Targeting Zero Occupational Injuries Through Risk Reduction by All Personnel, from Top Management to the Plant-floor Frontlines
Each and Every Employee Has the Ability to Identify Dangerous Situations
SEKISUI CHEMICAL Group has positioned the establishment of a workplace environment in which employees can carry out their duties with safety and security as a key corporate responsibility and one of management’s most important priorities. Accordingly, we are 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 ((1) through (5) listed below). Despite a company’s efforts to provide a safe and secure environment, however, employees must also take it upon themselves to prevent accidents from happening. Ultimately, safety is a byproduct of the actions undertaken and behavior of each individual. 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.
(1)Safety management using OHSMS
(2)Intrinsic Equipment Safety*
(3)Safety education of employees
(4)Risk management and control, etc.
(5)Safety audits and accident-prevention audits that assess the status of the above activities
- The term for machine safety activities implemented by SEKISUI CHEMICAL Group. These activities promote improvements to unsafe areas of production equipment through intrinsic safety design policies and safeguards.
Activity Policy and Promotion System
We formulated and shared the SEKISUI CHEMICAL Group Safety Policy among all Group employees as our basic philosophy on occupational safety.
In terms of our efforts related to occupational health and safety, policies and activity guidelines are formulated by the Safety Sub-committee established under the Sustainability Committee. Each site puts into practice and promotes these policies and activities under the guidance of the Safety & Environment Group of the Manufacturing Infrastructure Enhancement Center.
In addition to data generated from ongoing work at SEKISUI CHEMICAL Group production and implementation sites and from research activities, a wide range of Group occupational health and safety data including data from partner companies (contractors) outside the Group is also collated.
In fiscal 2021, two meetings of the Safety Sub-committee were held online in October and March.
In event of an actual occupational injury, information including the form of employment of the injured party is collected. Improvements as required are also sought when there is a problem with the management of a business site.
SEKISUI CHEMICAL Group determines the necessity of ISO 45001 certification for each business site, and promotes acquisition of and acquisition activities for this certification. Business sites that have not acquired this certification also build and apply safety and health management systems that reflect ISO and Occupational Health and Safety Assessment Series (OHSAS) requirements. Activity status is monitored through safety audits and disaster-preparedness audits in an effort to encourage the continuation and vitalization of safety management activities.
External certification (ISO 45001) Acquired
[No certified business sites as of the end of fiscal 2021]
Safety-promotion System (from fiscal 2021)
Occupational Safety Committee Meeting Held
Each business site within the Group convenes legally mandated Occupational Safety Committee meetings on an individual basis, during which labor and management work together to conduct disaster-related investigations and make strategic proposals related to occupational health and safety.
Meetings of the Central Occupational Safety Committee were held as a Group-wide forum for discussion between labor and management up to fiscal 2019. Since fiscal 2020, however, these committee meetings have not been held, due to the impact of the COVID-19 pandemic. In the interim, steps have been taken to review methods for how these meetings should be held.
Declaration of Commitments to Safe Business Practices by the Leadership of Each Division
Based on the recognition that it is of the utmost importance for the top managers at business sites to exercise leadership and take the initiative in safety activities, leaders from each division, including the president, declare their commitment to safe business practices each fiscal year, and their personally written declarations are posted on the intranet.
A safety declaration posted on the intranet
Implementation of Safety Audits
SEKISUI CHEMICAL Group has identified occupational health and safety management system evaluation categories, which are employed in the self-evaluations conducted at each business site as well as safety audit evaluations by Corporate Headquarters. We review evaluation categories each year, taking into account issues related to Group-wide safety management activities.
With a view to preventing the spread of COVID-19, certain business sites were audited remotely online in fiscal 2021. SEKISUI CHEMICAL Group succeeded in completing safety audits as initially planned at 17 business sites in Japan.
In the remote audits, document audits were executed with comparable efficacy to in-person audits. Site inspection tours, on the other hand, were more time-consuming than usual, as they required communication between auditors at remote sites and on-site staff touring the facilities with wearable cameras. In the future, the Group plans to make continuous improvements to its safety auditing procedures, to ensure that they are carried out appropriately in line with audit objectives and the circumstances in each case.
