Asia Pacific Safety Training Center AP-STC TOYOTA DAIHATSU ENGINEERING & MANUFACTURING CO.,LTD (TDEM)
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On behalf of Toyota Daihatsu Engineering & Manufacturing (TDEM), I would like to express my gratitude to all stakeholders, who have been promoted Safety Activities and Training in AP Region through Asia-Pacific Safety Training Center (AP-STC). From the basis of the Toyota’s philosophy for Safety & Health by Mr. Eiji Toyoda, former president of TOYOTA MOTOR CORPORATION, AP-STC has been established in order to develop Safety Training, which is the key to build up Human Safety (Knowledge, Mind/Awareness & Sense). From above reason, AP-STC play very important role to support Safety Training Establishment for all Asia Pacific Manufacturing Companies (ASMCs), AP ALL TOYOTA, Suppliers and Contractors in Asia Pacific Region. Along with providing direct training for TDEM, TMT and STM Employees, Thai All Toyota Companies, Suppliers and Contractors located in Thailand. Finally, I truly believe that all stakeholders will sustain own operation & activity with “Zero Accident” at the Inter-Dependent level of Safety Message fromPresident of TOYOTADAIHATSUENGINEERING &MANUFACTURINGCO.,LTD. SafetyDeclaration “Safetyismytoppriorityand Iwillleadforsafety” Mr. Y. Konishi (President) Toyota Daihatsu Engineering & Manufacturing 3
CONTENTS Overview Outline of Asia Pacific Safety Training Center General Information Outline of Safety Training Course Overview Training Courses Training Curriculum Course Description Appendix Prerequsition & Qualification of Trainee 4 Improvement & Develop of AP-STC 5 6 11 13 13 14 15 16 33 34
Overview AP-STC Asia Pacific Safety Training Center Outline of Asia Pacific Safety Training Center General Information Outline of Safety Training Course Overview Training Course 5
Outline of Asia Pacific Safety Training Center AP-STC under Safety Promotion Department a prat of Manufacturing Group in Toyota Daihatsu Engineer & Manufacturing (TDEM) has been established since 2008 to promote safety activity in Asia Pacific region in term of Safety Management, Accident case information sharing, Machine Safety and Construction Safety. In the past, many Fatal and Lost Working Day accidents occurred in our region mainly caused by specific work operation and machine. Therefore, we started promoting many activities, including Accident case information sharing and developing 6 specific hazard work training program by cooperation from TMC Safety & Health Promotion Division and ASMCs as model plants. Meanwhile, Machine risk assessment and assessor development program were developed and educated to ASMCs to eliminate accidents from machine. We continued to promote safety activities in Asia Pacific region based on accident analysis result until we could achieve some levels of accident reduction. In year 2012, market demand for TOYOTA’s vehicles in Asia Pacific region rapidly increases. Some ASMCs and Suppliers have been expanding their production capacity by constructing new plants, installing equipment and recruiting new employees. Consequently, these activities cause an increase of Fatal and Lost Work Day accident cases, not only for ASMCs but also for Suppliers and Contractors as well. As TDEM & TMC always realize the importance of Human development concerning safety knowledge, awareness, mind & sense of employee, we have decided to officially establish Asia Pacific Safety Training Center (AP-STC) on October 4, 2013 aiming to be a master model of safety training in Asia Pacific and provide safety education to TDEM, Thai affiliates, ASMCs, AP ALL TOYOTA companies, Suppliers and Contractors and expend scope to support Government, State enterprise, Public organization and University in year 2021 for sustainability of safety, which is the key to achieve Zero Accident. 6
What is Asia Pacific Safety Training Center (AP-STC) Safe work Reliable work Skilled work Safe work is "the door" to all work. Let us pass through this door. Eiji Toyoda, 1957 Former TMC President (1967-1981) Thinking way of Safety : The principles of Toyota Basic Philosophy for Safety by Mr. Eiji Toyoda are AP-STC is responsible for Safe work training, to support all trainees Subsequently, Reliable and Skilled work would be developed by each company in order to ensure safety, quality and productivity in AP Region 7
Safety Strategy to achieve“0”Accident "Need Safety Human Enhancement" 8 This is our Strategy to achieve “Zero Accident” in AP region. There are 2 Pillars and 1 basement 1ˢᵗ Pillar is about Human Safety. Safety Human development is one of the key to achieve inter-dependent level of safety culture which everyone cares for others. Thus we need to provide knowledge to our employees in order to increase safety mind and sense. 2ⁿᵈ Pillar is about Safe Workplace. We need to ensure that all employees work under good condition of workplace in every area for this pillar including safe condition of Machine & Safety device using in each workplace and also ensure about worksite environment maintained & keep in good condition such as Lighting, Sound, Heat…etc. Fundamental is the basement to drive all safety to reach interdependent level of safety to ensure “Zero accident” achievement from each pillar including Safety Culture, Safety activity management, System (OSHMS) and Accident Yokoten & Yarikiri.
