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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.
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.
October, 2009
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 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
-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
- 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
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
Use flourescence vest in shipment area of logistic If forget to bring the flourescence vest, borrow it in hand each
5
division shipment area
Maintain the health and safety equipment to use Put in control box
10
it effectively
-3-
Common 1-4 Construction Control Board
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
7 Fill the KYM dangerous point with a sentence Multiple choice type is prohibited
-4-
Common 1-5 4S in working area
-5-
Common 1-6 Passage in field
String
concatenation Linchpin
-6-
Falling down 2-1 Work in high place (General)
and rolling down
2 hook safety
belt
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
-8-
Falling down Working with horse scaffolding
and rolling down 2-3
sticking out
part is danger !
Tied up
7 Install the scaffolding plate horizontally Lap portion : more than 20 cm, sticking out : less than 10 ~ 20 cm
-9-
Falling down Working on scaffolding and
and rolling down
2-4
work floor
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
11
Single-tube
scaffolding
- 11 -
Falling down Working with ladder
2-5 (movable type)
and rolling down
Prevent
dislocation
(tied up) More than
60cm
Around
Anti-slip
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
- 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
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
Caster (Stopper)
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)
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
- 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
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.
- 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
- 17 -
Falling down
2-11 Working near opening-area and pit
and rolling down
Restriced area
- 18 -
Electric shock 3-1 Common electrical operation
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
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.
- 19 -
Work with electric tools and equipment
Electric shock 3-2
(Including moving & portable)
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
- 20 -
Wiring the distribution electrical panel
Electric shock 3-3
for equipment & construction
Protector
cover
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
Fire Fire
extinguisher extinguisher
water
water
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
Electroscope
8 Check the illuminance intencity in working area More than 150 lux in working position Law 335
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
Lock used by
many people
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
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
Confirm the power transmission, air supply, working Ensure to inform the working procedures
1
range, process, etc prior to work
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
- 25 -
Adjustment and trial
Pinched 4-3 of the equipment
- 26 -
Pinched 4- 4 Loading and unloading
work of forklift
Instructor
For inspection on
Tilt operations
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
Prevention for
inadvertence removal of
linchpin put the door knob
put back mirror
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
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
- 29 -
Explosion and fire 5-2 Work using fire
Construction control
board
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
Fixed the
trolley
Eyewear protector
dust mask leather
gloves
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
- 31 -
Lack of oxygen Painting work
6-1
and toxicosis (using organic solvent)
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)
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)
- 33 -
Slinging equipment
Heavy equipment 7-1 and slinging works
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
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
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
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
- 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
- 37 -
Handling work of vibration tool
Other 8-2 (such as chipping)
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