Implementation of Occupational Safety Assessments
Article 14 of the Group’s Safety Management Rules stipulates that a comprehensive preliminary occupational safety assessment must be undertaken by the business general manager concerned when launching a new business. Based on this stipulation, the relevant divisional company that is looking to launch a new business implements an assessment.
Statutory and regulatory requirements differ by region, country, and state. With this in mind, overseas business sites are audited by external consultants (experts in local laws and ordinances) to confirm compliance.
Implementation of medical examinations
As far as medical examinations for employees are concerned, measures are applied based on the medical examination results of high-risk individuals under the work aptitude assessment guidelines for high-risk individuals (for health management officers). In addition, SEKISUI CHEMICAL Group confirms that the following legally mandated medical examinations are conducted at each business site through various means including safety audits.
- Special medical examinations
- Medical examination for specified work employees
Development of Human Resources to Take the Initiative in Safety Activities
SEKISUI CHEMICAL Group established a Safety Leader (SL) certification system as a qualification for personnel who assist safety managers and promote safety management activities at each site. The Group has continued to promote this system since fiscal 2017 for the purpose of enhancing safety activities.
In fiscal 2021, 36 employees (122 in total since fiscal 2017) were certified under the SL qualification system. Safety leaders are tasked with identifying and mitigating risks at their respective workplaces, holding workshops with other safety leaders Group-wide, upgrading and expanding the content of safety training, and promoting the rollout of best practice examples.
In addition, we also encourage employees to obtain safety sub-assessor* (SSA) qualifications, holders of which promote machine safety activities. Since fiscal 2017, a total of 164 employees have been certified as SSAs. We have organized a cross-sectional SSA project that extends across business sites to promote improved safety in such areas as pinch rollers and sheet cutting machines. This initiatives is being shared between sites. In addition, we also encourage employees to acquire the SA* qualification, which ranks above SSA. As of fiscal 2021, 22 employees have been certified.
- A Japan Certification Corporation safety qualification acquired to certify the knowledge and skills for machine safety. This certification is based on international safety standards.
Review of Equipment Design Safety Standards
Along with formulating the Equipment Design Safety Standards, which summarize the safety specifications necessary for production equipment used by the Group, and promoting Intrinsic Equipment Safety* activities, we verify that workplaces actually comply with equipment design safety standards. Moreover, we have issued Equipment Design Safety Guidelines for manufacturers that supply production equipment to the Group, and require these manufacturers to submit the safety specification checklist attached to the Guidelines at the time they provide estimates. This effort ensures the safety of newly installed equipment.
- Machine safety activities promoted by SEKISUI CHEMICAL Group. These activities promote improvements to unsafe areas of production equipment through intrinsic safety design policies and safeguards.
Increasing Risk Discovery Opportunities and Deploying Best Practices through Mutual On-site Inspections
Starting in fiscal 2021, the Technology & CS Promotion Department at each divisional company took the lead in initiating mutual on-site inspection activities through which employees from different manufacturing sites seek to uncover risks at each other’s sites. Conventional safety, accident-prevention, and environmental audits are only conducted once every three years and cannot audit sites frequently, which has made it difficult to horizontally deploy the best practices of other business sites.
Mutual on-site inspections help participating employees to become more aware of and sensitive to risk, while leaders and others at the sites that host these inspections are able to learn from other business sites, thereby making it easier to horizontally deploy best practices.
In addition, we distribute a Site Risk Identification Handbook, which was prepared by the Safety & Environment Group, to safety officers at each business site as a guideline for uncovering risks on their own.
Measures to Prevent Fires and Explosions
To prevent fires and explosions that, once they occur, have a major impact on the surrounding environment and on business continuity, we invite outside disaster experts to perform emergency response audits when conducting safety audits.