AP-STC Mission 1 ) To develop theoretical and practical safety training to be a master model in Asia Pacific region under PDCA concept. 2 ) To support ASMCs to establish safety training courses and ensure safety training content is implemented efficiently. 3 ) To conduct direct training for Thai TOYOTA affiliates, All TOYOTA Groups, Suppliers and Contractors. How to develop Safety training 9 (5) Trainer EVA by TMC / Master Trainer (6) Can conduct training to trainees TDEM & ASMCs (2) Join Training at TMC (If available / Other) (1) Gather Knowledge / information from TMC / Other Sources (3) Develop training content & facility (4) Simulate training and practice (7) Regional Master trainer Can Support AP region Train the trainer Improvement Training Material Continue Develop Be a Trainer Pass TDEM
TOYOTA INDUSTRIES CORPORATION AICHI STEEL CORPORATION Our Customer 6. Others TOYOTA TSUSHO CORPORATION TOYOTA BOSHOKU ASIA CO., LTD. HINO MOTOR, LTD. JTEKT CORPORATION AISIN SEIKI Co., Ltd. TOYOTA MOTOR EAST JAPAN, INC. Vietnam (TMV) Pakistan The Philippines Thailand (IMC) (TMP) (TMT, STM) TOYOTA AUTO BODY CO., LTD. DENSO CORPORATION TOYODA GOSEI CO., LTD. Asia Sale & Manufacturing companies India Indonesia Malaysia (TKM, TKAP) (TMMIN) (ASSB) 1. TDEM 2. ASMCs : AP-STC aims to provide safety training courses for all members as ; 4. Supplier 5. Contractor 3. AP All TOYOTA Groups (Example) 10 Myanmar (TMY) University Government State enterprise Public organization
General Information BTS ปู่เปู่จ้าจ้ Name : Established : Location : Address : Asia Pacific Safety Training Center (AP-STC) October 4, 2013 3rd Floor behind Head Office 2 building (TMT Samrong plant) 274 Moo 9, T.Theparak, A.Muangsamutprakarn, Samutprakarn 10270 Building Area : 3,750 Square meters Training Room : 6 Rooms Training Station : 14 Stations Concept : To be a master model a safety training in AP region under PDCA concept Capacity : 50 Trainees / Day 11
Safety Promotion (SEP) Safety Engineering (SEN) AP-STC Operation (ASO) Training Management (Reginal Trainer, Trainer, Trainee) Training Plan Training Administration Budget and Expense Manage client relationship and Trainee in formative Training Database Management Organization Safety Promotion Safety Management (SMS) AP-STC Operation (ASO) Training Strategy and Development Trainer Development Process and Basic Requirement Training Facility and Tool Maintenance & Management Support ASMCs for trainer development & Training Training quality assurance & improvement AP-STC Training (AST) Asia Pacific Safety Training Center Safety Promotion Dept.(ST) Asia Pacific Safety Training Center (AP-STC) AP-STC Training (AST) 12
D. Basic Safety Awareness Training Trainin g for n e w e m plo y e e (E d u c atio n u p o n hirin g) A. Role-based Training B. Hazardous Job (License) Training C. Specialist Training Toyota Safety TrainingStructure <---K n o wle d g e & S kill a s p e c t s---> New employee General employee Supervisor Management Aw are n e s s & m a n a g e m e n t a s p e c t s 13 A. Role-based training Manager role Occupational based Safety & Health for Newcomer B. Hazardous Job (License) Training Crane & Sling Forklift Gas Welding High Place Work Low Voltage Electrical work Robot Teaching In-Machine Work Electric Vehicle Work Safety C. Specialist Training Anzen Leader Construction Safety Management Ergonomics Principle Ergonomics principle & Assessment Machine Safety Standard & Risk Assessment Machine Safety Inspection D. Basic Safety Awareness Safety Awareness Fire & Explosion (Safety Dojo & & Accident Simulation) Kodokan Hydrogen Future
AP-STC Training Course Establish Asia Pacific Safety Training Center (AP-STC) 2012 2013 2014 2015 2017 2018 2019 2020 2023 2024 Development Anzen Leader In machine work Conduct safety training Forklift Crane & Sling M/C safety risk assessment Gas welding High Place work Develop training course Basic Safety Awareness Robot Teaching Low Voltage Electrical work *M/C safety device check Develop training course Ergonomics Develop training course Construction Safety Fire & Explosion Kodokan Develop training course Management Role based Training Role based Training for GL Develop training course Manager (KY DOJO) Manager role based Training Develop training course M/C Safety Inspection Electric Vehicle Work Safety Develop training course Future Develop training course ~ to be continued 14 Remark *M/C safety device check combine with M/C Safety Standard & Risk Assessment Apr 2022 onwards
Training Curriculum AP-STC Asia Pacific Safety Training Center Course Description 15
