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Revision 2009

Safety and Health Manual Guidance

Toyota Motor Corporation


Toyota Motor Safety and Health Cooperation
Preface

This book has been established based on law of occupational safety and
health and Toyota suppliers work procedures. The point describes about
how to prevent the industrial accidents in advance of being explained by
illustration.

The revision of industrial Safety and Health Regulation (about the


mandatory of risk assessment and scaffolding) and Toyota industrial rules
have been added in this revision.

Based on the concept of risk assessment and consideration of the vitals


and important point for each task, the work plan to reduce cost was made
and implemented in field. In addition, we ask you to conduct the activity
to reduce the workplace accidents.

By using this manual, the education about safety and health can be
conducted for person-in-charge of construction and works, top level of
related company and general staff.

Moreover, we hope this manual can be used by top level management,


safety and health staffs, and supervisors as a basic to conduct safety and
health inspections.

October, 2009

Toyota Motor Corporation


Toyota Motor Safety and Health Cooperation
Common 1-1 Person in charge in construction

Companys top representative has responsibility to control the


construction, he is a person who maintains the safety, health, quality, Main task
and cost control. Moreover, he also directs instructions, guidances, < Detail >
and supervisions to the PIC (person-in-charge) of work 1. Maintain safety and health
2. Maintain and improve
Companys top representative
quality
3. Maintain the deadline
Safety 4. Reduce cost
Health Deadline
5. Improve the human
relation in working area

Name Kyouryokukai Taro


Born : 10-11-1947

Working permit until : 30-09-2010

Quality Cost Applied company


Toyota Cooperation System Life safety
Engineer Corp
Toyota Safety and
Affiliation company Health Research
Kaiyama industry Society

Human relation Person in charge : V08- 0007


Toyota Motor Safety
Person in construction : V08-0023 and Health
2008/08/01 Coorporation

No Working points Vital points Related document

Qualified personnel will be engaged to carry out a certification


1 Have completed the training from person-in-charge of construction
qualification
As a basic rule, person-in-charge of construction is appointed by In unvoidable condition, choose from primary subcontractor and delegate
2
primer contractor or supervising contractor some of duties

As long as there is no trouble to this duties as person-in-charge of


3 Managing the PDCA of safety, health, deadline and cost
construction, we can charge more than one construction to him

An condition where several construction company working in


If person-in-charge of construction cannot stay on field, he can appoint one
4 same place and have some mix works, person-in-charge of
of person-in-charge of work to manage it
construction should stay on that field

Before commencing the construction, conduct enough meeting


Check the actual site, including risk assessment activity such as obtain the
5 and consultation with working management department and
hazard information
beneficiary department in customer and make the record

The implementation plan of the entire work including work summary,


6 Establish a work plan
scheduling, construction system, safety matter and etc

Giving instruction and guidance to person-in-charge of works Working procedure, working instruction, placement of qualified personnel,
7
based on work plan inspection prior to starting the work, KYM, health check and etc
Conduct patrol at site and check whether the work is going
8 smoothly. Grasp the work progress and make planning for Patrol is conducted at site at least once a day
tomorrow based on it
In abnormal condition, get report from person-in-charge of work
After safe condition is confirmed, contact the work management department
9 and give appropriate instruction. Then, report promptly to the
and continue the work
relevant departments
Receive a report from the person-in-charge of works about Customer's damaged equipment repairing, return notification, 4S condition,
10
completion of work and make a confirmation about it broken equipment, the existing nearmiss, and etc
After completion of construction, check and evaluate the
Conduct an evaluation meeting to evaluate the general construction, person-
11 construction generally and then use it as feedback to next
in-charge of works and etc
construction

-1-
Common 1-2 Person in charge of work

Person in charge of works is a key person


of safety management 5 major task
Person in charge (PIC) of works reponsible < Detail >
for implementing 5 mayor task in construction units 1. Maintain safety and health
2. Achieve the production target
and keep the construction target
3. Maintain and improve the
quality
Worker
4. Reduce cost
5. Improve the human relation in
working area
Person in charge Person in charge
(PIC) of construction (PIC) of works Capacity of Supervisor
Key person of safety management

Name Kyouryokukai Taro Having capability


Having to improve
Born : 10-11-1947 knowledge and human relation
skills
Working permit until : 30-09-2010
Having problem
Applied company solving skills Able to educate
Toyota Cooperation System Life safety which capable person for
Engineer Corp to respond and delegation or
Affiliation company
Toyota Safety and
make general succeesor
Health Research
Kaiyama industry Society decisions
Person in charge : V08- 0007 Person who is able
Toyota Motor Safety to lead the team by
Person in construction : V08-0023 Having capability
and Health
2008/08/01 Coorporation to instruct and example and train
guide the workers who
violated the rule
strictly

No Working points Vital points Related document

Person who familiar with works and able to supervise. Person who
Qualified personnel will be engaged to carry out a
1 has completed the particular training about prevention of
certification qualification
electrical shock and working in high place

Conduct a pre-survey of the construction site, create work Check the working methods and procedure based on risk
2
instructions and deliver them to the workers assessment
Appoint the workers properly based on working
3 environment, worker's experience, qualification, health and Especially for inexperienced person and middle-aged person
etc
Appoint working leader who can supervise the workers
4 Appoint 1 person for 2 persons who work
directly in each unit of work
Person-in-charge of work wear the armband and always
5 Be careful of the low battery condition of electrostope
bring electrostope (voltage detector)
If the person-in-charge of work will be away from the work Delegated person is limited to those who own the PIC of work
6
place, his task will be taken over by his delegation certification

Implemet KYM, define the danger point and apply the


7 Understood and signed with full name by all workers
countermeasure action for it

Inspect and maintain the use of tools, equipment, and


8 Use checklist
personal protective equipment before used

Give proper guidance for unsafe conditions and behaviour


9
directly on site
In abnormal condition, stop the activity, report to PIC of
10 contruction and receive the information from him. Continue Discuss with related departments, and re-implement KYM
the work, if safe condition is confirmed
11 Implement 4S in working area

-2-
Toyota Motor Safety and Health Coorporation
Safety and Health Manual Revisi 2009 Material Subcommittee Chairman Mr. Inokuchi
Executive Director of the Secretariat Mr. maeda
08 10 - 2009