We verify items such as the storage and handling status of hazardous materials as well as the recovery systems used following a disaster, including natural disasters, and promote the quick identification of disaster risks and the subsequent implementation of preventative measures. In fiscal 2021, these audits were performed at 10 business sites uncovering 273 items. Each business site has been making improvements in regard to these items.
|Type of audit||Target / aim of audit|
|Disaster-preparedness audit||Primarily consists of audits for accident-prevention measures relating to business continuity
Enhancement of Emergency Response Skills
SEKISUI CHEMICAL Group has identified getting caught or entangled in machinery at a production facility, falling off equipment or falling over at a business site, and a chemical process-related fire or explosion as high-risk scenarios on which particular emphasis should be placed on prevention.
The Company conducts Heads-up Training where chemical processes are integral to production.
At 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, supervisors with years of experience will ask trainees what they would do if equipment designed to prevent danger fails. Trainees are then tasked with providing responses off the top of their heads. This training improves the skills needed to respond to unexpected situations in the event of a disaster by passing 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 operating procedures. In addition to teaching trainees how to handle potential problems, the training has been applied on various occasions, including evacuation drills and disaster prevention drills.
Deepening Understanding of the Basic Safety Principles
SEKISUI CHEMICAL Group is working to prevent occupational injuries caused by manufacturing machines and equipment through activities that make equipment itself intrinsically safer* while also preventing occupational accidents caused by worker operations. Based on the lessons learned from past occupational accidents that actually occurred on Group business sites, the Six Basic Safety Principles, which summarize compliance matters and matters prohibited during operations for each operational process, were established and are currently in use.
In order to promptly disseminate these principles within the Group, we created and distributed to each workplace a poster that displayed details in an easy to understand, illustrated format.
- Machine safety activities implemented by SEKISUI CHEMICAL Group. These activities promote improvements to unsafe areas of production equipment through intrinsic safety design policies and safeguards.
Six Basic Principles for Hot Work Poster (Thai version)
Overseas Business Site Safety Audits
At our overseas production sites, which operate within different legal, regulatory, and cultural environments, SEKISUI CHEMICAL Group has established and deployed safety global standards to raise the level of safety activities.
In fiscal 2021, we conducted remote site inspections at 13 business sites while checking images from the premises in real-time. Moreover, we conducted occupational health and safety management audits based on the Group’s evaluation standards with a focus on business sites that newly joined the Group.
The SEKISUI CHEMICAL Group Safety Conference is held each year.
In an effort to prevent the further spread of COVID-19, awards were bestowed by the president and case studies were presented by the business sites with the best safety records using an online format on May 21, in fiscal 2021.
Safety Management Along Supply Chains
In order to secure the safety of employees from partner companies (contractors) involved in the on-site construction of housing, the Housing Company organizes the Sekisui Heim Cooperation Association with its partner companies (contractors) and holds periodic meetings. During these meetings, the Housing Company shares SEKISUI CHEMICAL Group’s safety policy, offers safety education sessions, and provides a variety of training opportunities related to occupational safety.
Aggregate scope: 45 production sites and 5 research institutes in Japan
Number of Occupational Accidents
Note: Certain data has been revised due to changes in aggregate scope for past fiscal years.