OBJECTIVES : Understand role & responsibility of job leader in construction / Machine installation work Acknowledge the safety rule to control construction work inside TOYOTA premise Enhance KY ability by KY3R method / Machine installation work Understand time frame of construction / Machine installation work and what to do in each period Utilize work instruction of construction / Machine installation work Understand key point for giving instruction to subordinate Understand correctly response to emergency case PROPOSE : Participants are able to To develop Job Leader for control Construction & Equipment installation at work site to achieve (Concept of S.Q.D.C Safety, Quality, Delivery and Cost TARGET GROUP : Workshop Session 2 Days (Lecture 1.5, Workshop 0.5) Foreman of contractor or job leader at work site Job controller, Job planner, Project leader of construction / Machine installation work Safety leader at construction site (Minimum 0.5- 1 year experience is preferable) Anzen Leader Training Period of training (Day) TRAINING CONTENT : Class capacity 20 Persons Lecture Session Role of Anzen leader Safety rules for work operation Kiken Yochi training (KYT) Duty and responsibility of Anzen leader Work instruction Countermeasures against abnormal situation Create work instruction sheet Role play as Anzen Leader to instruct work to member Training Atmosphere : 20
To ensure that all concerned parties about construction and equipment installation (Safety, Project owner, Area owner, contractor) know Construction safety management, able to implement and control project align with Toyota requirement that lead to achieve Zero accident during construction and equipment installation period PROPOSE : OBJECTIVES : Understand detail of safety management system. Understand make Denwacho and JSA for construction & E/Q installation To know facilities standard for site preparation. To know safety activity that have to conduct during work. Can adapt the requirement to be a guideline of company practice. Participants are able to TARGET GROUP : Construction Safety Management Training TRAINING CONTENT : 2 Days (Classroom 1, Workshop 1) Period of training (Day) Class capacity 16 Persons Classroom session Project planer, Area owner & Safety officer Accident in construction work & Thai law regarding construction & installation work. Overall construction safety management (from biding until after project) Construction Planning (pre-condition list, schedule, organization, Denwacho, WI, RA & overlap work management) Safety Requirement (Training program, Work permit, Safety Activity, Site Facility & standard, Document support) On site implementation (Main hazard & preventive measure) Training Atmosphere : 28
TARGET GROUP : OBJECTIVES : Acknowledge crane work regulation according to Thai Laws and TOYOTA safety rule Check condition of crane and lifting equipment before crane work Select and handle lifting equipment properly Perform rigging work safely Operate crane safely under TOYOTA safety rule Give signal to crane operator corresponding with the standard signal in Thai Laws Estimate the weight of lifting load to be lifted safely with safety factor PROPOSE Participants are able to : To develop skilled member to be crane operator, crane signaler, rigger and crane work controller for overhead crane work Practical Session Give signal to crane operator Weight estimation and perform rigging work Rigging tool selection Technique to stop swing load Operate crane L- course and full course 3 (Theory 1.5, Practical 1.5) Crane operator Crane signaler Crane & Sling Training Period of training (Day) TRAINING CONTENT : Class capacity Classroom : 15 Persons Practical : 5 Persons Classroom Session Thai Laws concern with crane work Type of crane and definition of crane technical term Crane structure & safety device Mechanic & Electric concern with crane work Safety regulation of overhead crane work Safety sign concern with crane work Lifting equipment handling and selection Rigging method Rigger Crane work controller Training Atmosphere : 17
