kuraray


Safety Report

Safety Activities

Concept, Policy, and Guideline

Guiding Principle on Ensuring Safety

“Safety is the Cornerstone of Everything We Do”

Action Cources on Ensuring Safety (FY 2016)

  • Ensure “Safety First, Production (Construction and R&D) Second”
  • Take 5 seconds before You Act, and Do “CHECK” in order to eliminate Unsafe Situation (action, behavior, condition)
  • Act with sense of ownership and responsibility for all employees, aiming to achieve zero accidents and disasters.

Basic Policy on Product Safety

Targeting contribution to realizing an affluent and comfortable society by responding to customer needs through supply of products that are safe and reliable.

Activities on Occupational Process Safety, and Disaster Prevention , Safety, and Disaster Prevention

The Kuraray Group is promoting creating safe workplaces that are free of occupational incidents, process accidents, and disasters by raising the safety awareness of our employees and operating a safety management system for preventing occupational incidents and process accidents through early discovery of the risks for them. In preparation for accidents or disasters, we make efforts to minimize damage and to prevent the recurrences accidents or disasters, such as emergency drills, sharing information of accidents or lessons.

Targets and Performance in Safety Priority Activities

Evaluation: Ο Accomplished, Δ Nearly accomplished, Χ Not accomplished

Item FY2015 FY 2016
Priority Activities
Target Performance Evaluation
Process Safety, and Disaster Prevention
Occupational Safety
Measures to Prevent Process Accidents Setting the detail conditions to prevent process accidents Implementation of risk assessment of unusual situations Enhancement of capability to deal with abnormal situations Accomplished
  • Enhancement of process safety manegement level
  • Implementation of risk assessment of unusual jobs
  • Capability of detecting abnormal signs and dealing with abnormal situations
  • Transfer of operational skills and techniques from experienced persons to inexperienced persons (know-Why activities)
  • Enhancement of safety awareness of individual persons
  • Dissemination of and compliance with rules
  • Comprehensive understanding of risks
  • Implemention of constitutive countermeasures for serious risks
  • Constructing the base for globalization of safety activity management
Transfer of Operational Skills and Techniques from experienced persons to inexperienced persons
(Know-Why activities) and sustainable continuation
Transfer of operational skills and techniques utilizing career development program (CDP) incorporating "know-why" activities Installation of new system that integrate education and training Accomplished
Comprehensive Understanding of Risks and Steady Implementation of Measures Implementation of risk assessment (RA) aiming at improvement the comprehensiveness
Implemention of constitutive countermeasures for serious risks
Accomplished
Enhancement of Safety Awareness of Individual Persons KY (Kiken Yochi - hazardous prediction) before starting operation Pointing & call activities
Compliance with rules to be observed
Safety education incorporating training"
Accomplished
Globalization of safety activity management Activating intercommunication with overseas affiliates Construct the database "Global Safety Info"
Globalization of occupational incidents evaluation system
Accomplished

Numerical Targets and Accomplishments

Item FY2015 FY 2016 Target
(Inside and Outside Japan)
Target (Inside and Outside Japan) Actual Evaluation
Japan Outside Japan Inside and Outside Japan
Process Safety, and Disaster Prevention Number of Accidents: 0 cases 3 cases 1 cases 4 cases Not accomplished Number of accidents: 0
Occupational Safety Number of Lost Time Incidents: 0 cases 6 cases 17 cases 23 cases Not accomplished Number of Lost Time incidents: 0
Frequency Rate of All Occupational Incidents: 1.5 or less 1.32 7.26 2.91 Not accomplished Frequency Rate of All Occupational Incidents*
Japan:0.8 or less
Outside Japan:4.0 or less
  • Frequency rate of all occupational incidents: Number of all occupational incidents per million working hours.
    All occupational incidents are defined as incidents requiring at least minor medical attention, based on the definition of a recordable incident by OSHA (Occupational Safety and Health Administration) of the US.