After three years from the last revision, the most recent legislation and risk
assessment, such as standardization for the scaffold and record and
inspection keeping standard has been made as mandatory in the meantime.
Beside that, the some part of rules that have been revised in Toyota Motor
and the countermeasure for the take qualification certificate were update,
Those mentioned above were added on this revision
Clothes and personal protection
Common 1-3
equipment

- Helmet to prevent falling


crash
5 Logistic Division
- Helmet for fall flying
- Helmet to prevent Safety belt
electrical shock Reflective vest

- Hand wear
cover
- Arm cover
- Foot cover
- Safety shoes
- Electrostatic
- Insulated shoes
- Anti-cut gloves
- Safety rubber boots
- Chemical resistant gloves
- Underground shoes
- Insulating gloves
- Bag Jika tabi shoes - Ear plugs
- Heat restant gloves
- Anti vibration gloves - Ear muffs
- Leather gloves

- Glass for dust protection - Dust mask


- Light shielding protector - Gass mask
glasses - Air fed mask
- Disaster preventive - Self contained - Insulating clothes
surface - Breathing - Electrostatic
- Shielding surface apparatus clothes

Related
No Working points Vital points
document
Use proper and clean for work. Work with
1 prediction of burns, electric shock, cuts are Rules 110
prohibited

Tighten the chin strap and write the company's


2 Use appropriate helmet for work Rules 110
name

Check periodically the wounds and crack of body


3
and mounted unit of helmet Helmet that got impact even once or has abnormal condition
Safety belt must be checked before use, make after inspection should be discarded
4
sure the damage on hook, belt, etc

Use flourescence vest in shipment area of logistic If forget to bring the flourescence vest, borrow it in hand each
5
division shipment area

6 Use proper footwear for work Tabi boot is possible to be used


Use 2 (double) hooks of safety belt if there are no working
7 Use safety belt for working in high place
floor and safety net
Use proper personal protective equipment for
8 Mask, Gloves, Glasses, earplug, etc
working
Number of safety equipment should be same
9 Can not be shared Law 596
with the number of workers

Maintain the health and safety equipment to use Put in control box
10
it effectively

-3-
Common 1-4 Construction Control Board

No Working points Vital points Related document

Place the construction control board at the Put the survey work, attendance etc prohibited in a place that has
1
work place with a good visibility been switched off, such as control panel
Construction sign board, risk assessment implementation record,
Put the document needed in the pocket on the
2 working instruction, KYM, workers list, work notification, customer
construction control board
approval, etc

Attendance clarification of today's workers in


3 List of qualification is mandatory
worker list

Devide the contents of working instruction into


4 Not include KYM and 4S
3 or more items
Write the fullname of person in charge of
5 construction and works in construction
signboard
Fill the sign with fullname of workers in
6 document, such as KYM implementation Check the health of workers
record

7 Fill the KYM dangerous point with a sentence Multiple choice type is prohibited

Display the insurance number of prime


8 Display in construction signboard
contractor
Insert the document needed in each company,
9 qualification, certificate, etc in storage pocket
on backside

-4-
Common 1-5 4S in working area

4S consists of sorting, straightening, sweeping, standardizing


(5S if include sustainning the practice)
4S is the first step of safety, basic rule to prevent disaster
Commited to 4S activity on working
Participation of all workers is important

No Working points Vital points Related document


Do not bring tools that have no relation to
1 Materials or tools
work
Passage, stairs, exit and entrance door,
2 Ensure that working passage is safe Law 540
emergency door, etc
Do not put material in front of electric
3 distribution box, power box, fire extinguisher,
first aid equipment
Check the place, method of material placement Stability, height, collapse load, preventing rolling (section, sign,
4
, and stack material and stuff etc)
Prevent material and tools scattered by strong
5 Check the fixing method
wind
Dispose the remaining material, scrap, and Separation, manifest management, and customer trash are
6
waste properly prohibited
7 Prevent dust and dirt scattered Sheet ring, etc
8 Do not leave hazardous materials
Inspect before starting the work, prevent the
If the leak occured, report to the related departement and take
9 leakage of liquid waste and oil vehicle from the
the appropriate treatment as soon as possible
machine
10 Smoking is allowed in specified location Prohibited inside the building

-5-
Common 1-6 Passage in field

NOTE : Its use is accordance to the regulation depends on the risk of


work and transport packing. (there are separate rules depend on
the factory)
Sample of safety sign
To prevent
forget removal
First priority to
unmanned
vehicle
To prevent forget removal of
linchpin. Hung on doorknob.
Hung on rear-view mirror
Please contact
to entrance

String
concatenation Linchpin

Follow the sign

No Working points Vital points Related document


Do not run inside the building. Do not put your hand in
1 Inside the building, pedestrian walk on the right side
the poket when walking
On the road where there is roadway pedestrian step
Prohibited in front of car and diagonal crossing
2 are walk on sidewalk and crossing the road through the
crosswalk
On the foot mark, stop for a moment and check the left
3 Use the pedestrian zone when walk inside the building
and right side
Use the door for human use if you want to go inside and
4 Entrance and exit through the shutter is prohibited
outside the building
5 Vehicle should obey the speed limits inside the building

For driving inside the building, display the name of prime


6 Include rental car
contractor, supervising contractor and company name
Path for emergency vehicle, fire fighting box, hydrant
7 Do not park in prohibited area
box, etc
Unplug the engine key, use linchpin for work to unload
8
stuff (from truck, etc)
9 Do not use the mobile phone when driving Include when walking
Operate manually the quick shutter of entrance when
10
using serial work platforms
11 Turn on the light when driving inside the building
For cab back crane car, do not raise the boom when
12 Check the height limit
running

-6-
Falling down 2-1 Work in high place (General)
and rolling down

2 hook safety
belt

Rope network installation,


use safety belt
Height of handrail is more
than 90cm
Space less than 3cm

Working in high place


Width more than 40cm

Stairs to go up and down

No Working points Vital points Related document


Work in high place is working at height or dept
1 Worker who already completed the special training
more than 2 m
Install the safe working floor with width more
2 Space between the floor is less than 3 cm Law 536
than 40 cm
Provide the edge and open part of working floor Height of handrail is more than 90 cm and
3 Law 563
with the handrail install the baseboard
4 Providing a safe lifting equipment Place with height or dept more than 1,5 m
5 Display the banner of serial work Placed in area with a good visibility
Check and use the proper personal protection
6 For risk prevention from falling down Law 539
equipment for works
Keep the illumination level needed in working
7 In worker position : More than 70 Lux Law 523
area
When the scaffolding cannot be installed, use Always use 2 hooks (double) of safety belt
8 Law 521
safety net, rope network and safety belt when moving
Install equipment which can be applied with safety belt with
Use safety belt when working on working floor or
9 position higher than stomach
opening wall