To build up knowledge about safety of electrical vehicle, Battery and increase safety awareness of worker who conduct electric vehicle related work PROPOSE : OBJECTIVES : Understand principle of electric vehicle, battery and its components Understand hazard of electric vehicle and battery & Conduct work with safety Participants are able to TARGET GROUP : Electric Vehicle Work Safety Training TRAINING CONTENT : 1 Days (Classroom 0.5, Practical, 0.5 ) Period of training (Day) Class capacity 20 Persons Classroom session Person who work in battery assembly process Person who do maintenance work for electric vehicle Person who do development, test and quality check for electric vehicle and battery Related laws & Toyota EV requirement Basic knowledge of electricity, Basic knowledge of Electric Vehicle Basic PPEs and Tools for safe work with Electric Vehicle Safe operation method for Electric Vehicle Practical session Safe operation for EV maintenance Electric shock rescue - Components of Electric Vehicle and Battery - Past incident - Hazard of Electric Vehicle and Battery - Fire extinguisher (Type & Method) EV Dojo Training Atmosphere : 31
OBJECTIVES : Understand about basic knowledge of ergonomics Understand about Musculoskeletal Disorders (MSDs) and how to avoid them Understand key aspects of ergonomic design and how to apply Ergonomic Design Guidelines to improve safety, increase efficiency and productivity in workplace Identify/ check for ergonomic concerns in production line by utilizing JT & SJT or TEBA & MEBA tools to identify ergonomic issues Understand ergonomics in daily management Participants are able to TARGET GROUP : Practical session Safety, Supervisor and Engineer Ergonomics (TEBA&MEBA) Training TRAINING CONTENT : To develop a proactive mindset & knowledge about ergonomic activity which will reduce the risk of employees getting musculoskeletal injuries (MSDs) caused by manual handling activities PROPOSE : Period of training (Day) 3 Days Day 1 : Classroom Day 2 : Classroom + Practical Day 3 : Practical Class capacity 15 Persons Classroom session Introducing Ergonomics Musculoskeletal Disorders (MSDs) General Ergonomic Principles and Design Guidelines Ergonomic Assessment Tool (TEBA and MEBA) Ergonomics in Daily Management Ergonomic Guideline Forces, Postures, Weights, Tools, Working Heights Ergonomic Assessment Simulation (TEBA & MEBA ) *TEBA = Toyota Ergonomic Burden Assessment **MEBA = Material Handling Ergonomic Burden Assessment Training Atmosphere : 23 * ** * **
To develop a proactive mindset & knowledge about ergonomic activity which will reduce the risk of employees getting musculoskeletal injuries caused (MSDs) by manual handling activities PROPOSE : OBJECTIVES : Understand about basic knowledge of ergonomics Understand about Musculoskeletal Disorders (MSDs) and how to avoid them Understand key aspects of ergonomic design and how to apply Ergonomic Design Guidelines to improve safety, increase efficiency and productivity in workplace Identify/ check for ergonomic concerns in production line by utilizing JT & SJT or TEBA & MEBA tools to identify ergonomic issues Understand ergonomics in daily management Participants are able to TARGET GROUP : Practical session Engineer who design machine and process in workplace Ergonomics (Principle) Training TRAINING CONTENT : 1 Day (Classroom 0.5, Practical 0.5) Period of training (Day) Class capacity 15 Persons Classroom session Introducing Ergonomics, Musculoskeletal Disorders (MSDs), General Ergonomic Principles and Design Guidelines Briefly Overview of Assessment Tool (JT, SJT & TEBA) Ergonomic Design Guideline (Forces, Postures, Weights, Tools, Working Heights) Training Atmosphere : 24 * ** [*For Toyota only]
To enhance Fire & Explosion Knowledge and Awareness of all members and strengthen Fire & Explosion prevention PROPOSE : OBJECTIVES : Understand importance of fire & explosion and past accident cases Composition of the fire Fire source & prevention in TOYOTA Gain virtual experience thru simulations Understand how to handle when fire situation occurred Fire & Explosion prevention activities Participants are able to TARGET GROUP : Fire and Explosion Kodokan Training TRAINING CONTENT : 0.5 Days (Classroom 0.25, Workshop 0.25) Period of training (Day) Class capacity 15 Persons Classroom session All TDEM employee & Interested persons Top Mangement Speech to prevent Fire & Explosion History of Fire & Explosion and example case in TOYOTA Pinciple of fire occurrence Source of fire & explosion in TOYOTA Fire prevention principle How to response in case of Fire & explosion occurred Fire prevention activities Training Atmosphere : 28 Practical session Electrostatic Simulation Wire Loosen Simulation Grinding Work Simulation Dust Explosion Simulation Fire Alarm Simulation