Index Calculation Method Number of Occupational Accidents The number of occupational accidents (both those resulting in lost time and those not) occurring during a given fiscal year (April through the following March)
Number of Facility Accidents
Index Calculation Method Number of Facility Accidents The number of incidents where facilities malfunctioned (fires, leaks, etc.) that fulfill at least one of the following criteria (SEKISUI CHEMICAL Group criteria), from (1) to (3), occurring during a given fiscal year (April through the following March)
(1)Human harm: An accident causing at least 30 days’ lost work
(2)Material harm: 10,000,000 yen or greater
(3)Opportunity loss: 20,000,000 yen or greater
Number of Cases of Long-term Sick Leave
Index Calculation Method Number of Cases of Long-term Sick Leave Describes leave of 30 days or more consecutively for sickness or injury occurring in a Japanese production site or research institute during the given fiscal year (April to the following March), and which is newly-occurring. Recurrences within 6 months of the start of work attendance are not counted. However, leave attributable to an occupational injury is counted as an occupational accident and not classified as long-term sick leave
Number of Commuting Accidents
Index Calculation Method Number of Commuting Accidents The number of accidents occurring during commutes to Japanese production sites and research institutes during a given fiscal year (April to the following March); counting assault, damage, self-inflicted injury, and accidents; includes accidents while walking
Frequency Rate Over Time
* Source of information for the Japanese manufacturing industry: Ministry of Health, Labour and Welfare, Survey on Occupational Accidents
Index Calculation Method Frequency Rate The total number of injuries, illness and fatalities in occupational accidents with lost time per 1,000,000 hours of total time worked during a given fiscal year (April through the following March) Formula for calculation: (Number of injuries, illness and fatalities in occupational accidents with lost time / total number of man-hours worked) × 1,000,000
Severity Rate Over Time
* Source of information for the Japanese manufacturing industry: Ministry of Health, Labour and Welfare, Survey on Occupational Accidents
Index Calculation Method Severity Rate The total number of days of work lost per 1,000 hours of total time worked during a given fiscal year (April through the following March) Formula for calculation: (Number of days of work lost / total number of man-hours worked) × 1,000
Lost Time Injury Frequency Rate (LTIFR)
Index Calculation Method Lost Time Injury Frequency Rate (Number of accidents causing sick leave / total number of man-hours worked) × 1,000,000
Occupational Illness Frequency Rate (OIFR)
Index Calculation Method Occupational Illness Frequency Rate (Occupational illnesses / total number of man-hours worked) × 1,000,000 Occupational illnesses as defined by the Ministry of Health, Labour and Welfare, including heat stroke, lower back pain, and intoxication by chemical substances
Safety Performance in the Housing Company’s Construction Sites
Index Calculation Method Safety performance on the Housing Company’s construction sites The number of occupational accidents (both those resulting in lost time and those not) occurring on construction sites under the jurisdiction of the Housing Company during a given fiscal year (April through the following March)
Safety Performance with Respect to Construction Sites in the Urban Infrastructure & Environmental Products Company
Index Calculation Method Safety Performance with Respect to Construction Sites in the UIEP Company The number of occupational accidents (both those resulting in lost time and those not) occurring on construction sites under the jurisdiction of the UIEP Company during a given fiscal year (April through the following March)
Aggregate scope: 46 overseas production sites
Number of Occupational Accidents
Index Calculation Method Occurrence of occupational accidents at overseas production sites and research institutes The number of occupational accidents (both those resulting in lost time and those not) occurring at overseas production sites and research institutes during a given fiscal year (April through the following March)
Japan and Overseas
Aggregate scope:45 production sites, 5 research institutes, and 27 construction offices in Japan
46 production sites and 2 construction offices overseas
Occurrence of fatalities due to occupational accidents
|Partner Companies (contractors)||0||0||0||1||0|
Health and Safety / Accident Prevention Costs
Aggregate Scope: 45 Production Sites, 5 Research Institutes, Corporate Headquarters Departments, Back Offices of Divisional Companies in Japan
Accident Prevention Costs
|Item||SEKISUI CHEMICAL Group|
|Classi cation||Details||Expense amount||Investment amount|
|1) Costs within business site areas||Health and safety measures, rescue and protective equipment, measurement of work environment, health management, workers’ accident compensation insurance, etc.||1,380||3,390|
|2) Administrative costs||Establishment and implementation of OHSMS, safety education, personnel costs, etc.||1,941||－|
|3) Other||Safety awards, etc.||5||－|
Costs and Investments Over Time
Index Calculation Method Costs Costs associated with health and safety as well as accident prevention activities during a given fiscal year (April through the following March) Investment amounts The amount invested in health and safety as well as accident prevention-related measures authorized during a given fiscal year (April through the following March)
Loss Costs Over Time
Index Calculation Method Loss costs The costs of responding to, and the labor costs incurred due to, occupational accidents, facility accidents, commuting accidents, and long-term sick leave due to illness occurring within a given fiscal year (April through the following March)