Throw up and throw down the stuffs are prohibited


10 Use hanging bag when raising and lowering stuffs

Install the construction control board outside the


11
prohibited area

12 Do the inspection of 4S after finishing the work Check the left things on high place, etc

-7-
Falling down 2-2 Work with stepladder
and rolling down
Example of prohibited use of stepladder

1. Work on top board 2. Uneven and weak surface 3. Use on schaffolding

Display red colour


5. Work with head directly facing 6. Work that need effort
4. Use on the edge above

7. Also hip work 8. Instable work that


9. Do not use ladder
need 2 hands

No Working points Vital points Related document


There is no damage and corrosion on
1 Law 528
stepladder
Check the angle between stepladder's leg and
2 Around 75 degree Law 528
horizontal plane of the floor
Use with the condition of stopper on bracket is
3
locked
Place the ladder tread in the area where
4 Width of tread is more than 5 cm Law 528
workers can be work safely
Work place with height more than 2 m is defined as working in
Paint the part of stepladder with height more
5 high place
than 2 m with red colour
Use safety belt for activity with height more
6
than 2 m
7 Do not use stepladder by 2 persons
Do not install stepladder near a place for
8 moving equipment or a place that has risk of
falling, such as opening area
Use lifting equipment and hanging bag for Throw up and throw down the materials and tools are prohibited
9
materials and tools
10 Do not use stepladder as a lifting equipment Do not use as ladder

-8-
Falling down Working with horse scaffolding
and rolling down 2-3

sticking out
part is danger !

Falling down when


climbing up or down

More than 10cm, less than 20cm

Loading weight between stepladder should be less than 100kg

Tied up

less than 1,8m less than 1,8m

No Working points Vital points Related document


There is no damage or corrosion on horse
1 Use height is less than 2 m
(round pipe) and scaffolding plate
Check the degree between horse and
2 Around 75 degree
horizontal level from floor
Ensure that condition of stopper on bracket is
3
locked

4 Use anti slip material, such as rubber on the leg

5 Do not use on rough floor or weak surface


1 worker on each space between supporting
6
point

7 Install the scaffolding plate horizontally Lap portion : more than 20 cm, sticking out : less than 10 ~ 20 cm

Check the condition of lap portion and sticking


8 Law 563
out part of scaffolding plate
Use the scaffolding plate with 3 supporting
Use 2 layers of scaffolding plate for 2
9 point space between supporting point is less Law 563
supporting point
than 1,8 m
10 Fixing the plate to prevent sliding Use rubber band, steel wire
11 Do not use horse (round pipe) separately Do not use as stepladder Law 528

-9-
Falling down Working on scaffolding and
and rolling down
2-4
work floor

More than no.13 are


mentioned on next page

Related
No Working points Vital points
document
Appoint the chief worker when erecting, dismantling, or changing the
1 scaffolding with height more than 5m, appoint the leader worker for
scaffolding with height less than 5m
2 Erecting and dismantling work are only allowed for authorized person
3 Scaffolding from round wood (log) is prohibited

4 Use material with no damage, deformation and corrosion for scaffolding Law 559

Apply nail stopper, floor plate, cult roots, briding batten of floor post, and Install anti slip and sinking prevention
5
metal base on the leg scaffolding
Install parent preceeding rope and handrail for erecting, dismantling, and
6 Use safety belt Law 564
change the scaffolding
7 Use arm lock, connecting pin, etc in connecting part Check the condition

Attach wall tie for single tube scaffolding (vertical 5m, horizontal less than
8 Law 570
5,5m) and framework scaffolding (vertical 9m, horizontal less than 8m)

9 Use working floor with width more than 40cm and space less than 3cm Check width and space Law 563
For height more than 15cm :
Use underbar less than 40cm,
10 Install the brace, handrail, underbar, baseboard, mesh sheet, etc Law 563
and baseboard with height
more than 15cm
Height of handrail is more than
11 Install handrail and middle bar in lifting stairs 90cm, and middle bar with Law 552
range 35cm - 50cm
Calculate the required measurement when approaching the overhead Attach the insulating protective
12 Law 570
electric line materials

- 10 -
Falling down Working on scaffolding
2-4 and work floor

and rolling down

Bike scaffolding

Display the maximum load


weight

11

Single-tube
scaffolding

No Working points Vital points Related document


Handrail with height more
Install the handrail and middle bar for all scaffolding
13 than 90cm, middle bar with Law 552
frame
height range 35-50cm
The space between the building and frame should be Install safety net per 2 layer of scaffolding if there is a
14
less than 30 cm risk of falling down
Install the crosspassing road between scaffolding and
15
building frame
16 Do not leave any material on scaffolding
Define the maximum load weight of scaffolding any
17 Displaying Law 562
inform to workers
Do not remove the crossbrace, handrail, middle bar,
18
baseboard wall tie, etc without permission
Use safety belt for works with possibilty of kickback,
19
work in a crouch, etc
Attach mesh sheet (without broken parts, slack, space,
20
curling, etc) on falling preventive equipment
Repair scaffolding properly Law 567
Do inspection to the scaffolding after erecting,
21 when abnormal condition
dismantling, and change Law 568
found
Inspect the scaffolding after erecting, dismantling, and Keep the inspection record Law 567
22
change until the construction finished Law 568
Inspect the scaffolding in case of bad weather and after Law 567
23
earthquake with magnitude more than average Law 655

- 11 -
Falling down Working with ladder
2-5 (movable type)
and rolling down

Prevent
dislocation
(tied up) More than
60cm

Total lenght less than


9m

Space range : 25-


35cm

Around

Anti-slip

More than 30cm

Related
No Working points Vital points
document
Broken part, dent part, wearing rope
1 Damage, corrosion, loosen are not allowed on ladders