To give the basic knowledge and key point about forklift driving & Forklift license to forklift operator PROPOSE : OBJECTIVES : Understand safety operation Step by Step Understand safety key point for forklift driving & can operate forklift safely Understand basic of forklift inspection Understand about basic calculation concern with forklift operation Participants are able to TARGET GROUP : Practical session Employee who have to drive the forklift Employee that have to do operation concerning forklift & F/L driver supervisor Forklift Training TRAINING CONTENT : 2 Days (Classroom 1, Practical 1) Period of training (Day) Class capacity Classroom : 8 Persons Practical : 4 Persons Classroom session Overview of Forklifts Control of Forklifts Dynamics Related Law & Requirements and TOYOTA Safety rule for Forklift Operation Step 1: Moving Forward, Backward & Forklift Step 2: Driving without a pallet in the Step 3: Driving without a pallet in the Step 4: Driving with a pallet in the full Step 5: Driving with a pallet in the L- course Step 6: Driving with a pallet in the half course Step 7: Driving with a pallet in the full course Control L- course full course course (No Stacking) Training Atmosphere : 25
OBJECTIVES : To enhance basic knowledge about gas and gas welding equipment, and increase safety awareness of gas welding to operators. PROPOSE : Operate gas welding safely. Can identify hazard of gas welding and countermeasures Understand how to check gas welding equipment Participants are able to TARGET GROUP : Practical session 2 Days (Classroom 1, Practical 1) Person concerned with gas welding Gas Welding Training Period of training (Day) TRAINING CONTENT : Class capacity 8 Persons Classroom session Basic knowledge about combustible gas & oxygen Structure and handling of gas welding equipment Safety operation & Safety rules of gas welding work Hazard of gas welding operation and examples of accident case. Laws & Regulations related with gas welding How to install and remove regulator properly How to check gas leakage How to adjust gas pressure for use How to safely ignite, extinguish and adjust fire and flame Basic 1 + Basic 2 Basic 1 : Basic 2 : Basic 3 : Training Atmosphere : 22
TARGET GROUP : OBJECTIVES : Practical Session 2 Days (Theory 1, Practical 1) Working at height Safely Control, Check & Advise subordinate for working at height Understand basic for High Place PPEs, Tool & E/Q inspection Understand basic knowledge of rescue & support operator Manage Work at height job follow standard & principle to prevent the accident Participants are able to High Place Work Training (For Controller) Period of training (Day) TRAINING CONTENT : Class capacity 15 Persons Classroom Session Basic knowledge of working at height Law, Regulation & Safety Rule for working at height High Place Work Management Fall Protective Equipment Fall Prevention principles Fall Calculation & Effect of falling - Equipment & Facility for working at height Basic Principle for Rescue Example of accident for working at height (Root cause & Countermeasure) Roof Work Safety, Related E/Q & work method PPEs & Tools inspection for controller Scaffolding & A ladder composition and Inspection Working at height Simulation Job Leader / Job Planner /Job Controller, who have to take care High Place Operation PROPOSE : To give working at height related knowledge, practice & Control principle for High Place Work Controller Training Atmosphere : 18
TARGET GROUP : OBJECTIVES : Practical Session 1 Days (Theory 0.5, Practical 0.5) Operator or anyone, who have to do work at height Understand basic knowledge before working at height Understand & Comply with Safety Rule for working at height Understand & do the correct practice when working at height Understand past accident & root cause to prevent accident reoccurrence Understand how to correctly use PPEs, Equipment & Tool when working Participants are able to PROPOSE : To give the basic knowledge & practice for High Place Work Operator High Place Work Training (For Operator) Period of training (Day) TRAINING CONTENT : Class capacity 15 Persons Classroom Session Basic knowledge of working at height Law and Regulation Rule & Standard for working at height Fall prevention principles & PPEs Example of accident for working at height Roof work safety & basic principle PPEs & Tools inspection & Usage Working at height Simulation Training Atmosphere : 19
