43 persons responsible for the safety management of the Sekisui Chemical Group nationwide.

Practicing safety checks after training Plant floor patrol training
Practicing safety checks at the beginning of after training Training to patrol plant floors

 

Measures to Prevent Fires and ExplosionsInitiated emergency audits, to which outside experts are invited

To prevent fires and explosions that, once they occur, have a major impact on the surrounding environment and on business continuity, in addition to the safety audits performed thus far, we implement emergency response audits, to which we invite outside disaster experts. We verify the storage and handling status of hazardous materials as well as the recovery system in time of disaster, including a natural disaster, thereby promoting improvements by detecting the risk posed by disasters at an early stage.

Type of audit Target and objective of audit
Safety audits Mainly audit occupational injury prevention measures
・Audit documentation
  Confirm status of activities to manage occupational safety
・Make the rounds at worksites
  Confirm the movement of people, work environments, immediate safety, etc.
* Business sites that only conduct safety audits conduct the following equipment audits and
   disaster prevention audits at the same pace as before.
Equipment audits Mainly audit measures to prevent injuries caused by equipment
・State of essential safety measures
   Build in measures to prevent injuries when designing and installing equipment
・Audit the operations of equipment management divisions
   Manage equipment introduction, installation and maintenance
Disaster prevention audits Mainly audit disaster prevention measures related to business continuity
・Confirm status of storage and handling of hazardous materials and designated combustibles
・Confirm status of fire prevention systems
・Measures to counter natural disasters such as earthquakes
Business sites subjected to fire prevention and equipment audits in fiscal 2016
Business site name Date Facility Audit Disaster
Prevention Audit
High-Performance Plastics Company
R&D Institute
July 13  
Kyoto R&D Laboratory July 15  
Shiga Minakuchi Plant July 28–29  
Gunma Plant Oct. 27
Sekisui Board Co., Ltd.’s
Gunma Plant
Oct. 28
Musashi Plant Nov. 16–17  
Taga Plant Nov. 21  
Shiga Ritto Plant Nov. 24–25  
Nara Sekisui Co., Ltd. Dec. 16
Chushikoku Sekisui Heim
Industry Co., Ltd.
Dec. 8
Tokuyama Sekisui
Industry Co., Ltd.
Dec. 9  
ENAX Chubu office Jan. 24  
  • Note:In fiscal 2016, the Company conducted safety audits at 29 business sites, including those listed above
 

Emergency Response MeasuresWays to pass down accumulated knowledge of emergency preparedness

Ways to pass down accumulated knowledge of emergency preparedness

At the Sekisui Chemical Group, we conduct “heads-up training” to fortify the decision-making abilities of all our employees in the event that they encounter an emergency situation. More specifically, emergency crews are given scenarios where equipment designed to prevent danger fails and challenges the trainees to ask questions to solve the problem on the spot. This training aims to pass down to younger employees the on-site safety know-how accumulated over many years by senior employees. Through this training, we were able to improve equipment countermeasures and revise work operating manuals. The training acts to verify the effectiveness of procedures taken during emergency situations, and presents opportunities for employees to engage in evacuation drills and disaster prevention drills. This training has been applied on various occasions, including to handle problems, and in evacuation and emergency drills.

In fiscal 2016, a total of 838 people participated in the training sessions that were held a total of 107 times in 21 departments at five business sites.

 

Emergency Response MeasuresMaking of Sample Operation of How to Use a Fire Hydrant DVD

We regularly carry out firefighting drills as a response to the occurrence of fire etc. within our business sites, but the procedures for those eventualities are not documented, as they were passed on verbally or by means of a demonstration. Therefore, in fiscal 2016, we created a DVD to provide a sample of the operation method, based on a simulated demonstration given by a fire department, to share awareness at all workplaces regarding how to handle a fire hydrant correctly; the DVD was distributed to each business site.

Sample Operation of How to Use a Fire Hydrant (DVD)

Sample Operation of How to Use a Fire Hydrant (DVD)

 

 

Overseas Business Site Safety AuditsVisualizing safety management activity status at overseas business sites

At our overseas production sites, which operate under the varying laws and regulations and differing awareness of safety issues in each country, the Sekisui Chemical Group has, since fiscal 2013, been deploying safety management rules as a global standard and strictly adheres to these rules in order to achieve the same level of safety at all its business sites. Commencing in fiscal 2014, by fiscal 2016 we had implemented audits at 41 business sites to confirm that the safety management activities of each business site are being promoted appropriately. In fiscal 2016, we commenced audits to verify the status of improvements included under points to be noted in the previous audit and carried out audits of this type at five business sites. We also visited business sites in Thailand and India to support the safety management activities of newly established overseas offices. In India, we supported 4RKY (four round risk detection), on-site patrols, etc. In the years ahead, we will continue to provide effective support in accordance with the corporate and national cultures of each region.

4RKY practice exercise (India)

4RKY practice exercise (India)

 

Safety Conference and Safety AwardsPresidential award given to business site with best safety record for fiscal year

The Sekisui Chemical Group Safety Conference is usually held to coincide with National Safety Week in July of each year. In fiscal 2016, Chairman Naofumi Negishi and President Teiji Koge were among the total of 223 people, who also included other directors, business heads from domestic production plants and laboratories, construction companies as well those in charge of safety, etc. who attended the conference on July 8. Outside Audit and Supervisory Board member Mr. Kazuyuki Suzuki gave a lecture entitled Proposal for Zero Work-related Accidents—Prevention by Everyone’s Participation. Attendees were able to obtain logical, specific measures to prevent the occurrence of accidents by the way each person processes information.

During the conference, the fiscal 2015 presidential award was given to the business sites with the best safety record for the fiscal year.

Practicing safety checks at the Safety Conference Presidential award given to business site with best safety record
Practicing safety checks at the Safety Conference Presidential award given to business site
with best safety record

 

Example in Safety ActivitiesLeaders from each division declared their commitment to safe business practices

Based on the recognition that it is of the utmost importance for top managers to exercise leadership and take the initiative in safety activities, leaders from each division, including the president, declare their commitment to safe business practices, and their personally written declarations are published on the intranet for employees to see.

A safety declaration posted on the intranet