2 Install anti slip with rubber, etc on ladder's leg Damage is not allowed

3 Have a lock function work properly for slide type of ladder


Strengthen the surface using floor plate, etc if you
4 Do not place ladder on slope, rough, or weak floor surface want to use on the surface with problem

See the angle between lower part of ladder and horizontal


5 Around 75 degree
plane of floor properly
6 Install the ladder with upper part pushed out Push out part more than 60cm
7 Prevent dislocation by tying up the upper part, etc
Place assistant to support the lower part of ladder when it
8
is tied to the beam or remove from beam
Do the lifting activity one by one and do not bring anything Do not turn back on 3 supporting point ladder
9
on that activity
Prohibited regardless of the high
10 Do not throw up and down materials or tools

In case of working on the ladder, do not do the hip work,


11 Use safety belt if the height more than 2m
work that requires a lot of effort, or lead forward work

- 12 -
Falling down Working on hanging scaffolding
2-6 and safety net installation
and rolling down

Network rope

Handrail
Safety net

Tie/bunding

Middle bar
Railling pillar
Surveillant

Safety net
Authorized
person only

Related
No Working points Vital points
document
Appoint the worker who has qualification and skill in erecting,
1 Law 565
dismantling, and change the hanging scaffolding

Take measures to the prohibited area when do the erecting,


2
changing, or dismantling work

Use scaffolding floor, lifting chain, etc which have no damage,


3 Check before use
deformation, corrosion and have enough strength
Check the gap, sagging condition, etc
4 Install safety net on whole surface area
Prevent working surface material from dislocation and falling
5 Unite with clamp
out
Install the handrail and middle bar on open area and outer Height of handrail is more than 90cm
6
area
Determine the maximum load weight of scaffolding and
7 Display Law 562
inform to all workers
8 Using stepladder, ladder, etc on scaffolding are prohibited

Check the material damage and fixing condition before Include part assembling Law 567
9
starting to work and after bad weather and after changing Law 563
10 Scaffolding with log (round woods) is prohibited

- 13 -
Falling down
2-7 Working on rolling tower
and rolling down

Middle Prohibited activity


bar Handrail

Work floor (Lay


Base entirely)
board
Ladder to go up
Diagonal and down
braces

Do not use stepladder, - Do not lean some


ladder, etc on the stuffs,
work floor - Do not conduct activity
Display than can generate
(Precautions) reaction

Caster (Stopper)

Outrigger - Do not bring some stuff


Do not move when when climbing up and
people ride it down.
- Do not climbing more
than 2 person in same line

Related
No Working points Vital points
document
Appoint the chief worker when erecting, dismantling, or Law 565
changing the scaffolding with height more than 5m
1 Display the chief worker's name
(Appoint the leader worker for scaffolding with height less
than 5m) law 529

2 Cover whole surfaces of working floor Gap between floor material : Less S50.10.18
Install handrail, middle bar, and base boards on working than 3cm, Height of handrail : 90cm, Public
3 Base board : More than 10 cm
announcement
floor with no related to the number of stairs no.6
Do not bring some stuffs when climbing up and
4 Install the lifting equipment and use if properly down. Do not climb more than 2 persons in same
time
S50.10.18
Also display the company and user Public
5 Display the maximum load weight (less than 250 Kg)
name announcement
no.6
6 Install on secure place Surface with no rough
7 Ensure the out trigger is locked before use Frame work has three or more stages (H 7.7L-5)

8 Ensure the caster stopper is locked before use Ground all four wheels
9 Use safety belt when work on working floor
10 Do not move scaffolding when people ride on it

- 14 -
Falling down Working in high place
2-8
and rolling down (on or near the crane)

Risk range of moving

1. Area which are closer than 1,8m from the


bottom of the crane (not include hook)
(veritcal distance)
2. End face of girder crane and side saddle or
part which closer than 0,1m from girder
crane
3. All part of the space directly above crane

Related
No Working points Vital points
document
Working on high place near the crane is prohibited. If work on Display the working permit from related
1
that area is necessary, take the work permit in advance divisions

Check the equipment completely that executed by crane


2
operator and sling operator on that day
Determine the work leader and follow the guidance from a
3
conductor
4 Turn off the main switch of crane and all workers do lockout Workers do them selves the lockout activity

5 Do not use stepladder, ladder, etc on girder


Outside the load range, inside the protection
6 Workers wait in safe area when the crane is running
barrier, etc
Check the crane interference condition after activity is
7
finished

- 15 -
Falling down Working in elevating
2-9
and rolling down Work platform

(1) Telescoping boom type (2) Telescoping knuckle boom (3) Mixing type

Outrigger

Safety belt (4) Scissor arm type

Operation with work floor more than 10m can be done only by operator who
has completed skill trainning course.

Operation with work floor less than 10m can be done only by operator who
has completed special education.

No Working points Vital points Related document


Qualification depends on the
1 Only qualified person who can operate the crane Law 36
capability of the machine
Confirm the specific inspection emblem and check the
2 Inspect and display Law 194 point 23
crane before use
3 Determine the work plan based on type and capacity According to the leader Law 194 point 10
In case of work floor operating outside the work floor
4 area, operate the equipment based on instruction Define the fixed instruction Law 194 point 12
from work floor operator
5 Use the built in ramp to lift the driver's seat
Do not use elevating work platform outside of its own
6 Law 194 point 17
main function
Including scissor arm type
7 Use safety belt when working on work floor Law 194 point 22

Do not operate the machine near area where there


are people. In case where there is a person moving Only authorized personnel are allowed to enter when
8
closer to the equipment, stop the equipment and give equipment is moved or operated
some warnings.
Use brake, outrigger, etc when operating the
9 Ensure horizontally
equipment

- 16 -
Falling down Working on the roof
2-10
and rolling down
Vertical ladder
Parent rope Prevent glass window
broken
Gang plank

Straight roof

Work facing
behind is
prohibited

Roof

Rolling
Lifting down
equipment

Related
No Working points Vital points
document
1 Install safety equipment for lifting to the roof

Do the falling prevention action when lifting the vertical


2 Install safety block
boarding ramp

Do not walk directly on


In case of working on the straight roof, attach plank and straight roof
3 Law 524
install safety net and life rope Timber plank width should be
more than 30cm
Post warning sign at dangerous location inside the working
4 Sky light, opening area, etc
area
5 Distribute the placement of material Do not put in one place