Practical Session Pneumatic control system simulator (Residual pressure demonstration) Electrical control system simulator (one cycle continuous mode, machine waiting condition demonstration) Simulate machine troubleshooting work inside machine PROPOSE : To prevent “caught in machine” accident occurrence. To enhance troubleshooters knowledge and safety mind when working inside machine Classroom Session Danger while working inside machine Machine structure How to prevent getting caught/pinched when working inside the machine Related laws and regulations Inside machine safe work operation Designated troubleshooters Understand the cause of "Caught in machine" incident according to TOMEZU case Understand the structure of machine control system (Electric, Pneumatic, Hydraulic) Understand danger of residual pressure and countermeasure Understand the regulation and concept to prevent "Caught in machine" incident Understand concept of lock out handling and application Understand TOYOTA safety regulation and Thai laws while working inside machine Understand the process to designate the machine troubleshooter Perform machine troubleshooting work safely Participants are able to 2 (Theory 1, Practical 1) A person who work with machines and those who go to fix when machine have any trouble the preliminary machinery TARGET GROUP : OBJECTIVES : In-Machine Work Training Period of training (Day) TRAINING CONTENT : Class capacity 10 Persons Training Atmosphere : 16
To build up knowledge about safety operation of low voltage electrical work and increase safety awareness of worker who conduct electrical work PROPOSE : OBJECTIVES : Understand about Thai law & regulation that concerned electricity Understand basic knowledge of electrical work instruction & rules Understand how to use equipment, tool and personal protective equipment (PPEs) Understand about how to inspect electrical tool & equipment follow Toyota construction equipment & tool management system Understand low voltage rescue procedure and basic life support (BLS) Participants are able to TARGET GROUP : Practical session Person who have to conduct or control electrical work Exception : Persons who have a Heart disease, Asthma or cannot exercise in long times will be excepted in CPR practical part. Because they could get injury during practice. Low Voltage Electrical Work Training TRAINING CONTENT : 2 Days (Classroom 1, Practical 1) Period of training (Day) Class capacity 20 Persons Classroom session Thai law regulations Sample accident information Basic knowledge of electrical theory, Hazards & Safety protection Safety inspection & testing of electrical equipment Electrical work instructions & rules Low voltage rescue procedure and Basic life support (BLS) Accident simulation device Basic tool and equipment Actual CPR training Training Atmosphere : 26
To ensure safety awareness, safety knowledge and the role of Manager in Safety PROPOSE : OBJECTIVES : Understand role & responsibility of Manager to manage safety in workplace Understand OSHMS & safety training structure to assign work properly Enhance work risk assessment in all jobs Able to manage & control specific work such as M/C, construction, ergonomic Understand role & responsibility when accident occur Recognize & understand accident in the pass to promote accident prevention Create safety culture & good work atmosphere "Bad new first" Participants are able to TARGET GROUP : Manager Role Based Training TRAINING CONTENT : 1 Days (Classroom , Practical & Workshop 1) Period of training (Day) Class capacity 20 Persons Classroom session Management Position in Manager Level Manager basic safety role Safety experience sharing by GM Global OSHMS & Toyota safety training system Machine safety Construction safety Ergonomics Accident responsibility Practical session AP Serious accident learning Machine safety Technical KY DOJO : Kaizen shop Session Workshop Building safety culture Safety commitment Training Atmosphere : 29
Person who inspect new and modified M/C (ex. SEIBI, ES, Production, MTN, Safety, Kaizen & Karakuri team) Person who conduct periodical inspection of safety device / risk protection (ex. Safety, MTN) To build up knowledge about basic safety machine inspection since design phase until finish installation in order to ensure the machine are safety before handover to production. To build up knowledge about periodically inspection for safeguard devices in order to ensure the safety function of machine can be maintained. PROPOSE : OBJECTIVES : Understand and able to conduct machine inspection since design until finish installation Understand and able to conduct periodical inspection for safeguard devices Participants are able to TARGET GROUP : Machine Safety Inspection Training TRAINING CONTENT : 2 Days (Classroom 1, Practical 1 ) Period of training (Day) Class capacity 20 Persons Classroom session Machine safety assurance system, Power ON & Total link system (TLS) Basic machine safety inspection item for design & installation Maintain safeguarding function system Basic start-up devices & safeguarding function inspection Practical session Machine safety inspection item for design & installation Machine start-up devices & safeguardingfunction inspection PREREQUISITE : Basic Machine Safety for Designer & Risk assessor Basic Troubleshooting (In - Machine) Training Atmosphere : 32