Safety Management

Verification of Sites for Safety Activity at Okayama Plant

In accordance with Corporate's Safety Activity Management Regulations, the Kuraray Group develops a safety plans every fiscal year and operates them to ensure occupational safety, process safety, and disaster prevention. To be more specific, each year, at the Safety Promotion Committee attended by the President and executives in charge, we makes an overall assessment and discussion of safety activity performances of previous year and decides activity policy for the coming fiscal year, and we disseminate decided activity policy to all Group companies. In line with this policy, the Group companies are conducting safety activities that reflect the specific action plans of each plant and department. A group of safety representatives from the headquarters, including the executives in charge, visit every plant twice a year to conduct Internal Safety Audits on their safety activity plans, progress management, and the results.

Process Safety and Disaster Prevention

At the Kuraray Group, we consider it a major responsibility to prevent the occurrence of explosions, fires, leakage of hazardous materials, and other accidents that could have an immense impact on society, as well as to curtail the damage in the event of any occurrence to the minimum level. For this purpose, we have undertaken activities such as risk assessment related to process safety and disaster prevention, earthquake countermeasures for buildings and plants, and conditioning of the safety management system for facilities in all plants.

Industrial Safety Activities

At the Kuraray Group, we are promoting safety self-activities by implementing them as planned: ① Risk assessment, ② Utilization of accident information and ③ Transfer of technical background (Know-Why activity) in accordance with the “Activity Plan for Industrial Safety” compiled by the Japan Petrochemical Industry Association.
More specifically, we are undertaking risk assessment of unusual situations such as total power blackout and emergency stop and clarifying the criteria for discriminating abnormal situations in order to activate and enhance effectiveness of risk assessment activities.
Additionally, CDP *1 activity and KMMS *2 are continuously undertaken to promote the transfer of operational skills and techniques from experienced persons to inexperienced persons incorporating the Know-Why activities.
In Fiscal 2015, unfortunately, three minor fire accidents in Japan and one leakage accident occurred outside Japan. All these accidents had no impacts on the external environment or human health and safety.
We will continue to undertake the following activities in Fiscal 2016 and thereafter to prevent accidents.

  • Risk assessment activity of unusual situation
  • Enhancement of capability to detect abnormal signs and to deal with abnormal situations
  • Transfer of operational skills and techniques from experienced persons to inexperienced persons (incorporating Know-Why activity)
  • *1 CDP: A system to evaluate levels of knowledge, skills, techniques, technologies, and action characteristics needed for first-line operators in workplaces to visualize them and to compile an assessment chart for mapping of capabilities of all personnel, to set targets for individual persons, and to provide training based on it.
  • *2 KMMS: A facility management system based on the PDCA cycle (P: Plan making for maintenance, D: Do maintenance work, C: Check and evaluate activity results and reassess maintenance plan, and A: Act to review maintenance plan) by evaluating the importance of each piece of equipment in a unit of production activity and by setting an equipment management system in accordance with risks associated with each equipment. By undertaking activities under this system, operators participate in cause analyses of equipment problems and in reviewing countermeasures and equipment management norms, for furtherance of human resource development and transfer of techniques and technologies from experienced persons to inexperienced persons.

Comprehensive Emergency Drill

Kuraray Group handles large amounts of hazardous materials, high-pressure gases and other dangerous materials. For this reason, at the plants of Kuraray Group, we maintain fire protection and firefighting equipment and periodically undertake drills including anti-disaster drills, alert drills, tsunami evacuation drills, and other drills in cooperation with local public fire department anticipating a variety of situations. In Fiscal 2015, a drill was implemented by the Emergency Command Center headed by the president assuming that several plants were simultaneously damaged by Nankai Trough Mega Earthquake. As a first challenge, damage situations were reported to this center on real-time basis by connecting the head office and five locations via video teleconferencing system.

Scene at the Emergency Command Center headed by the president

Scene at the Emergency Command Center headed by the president

Scene at local headquarters in Tokyo

Scene at local headquarters in Osaka