6 Do not place remaining materials on the roof Cause of shatter roof


Use safety belt or harness in the edge of
7 Do not see backwards when working on the edge of roof
location
Make a damage prevention when working near the glass
8 Place watchman to see downside
windows in week days

- 17 -
Falling down
2-11 Working near opening-area and pit
and rolling down

Restriced area

No Working points Vital points Related document

Define the preventive method for opening-area in


1 construction when establishing the a construction When using and after using the opening-area
plan
Handrail height is more than 90 cm, middle bar,
2 Install handrail, cover, etc on pit and opening-area Law 519
base board, and display risk
Display warning sign of resticted area near opening-
3
area and pit
Implement neccessary measures when removing
4 Recovery of safety net, safety belt after use Law 519
the hand rail, cover, etc
Do not put any material or stuff near the opening-
5
area and pit
Make an action to prevent materials falling down
6 Safety net, etc
from opening-area
Use safety belt for activity which conducted at
7
surrounding of opening surface
8 Restrict the area below the opening surface area
9 Install the proper lighting equipment

- 18 -
Electric shock 3-1 Common electrical operation

No Working points Vital points Related document


Particular training for "Treatment on low and high Voltage"
1 The particular training is required for electrical work
2 Hot line work is prohibited Insulate the terminal after disconnection
Check the function of electroscope (voltage detector) before
3
use
Electrical checking should be done for every line. All electrical
4 Use electroscope for power outage check workers should bring the electroscope

Do the preliminary inspection and meeting with managemant


5 Check the working area before turning the power on department

Switch off the power and lock out the main control panel,
6 Lock out the opening switch to prevent input operation panel, etc. If direct locking is not possible, use
attachment
Ensure to use insulation helmet, insulation shoes, insulation
7 Use suitable personal protective equipment for working gloves, and safety belt

Appoint a watchman for activity near the high voltage hot


8
line
Do 4S thoroughly near the electric distribution board,
9
operation panel, etc

Confirm and make a contact between PIC (Person in charge) Handling for range of multiple operation of power switch
10
of work from other company on mix operation.

Conduct the periodical inspection for insulating protective


11 Do per one month Law 351
equipment and protector

- 19 -
Work with electric tools and equipment
Electric shock 3-2
(Including moving & portable)

Seal for 6 month


inspection Check the wearing of carbon brush
Switch condition & damage

Damage on connector

Cord reel
Damage on cable
Inspection seal
Insulation resitance
measurement method Power
3 Core cab tire distribution
Plug
cable panel
Ground Conductor
Electric
leakage
breaker Name tag of
company

No Working points Vital points Related document


Conduct treatment for electric power tools by Worker who has completed the particular training for electric
1
workers shock prevention
Connect the electric leakage breaker to Conduct the operation test by pressing the
2 Law 333
prevent electric shock test button
Conduct the periodical check of electric power
tool and the measurement of insulation Periodic inspection per 6 months (see the document about electric
3
resistor (more than 1M), put the inspection shock prevention 2 P is possible for double insulated device)
seal
Install the ground of electric power tools
4 2P is possible for double insluated device
(3plug)
Check and maintain the electrical power tools,
5 devices, cords, cables, etc before bringin and See the inspection point on illustration above
using the electrical power tools
Make sure that there is no any damage on
6 cover, cable and additional tape on connection Law 336
part
Use water proof equipment for activity in
7 Law 337
damp location
Install the guard on handlamps and flood light. Use 3P plug for electric source (charging source) case which made
8
Do not work when holding it. of metal
Use electrical power tools through the cord Do not take power directly from electrical outlet of customer /
9
reel with electric leakage breaker attached client.

- 20 -
Wiring the distribution electrical panel
Electric shock 3-3
for equipment & construction

Cord & Cable

Protector
cover

No Working points Vital points Related document

Install grounding of the electronic distribution panel


1
which made from steel box

Organize and manage the surroundings of panel to


2 Do not place unnecessary stuff in electric distribution panel
prevent trouble on operation

Lock the electric distribution panel which are


3 installed facing the passageway or in place with
possibilty of being touched by people

Install the electric leakage breaker on main source


4
electric power
Display the lamp and power distriction on
temporary power panel surface, and make clear the
5
company's name and the responsible person for
treatment
Do not make a direct connection to device from the
6 Do not make a wiring hook (Jamming process)
middle of connection
Install cover for cable and chord on passage and
7 Display the company's name on chord and cable
crossing line

8 Connect to the ground Exclude the generator less than 3KVA or 3KW

9 Always close the electronic distribution panel's door Pull out line from the lower part

- 21 -
Electric shock 3-3 Arc welding

Display 200V

Power
distribution
panel

Electrical
oulet for
welding
Grounding clips

Plug for arc welding Grounding bar

Companys name display board

Fire Fire
extinguisher extinguisher

water

water

No Working points Vital points Related document

1 Workers should have completed the particular training


Check the operating condition of automatic electrical shock
2 Record the inspection before use Law 332
arrestor for AC arc welding
Make sure that there is no any damage on insulation part of
3 holder. Moreover, check the storage condition when it is
being used
Make sure there is no any damage on cover or exposure Ensure the tape of connector before use
4
area of terminal
Install the electrical ground on ground bar in outlet
5 Install the electrical grounding for the welding machine
box
Install the secondary side of electrical grounding to the Exclude the corrosion or paint on welder
6
welder

7 Use a suitable personal protective equipment Shield surface, leather glove, dusk mask, etc

Make preventive actions for cable which have possibility of Crossing point on passage, place with possibility of
8
damage falling object
Conduct the periodical inspection and measurement of
9 insulation resistance (more than 1M) and attach the seal
after the inspection finished

- 22 -
Subsequent inspection
Electrical shock 4-1 of the control panel

Lock out the off condition


of power

Lock out Wait !!!


breaker

Confirm the off


condition of power

Electroscope

No Working points Vital points Related document


Confirm that the power source has been switched off
1 and make sure that there is no current flow by using
electroscope
Check and lock out the device that has been switched
2 See page 24
off
Confirm the blackout range and thorough Do the same thing after return back to
3
understanding of the workers work
Safety plugs, etc are brought and managed by
4
appointed person
(Caution) in case of not all power is being turn down or
5 Check the stop range of safety plug when pinch protector is needed, operate the interlock
device (emergency stop button and mobile plug) of
6 Confirm the recovery of safety plug operation panel and safety fench and do lockout