To build up knowledge about machine risk assessment, inherent safe machine and basic machine safety standard in order to identify machine hazard and consider safety measure by risk assessment PROPOSE : OBJECTIVES : Understand and able to conduct machine risk assessment. (Determine machine limit, Hazard identification, Risk estimation, Risk evaluation) Understand inherent safe machine and basic machine safety standard. Participants are able to TARGET GROUP : Practical session Machine Safety Standard & Risk Assessment Training TRAINING CONTENT : 2 Days (Classroom 1, Practical 1 ) Period of training (Day) Class capacity 20 Persons Classroom session Machine risk assessment practice with machine simulation Person who design machine (ex. Production engineer [PE], Engineering service [ES], Production, Kaizen & Karakuri team) Person who do machine risk assessment (ex. PE, ES, Production, Kaizen & Karakuri team) Person who confirm safety standard/ risk protection on design & installation (ex. Safety, Maintenance) Machine risk assessment Basic machine safety standard Inherent safe machine Safeguarding of machine safety standard Energy source disconnection/stopping of machine safety standard Protection against inadvertent start up of machine safety standard Start-up of machine safety standard Robot related measure safety standard Unmanned vehicle safety standard Electricity related measure safety standard Stair and ladder safety standard • Hoist using plain trolley installation safety standard Training Atmosphere : 27
OBJECTIVES : To build up knowledge about safety operation of robot teaching and increase safety awareness of robot teaching members PROPOSE : Understand the danger of robot and sample cause of robot concerned incident Understand basic structure and type of robot Understand robot controlling system Understand method and basic concept of robot teaching function Understand safety measure while working with robot - Understand the safety regulation while working with robot Perform robot teaching operation according to TOYOTA standard / rule Participants are able to TARGET GROUP : Practical session 2 Days (Classroom 1, Practical 1) Persons concerned with robot teaching operation Robot Teaching Training Period of training (Day) TRAINING CONTENT : Class capacity 10 Persons Classroom session Basic knowledge of robot Dangers of robot and countermeasures Robot safety operation Related laws and regulations Inspection before robot teaching work Confirmation of emergency stop function Robot movement confirmation Perform robot teaching operation PREREQUISITE : Completed basic machine troubleshooting training course (In-machine work training) Training Atmosphere : 21
To give basic knowledge of safety principle and enhance safety awareness of member to prevent accident occurrence PROPOSE : OBJECTIVES : Understand the basic safety principle to stop accident Understand the definition of STOP6 incident Understand the category of safety measure according to hierarchy of control theory Understand concept of KY and risk assessment Understand emergency response and accident YOKOTEN concept Understand concept of 4S linkage with safety Understand TOYOTA safety culture & Philosophy Learning and get the knowledge & awareness thru actual simulation Participants are able to TARGET GROUP : Safety Awareness Training TRAINING CONTENT : 1 Days (Classroom 0.5, Practical, 0.5 ) Period of training (Day) Class capacity 15 Participants Classroom session Newcomers , Safety officer ,Safety Leader , Job Supervisor ,Job Leader & Anyone who interested in basic safety knowledge Basic definition of safety (Safety, Hazard, Risk, Accident) STOP6 - Basic safety principle (Unsafe Act. & Unsafe condition, Stop-Call-Wait, etc.) KY ability and risk assessment Hierarchy of hazard control Emergency and accident response Accident YOKOTEN TOYOTA safety culture & Philosophy Practical session Safety DOJO simulator (14 stations) Accident simulation (6 stations + 2 VDO clips) KY DOJO Training Atmosphere : 30
Appendix AP-STC Asia Pacific Safety Training Center AP-STC Training Course Overview 33