Conduct mutual confirmation about work description,


working supervision, KY, and countermeasure
7 range, time, unity method, etc between the person in
charge of works in mixing works

8 Check the illuminance intencity in working area More than 150 lux in working position Law 335

9 Appoint a switch operating person in running test

10 Check to ensure the recovery of safety cover, etc Check the leaving material, tools, etc inside the panel

- 23 -
Pinched 4-1 Lock out

Check the name


and keys number
on KYM form

Lock used by
many people

Supply works inside Toyota. All workers lock th ebox


See the manual about lockout which brought by each
worker

No Working points Vital points Related document


1 Distribute lock key to all workers

2 Conduct KYM and fill the name and key Person in charge of works directly distributes the key
number in the KYM form
3 Check the power source, released residual Determine the lock out locking place
voltage, and the range of abnormal stoppage

Turn off the power source (main source and


4 pneumatics circuit) for operation in emergency
condition, push the emergency button

5 Worker should lock the machine and bring the Carry the portable plug and key with 5W Law 107
key by himself
6 When working with more than one person, use
the lock bracket for all workers
7 Do the grouping lock out of a number of Only PIC of work who has more than one key
machine in the same time is required
8 After finishing the work, the key should be Released by other person is not allowed
released by the person who lock it
9 The last worker who exit should restore the
plug and key
10 Person in charge of work should collect the key Verify the name and key's number
from all workers

- 24 -
Maintenance and inspection work
Pinched 4-2 of press and molding machine

Crown

Operation panel

Upright
Carrier trolly

No Working points Vital points Related document

Confirm the power transmission, air supply, working Ensure to inform the working procedures
1
range, process, etc prior to work

Customer management division and person in charge


Check and coordinate the safety aspect and working
2 of works should discuss together before doing the
installing and dismantling or both of processess are method prior to work
done
3 Check the stopping position of slide before Set the position of slide on the bottom dead position
diassembling the machine
4 Switch off the main power, unplug and bring the Lockout Law 107
portable plug
5 Conduct actions to prevent slide falling down Safety lock, etc Law 131-2

6 Close the air source valve and release the residual air
pressure
Check the inside of drive unit to prevent tools or
7 materials left after setting and before running test, Confirm the tools used, workers, etc
workers should wait in safety place

8 Do the reliable action to start the machine after the Law 104
work is finished
Stop the operation in case of abnormal condition
9 Law 137
(abnormal sound, vibration, etc) was detected

10 Do point 1-9 when setting the precision of machine

- 25 -
Adjustment and trial
Pinched 4-3 of the equipment

Activity where the equipment can not be switched off.


(Operation where lockout can not be done)

Supply activity inside Toyota


See the manual about lockout

No Working points Vital points Related document


Repairing, maintenance, running test of the robot Special training related to robot for
1 Law 36-31
should be done by certified and qualified person mass production
2 Confirm the emergency stop range Check the operating condition of emergency stop button
Implement the safety works instruction and determine
3 the workers distribution, stopping method for
emergency time and the position of watchman
Conduct the actions to prevent unauthorized person
4 Install fence, barricade, restricted area sign and etc
who enter the operating area or dangerous area
In case of joint work with other teams, choose a work
Check and maintain the working method prior to start the
5 leader and conduct the activity with reliable sign and
operation
communication based on instruction from leader

To assist human attention, provide the 2nd hand


6 control type safety equipment, push equipment, push
cutter operating button and teach about speed limit
Do the reliable actions to start the machine after the
7 Check surroundings Law 104
work is finished
Check the inside of drive unit to prevent tools or
8 materials left after setting and before running test, Confirm the tools used, workers, etc
workers have to wait in safe area

Stop operation immediately in case of abnormal


9
condition (abnormal sound, vibration, etc) is detected

- 26 -
Pinched 4- 4 Loading and unloading
work of forklift

Limitations of using outside its applications (Law 151-14)


With purpose to reduce and abolish the transportation works,
especially loading and unloading vehicle

Instructor

For inspection on
Tilt operations

See the safety operation


manual for operating
forklift For registered
inspector

No Working points Vital points Related document


Operating should be done by certified and qualified Special education < 1t <= skill
1 Law 76
workers trainning
2 Check the safety of starting point and dangerous place Running check
Keep the speed limits and driving method (back driving, Inside & outside speed less than 10
3 Law 151-5
etc) km/h
Turn on the front side headlight when running inside the
4
building
When forklift is running, height of fork should be 15-20cm
5
from road surface and the mast is tilt enough
To prevent rolling or falling down, check the obstacles or
6 Law 151-6
risky area on driving road and use seat belt
In a place with poor visibility, choose an instructor and
7 Define the fixed sign Law 151-7-9
follow the instruction from him
Fixed the stuff which under the
8 Check the load collapse protector and the stability of stuff Law 151-10
stability level
When the operator is away, unplug the key after turning Leave the driver seat without
9 Law 151-11
down the fork, switch off engine, and use side brake unplug the key is prohibited

10 The weight of load should be less than permitted weight Law 151-20

Check the special inspection implementation and seal Inspection seal should be attached.
11 checking parallel with recording the implementation of Inspection record before used Law 151-22-25
inspection before used should be existed

- 27 -
Transport activity
Pinched 4-5 using truck, etc

Vehicle for transportation inside the


building
Prevention for
inadvertence removal

Prevention for
inadvertence removal of
linchpin put the door knob
put back mirror

Coupling rope Linch pin

Related
No Working points Vital points
document
1 Check the safety of starting point and dangerous place Running check
2 Keep the speed limits See P6
3 Running with tailgate open is prohibited
When the operator is away, unplug the key after Leave the driver seat without unplug
4 Law 151-11
switching off engine and use side brake the key is prohibited
In a place with poor visibility, appoint an instructor and
5 Law 151-48-62/72
follow the instruction from him
Post the warning sign for high risk area such as area with
6
possibility of contact with cargo
Check the stability of load (do not transport with
7 Fixed the unstable load by bunding Law 151-10
imbalance load)
8 Use helmet when carrying luggage an carrying tray Do the activity on specified location
9 Luggages loading on slope surface is prohibited
Work carefully when lifting the luggage to carrying
10 Use ladder or stepping platform Law 151-67
vehicle
Start operation after inspecting the oil leak from luggage See the transportation guidelines such as. TMR
11 or vehicle. Work or transport activity of luggage outside SAS8010n, etc
is prohibited when raining
Use the linchpin when parking and leaving the driver Install straightly
12
seat
Remove before starting to move

- 28 -
Explosion and fire 5-1 Fire extinguisher (portable)

Inspection seal

Related
No Working points Vital points
document
1 Conduct voluntary inspection and attach the inspection seal 1 time/6 month

Seal not expired

Maintain the equipment by always performing the daily Safety pin, lock pin are not loosed
2
inspection No deformation on equipment body, hose and
nozzle
No rust on bottom surfce
Portable fire extinguisher is supplementary
3 Check fire extinguisher after 5-8 years of manufacturing date

The type of fire extinguisher for inside the building should be


4
10 or above

- 29 -
Explosion and fire 5-2 Work using fire

Construction control
board

Fire is being used


Fireproof sheet

Related
No Working points Vital points
document
Get permission before using a fire on work. (to factory safety Post the hot work permit on construction control
1
division) board
Fire extinguisher : more than 2 tubes, water
2 Provide fire extinguisher, water bucket, fire blanket, etc bucket: more than 2 pieces
Put in place with good accessibilty
Do not put flammable subtances, combustible materials, and
3
explosive materials near the working area
Put the banner /warning sign to show that the fire is being
4 Put in place with good visibilty
used
5 Appoint a fireman who wear a armband Also conduct monitoring at rest time
Install the fire blanket and shut off plate to reduce the fires
Applied for work on high place and grating work
6 works which produced from welding when use fire in high
place
7 Set the area below the working position as prohibited area
When working with elevating work platform, put
When working in high place, prepare fire extinguisher near the fire extinguisher on the work floor. (spray
8
the working area type is possible depends on the quantity of fire
used)
Check the fire sparks left from flying sparks after execting hot Give back the permit after completing the hot
9
work work
10 Watch the working area in certain time after hot work activity Report to the construction safety division after
finishing the monitoring
Conduct fire preventive action for works which produce fire Check the hot work permit to management
11
sparks, such as grinding division

- 30 -
Explosion and fire 5-3 Gas and cut welding activity

Display the quantity (empty or full),


prime conctractor name, companys
name, carried date

Fixed the
trolley
Eyewear protector
dust mask leather
gloves

Fire extinguisher : More


than 2, water bucket :
more than 2, Fire proof
sheet
Special sparkling
lighter

No Working points Vital points Related document


Person who has completed gas welding
1 Certified and qualified person should be involved Law 41
training course

Check damage, wearing, fault connection, etc of Check using inspection sheet before starting to work and
2
adjusment tools, pressure gauge and hose keep the record from in control board

Check the gas leakage from every connection and


3 Soap, water, etc
hose parts
Do not put flammable substances, combustible
Do not place the acetylene cylinder in floor with horizontal
4 materials, and explosive material near the working
position even it is empty
area

Release all substances, combustible materials, and


5
explosive materials near the working area

Release all substances or materials, such as


flammable liquid or steam, combustible gas, which
6
contains in vessel or pipe that will be cut by gas
welding

When working in high place, set the fall prevention


7
equipment for falling fireworks and cut places

Close the valve of acetylene & oxygen cylinder and


8 confirm that the pressure gauge is already zero when
it is not being used
Prevent from direct sunlight and keep with temperature
9 Do not place the cylinder under the blazing sun
below 40C

- 31 -
Lack of oxygen Painting work
6-1
and toxicosis (using organic solvent)

No Working points Vital points Related document


Appoint a chief operator for organic solvent
1 Display the name of organic solvent chief Law 18
work
Workers should have completed the trainning
2
course for handling organic solvent
3 Check the ventilation condition Use blower
Confirm that there is no fire near the working
4 Display the "fire is prohibited" sign
area
5 Painting is prohibited as principle
Place a warden and define instruction sign
6
when working used air supply respirator

Use gas mask for air supply respirator or Concentrated gas on gas mask should be more
7 Law 593
organic gas when working inside the building than 18% (from national assay)

Define the working area clearly when painting Display "fire prohibited sign" and restricted
8
the floor surface area sign in a place with a good visibility
Confirm the expired of suction can on gas mask
9 Considering the breakthrough characteristics
for organic gas
10 Always seal the containing organic solvent The circumstances of use

- 32 -
Lack of oxygen Working in tank or furnace
6-2
and toxicosis (Hydrogen sulfide poisoning and oxygen deficiency)

Hydrogen sulfide poisoning


Concentrate of hydrogen sulfide is
more than 10/1000000
Symptoms caused by absorbing the air

Oxygen deficiency
Condition where the oxygen
Concentretate is less than 18%

Related
No Working points Vital points
document
In case where the hydrogen sulfide is existed.
Workers shoud have completed the second
Appoint a person in charge for works with a type of work in oxygen deficiency training
1 Law 18
potential risk of oxygen deficiency course for leader, and the name of leader
should be displayed on construction control
board
Workers should have completed special
2
education for oxygen deficiency
Prepare the equipment with the number of workers on the work
Prepare evacuation equipment for emergency
3 day
condition. (air absorber, ladder, rope, etc)

4 Prepare the lifting equipment Use safety belt


Measure the concentration of oxygen and Measurement should be done and recorded by leader
5
hazardous gas prior to work
6 Use ventilation Hydrogen sulfide : less than 10ppm, Oxygen : less than 18%
Set restricted area for unauthorized person
7 Law 585
and post the sign in a place with good visibilty
Check the workers when enter and exit the
8 Appoint a warden
working area
Use air respirator equipment or air supplied
9 Oxygen below 18% Law 593
mask
Display "caution of the opening" on the safety
10
fence

- 33 -
Slinging equipment
Heavy equipment 7-1 and slinging works

Wire rope hanging angle, safety door

Instructor

Crane
operator

Slinging
operator

Related
No Working points Vital points
document
1 Appoint an incorporated worker and an instructor Instruction should be directed from 1 instructor
More than 1 Ton (Person who has completed
skill training course for slinging activity)
Incorporarated worker (instructor) should have qualification
2 Less than 1 Ton (Person who has completed
certificate depends on the crane capacity
special education for slinging activity)
(See the crane safety manual)
3 Do not stand below the hanging load Post a warning sign
Install radio contact or an intermediaries depend
Instructor shall stand on safe area with a good visibility to on condition
4 crane. Direct a brief explanation about the instruction method
Instruction method (Swing arm method, whistle
before starting to works
blow method)