Training Course Training Duration Expiration Duration Target Group Prerequisition Hazardous work 1.Crane&Sling Training (CS) 3 Days 2 Years Crane operator Crane signaler Rigger Crane work controller 2.Crane & sling Refreshment Training (CR) 1 Day 2 Years ↑ Need to pass Crane&Sling Training (CS) and certification expired less than 12 month.* 3. Forklift Training (FL) 3 Days 3 Years Employee who have to drive the forklift Employee that have to do operation concerning forklift & F/L driver supervisor Have driving license or forklift driving experience at least 1 Yr. 4.Forklift Refreshment Training (FR) 1 Day 3 Years ↑ Need to pass Forklift Training (FL) and certification expired less than 12 month.* 5.Gas Welding Training (GW) 2 Days 3 Years Person concerned with gas welding 6.Gas welding Refreshment Training (GR) 1 Day 3 Years ↑ Need to pass Gas Welding Training (GW) and certification expired less than 12 month.* 7.High Place Work for Controller Training (HC) 2 Days 3 Years High Place Work Controller Project Controller & Owner 8.High Palce work for Controller Refreshment Training (HCR) 1 Day 3 Years ↑ Need to pass High Place Work for Controller Training (HC) and certification expired less than 12 month.* 9.High Place Work for Operator Training (HO) 1 Day 3 Years High Place Work Operator ( > 2 Meters) 10.High Place Work for Operator Refreshment Training (HOR) 0.5 Day 3 Years ↑ Need to pass High Place Work for Operator Training (HO) and certification expired less than 12 month.* 11.Low Voltage Electrical Work (LV) 2 Days 3 Years Person who work relate to installation, inspection, testing, fixing, maintenance or other duties in the same manners with electrical system, electrical equipment or electric cable. 12.Low Voltage Electrical Work Refreshment Training (LR) 1 Day 3 Years ↑ Need to pass Low Voltage Electrical Work (LV) and certification expired less than 12 month* or Passed Government electrical work training. 13.Robot Teaching Training (RT) 2 Days 3 Years Persons concerned with robot teaching operation Need to pass In-Machine Work Training 14.Robot RefreshmentTraining (RR) 1 Day 3 Years ↑ Need to pass Robot Teaching Training (RT) and certification expired less than 12 month.* 15.In-Machine Work Training (IM) 2 Days 3 Years Persons concerned with In-machine work 16.In Machine Refreshment Training (IR) 1 Day 3 Years ↑ Need to pass In-Machine Work Training (IM) and certification expired less than 12 month.* 17. Electric Vehicle Work Safety Training 1 Day - Person who work in battery assembly process Person who do maintenance work with electric vehicle. Person who do development, test, quality check for electric vehicle and battery Specialist 18.Anzen leader Training (AL) 2 Days 3 Years Job leader or Foreman of contractor to be construction job leader at work site Job controller, Job planner, Project leader of construction work Safety leader at construction site 19.Anzen leader Refreshment Training (AR) 1 Day 3 Years ↑ Need to pass Anzen leader Training (AL) and License & certification expired less than 12 month.* 20.Construction Safety Management Training (CSM) 2 Days - Safety Project Owner Area Owner Contractor 21.Machine Safety Standard & Risk Assessment Training (RA) 2 Days - Person who design machine (ex. Production engineer [PE], Engineering service [ES], Production, Kaizen & Karakuri team) Person who do machine risk assessment (ex. PE, ES, Production, Kaizen & Karakuri team) Person who confirm safety standard/ risk protection on design & installation (ex. Safety, Maintenance) 22.Basic Machine Safety for Inspector (MI) 2 Days - Person who inspect new and modified M/C (ex. SEIBI, ES, Prod., MTN, Safety, Kaizen & Karakuri team) Person who conduct periodical inspection of safety device / risk protection (ex. Safety, MTN) Need to pass Machine Safety Standard & Risk Assessment Training Need to pass In-Machine Work Training 23.Ergonomic principle (EG1) 1 Day Safety Resource Supervisor - Engineer 24.Ergonomic principle & Assessment (JT,SJT,TEBS,MEBA) (EG4) 4 Days Safety Resource Supervisor Engineer Role base 24.Mananger Role Base Training (MR) 1 Day - Manager level Awareness 25.Basic Safety Awareness (SA) 1 Day - All 26.Fire & Explosion Kodokan (FK) 0.5 Day - All Government Law Government Law Government Law New ! Only TOYOTA Employee AP-STC Training Course Remark * = If certification expired more than 12 month, need to take Main Course Overview 34 For more information : www.AP-STC.com
Asia Pacific Safety Training Center (AP-STC) Revision 4 TOYOTA DAIHATSU ENGINEERING & MANUFACTURING CO.,LTD (TDEM) 274 Moo 9, Theparak, Muang, Samutprakarn 10270