Check and inspect the wire rope and hanging load before See the list above
5
used Wire with stand is prohibited
6 Set all hook with eye hook is a principle

Set the hanging load horizontally, then balancing the force on


7
hanging tools rope

Winding the wire rope slowly and calmly. When the wire is
8 strained, stop the crane for a moment. Check the condition of
wire

Check the stability of hanging load in position 20cm from Stop the crane for a moment after grounding off.
9
surface Then, lift it to predetermined height

- 34 -
Heavy equipment 7-2 Mobile crane operation

Certificate based on the capacity of mobile crane


Lifting capacity more than 5 tons : Person who has license
Lifting capacity less than 5 tons : Person who has completed skill traininig
Lifting capacity less than 1 ton : Person who has completed special
education

Work are not allowed under the strong winds


(Maximum wind speed during lifting operation is 10m/s)

Related
No Working points Vital points
document
1 Complete the crane with the inspection certificate For lifting load more than 3 Ton
2 Crane operator should has qualification certificate
Check the dislocation protector for hook

3 Check the crane before starting operation


Check the operating condition of over winding
prevention device
See the list
4 Check the crane prior to operation
Inform to related division
5 Check the hanging load weight and working radius
Conduct countermeasures for ground sinking
Prepare enough space and steel plate to prevent the cargo
6
from collapse, and also install the outrigger check the overload prevention device

Mark equipment and compartement


7 Display a prohibited area sign in radius of working area

Clarify and inform the system about the working method, Confirm the instruction method and work
8
collapse prevention, and placement of workers description

Crane operator is not allowed to leave the operator's seat Wire rope also is considered as load
9
when the load is still hanging

- 35 -
Vehicle type of construction
Heavy equipment 7-3 machine work

For inspection in
operation

For registered inspector

No Working points Vital points Related document


Machine weight more than 3 Ton : Person who has completed skill
training
1 Operator should has a qualification certificate
Machine weight less than 3 Ton : person who has completed
special education
Confirm the special inspection checklist form Check whether the inpection seal is attached or not. (see
2
and inspect the machine before used illustration above)
3 Prepare head guards Danger place, such as rock fall place
4 Do the activity based on work plan Operating road, working method, checking the burried object, etc
Check the safety of unloading work method
5 Determine the procedure for loading and unloading the self loader
(during transport)
Keep the stability level and the maximum load
6
weight based on the manufacturing company
Conduct actions to prevent contact during
7 Place a warden and display the prohibited area sign
operating
Stop the engine and unplug the key when the
8 Take down the working device and lock the side brake key
workers leave the driver seat
Do not operate the equipment outside of
9 admitted operation based on structure Do not use it outside of its function
machine
Ensure to conduct desorption of repair or
10 Appoint the working leader
attachment
11 Keep the vehicle in safe position Land slide, end side of opening part collapse, falling prevention

- 36 -
Other 8-1 Grinding operation

Related
No Working points Vital points
document
Trial test after part change should be done by person who has Trial test should be more than 3
1 Law 118
completed the special training minutes
Before start working
2 Check whether there is any damage or crack on grindstone
Keep the spare part in the case
3 Check before used and trial test More than 1 minutes Law 118
4 Install the safety cover of grindstone Diameter more than 50mm Law 117
5 Prevent workpiece to fly
6 Use dust mask and dust proof glasses National assay Law 593
7 Do not use saw blade to replace the grindingstone For used outside its function
Check the label of grindingstone. (peripheral
Use the equipment with speed more than maximum speed is
8 velocity)
prohibited

9 Prevent the flying sparks from grindingstone See page 30

- 37 -
Handling work of vibration tool
Other 8-2 (such as chipping)

About implementation of comprehensive


countermeasure for vibration failure
Reference (first group 0710 part 7 June, 10 2009)

No Working points Vital points Related document


Person with qualification certificate should be
1
involved
2 Prevent the dust from spreading Water spray and ventilation Law 577
3 Prevent the chipping glass to fly
4 Use dusk mask and dust proof glasses National assay Law 593
5 Use earplug Law 593
6 Use anti vibration gloves and safety shoes Law 594

Less than 2 hours per day, less than 10 - 30 minutes for continue
7 Working hours should not exceed the standard
use (depend on equipment)

- 38 -
Safety And Health Manual Guidance

December, 1982 1st version Created by Toyota Motors safety and health cooperation

April, 1988 2nd version Revised to Toyota Common Manual by Zen Toyota Safety Division

December, 1994 3rd version Revised by Toyota Safety and Health Cooperation Material Subcommittee

October, 1997 4th version Revised to "Liaison Committee responsibility and education work" by by
Zen Toyota Safety Division
April, 2002 5th version Revised by Toyota Safety and Health Coorporation Materials
Subcommittee. Approved by Zen Toyota Safety Division
October, 2006 6th version Revised by Toyota Safety and Health Coorporation Materials
Subcommittee. Because of the folding rules inside Toyota, the name of
Zen Toyota is erased
October, 2009 7th version Revised by Toyota Safety and Health Cooperation Material Subcommittee

7th Version Editor Toyota Safety and Material


Health Subcommitee
Coorporation

Mr. Sugisaka Takenaka Engineering Mr. Sugawara Toyota Tsusho Corp

Mr. Imaba Araki Manufacturing Mr. Kamiya Itou Enineering

Mr. Mizuno Maeda Engineering Mr. Shingu Toyotomi Kiko Corp


Mr. Tsuzaka Sanki Industry Corp Mr. Kamiya Meiwa Industries Corp
Mr. Kameda Midori Anzen Corp Mr. Shitamachi Daidan Corp
Mr. Tsutsui NIPPO Corp Mr. Unou Daidan Corp
Mr. Maeda Toyota Safety and Health Coorporation Mr. Shimadu Toyota Safety and
Health Managemnet
Corp
Mr. Matsumoto Toyota Safety and Health Coorporation

Supervision Mr.Ishikawa (Toyota Motor Corporation Safety And Health Division)

Issued by Toyota Motor Company


Toyota Motor Safety And Health Cooperation

Replication is not allowed

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