GSS-M

CONFIDENTIAL

Global
Safety
Standard
for Machinery

GSM-0G-A ・Machine Safety Inspection Guide
・Machine Operations Safety Guide
・Machine Safety Design Manual
・Machine Design Risk Assessment Manual
・Construction Safety Work Guide



Issuance of GSS-M SUMITOMO RIKO Group

SUMITOMO RIKO Group Safety and Health Committee

Safety philosophy

Safety is our top priority for happiness
of all employees and prosperity of the
company.
We confirm the safety before starting
operations of the day.

10 principles of safety

1. Always keep in mind that safety is our top priority.

2. Have conviction that all kinds of injuries and
industrial diseases are preventable.

3. It is the responsibility of the company and
individuals to establish, sustain, and improve the
safe condition.

4. The management has the direct responsibility to
prevent injuries and industrial diseases.

5. It is the basic responsibility of individuals in the
society to follow the rules.

6. Sufficient education and training must be provided
to all employees to ensure safe operations.

7. Safety and health audit in which all employees take
part must be conducted to establish PDCA of the
safety and health control system.

8. Report and investigate all accidents as well as
unsafe actions and conditions leading to accidents.

9. All defects on safety and health must be remediated
immediately.

10. Cooperation and participation of all employees are
inevitable to attain our zero-accident goal.



Issuance of GSS-M SUMITOMO RIKO Group

Machine Safety Requirements

Concept underlying machine safety
People make mistakes Safety must be ensured irrelevant of experience

●Under the notion that people make mistakes, design machines that won't Fool-proof
cause harm even if personnel make an operational mistake.

Machine breaks down Safety must be ensured for operation, adjustment and maintenance

●Design machines that ensure safety even if safety mechanisms/circuits go Fail-safe
out of order.

Requirements for machine safety design

(1) Risk assessment (RA)
RA shall be started with the machine planning and design phases to reduce the applicable risk to the

level acceptable to machine users and ensure safety. What are required for this purpose are:
・RA implementation and safety evaluation per correct procedures and standards; and
・RA education/training to improve the skills required in order to not overlook hazards.
(2) 3 step method for risk reduction
・Inherently safe design measures
　Fully consider the feasibility of hazard elimination or risk reduction before immediately taking
　safeguarding measures.
・Safeguarding
　 Principle of separation: Select safeguards that can firmly separate or protect personnel from risks
　Principle of stoppage: Protection device shall inhibit personnel from touching hazards when the
　machine is running and only allow personnel to touch hazards when the machine is stopped.
　During RA, also consider the safety method in case protection systems fail to function.
・Complementary protective measures
　Devices complementing safeguarding measures such as emergency stop buttond, which rely
　on human behavior.
・Information for use
　Last resort to take only when other safety measures are not effective or safety cannot be ensured
　under specific usage conditions. Information for use must not be employed for the purpose of
　simplifying design or cutting down on cost.

Requirements for sections associated with machine safety

(1) Machine Planning Section
Consider risk reduction measures giving top priority to machine and user safety, being the section
that can take inherently safe design measures through RA of materials and manufacturing methods.

(2) Machine Engineering Section

Conduct the design phase RA to reduce risks in accordance with the 3 step method giving top priority
to the machine user's safety.
(3) Machine Using Section

Use the machine safely recognizing the machine's residual risk(s) and employing personnel
protection means such as work procedures, protective gear and education.
(4) Machine Maintenance Section
Carry out the machine maintenance to maintain safety functions and prevent accidents. Prior to

maintenance, conduct maintenance RA to prevent accidents.
(5) Safety and Health Section

Acquire general knowledge for safety and health to educate, instruct or support applicable sections.



Contents GSS-M Guide Book SUMITOMO RIKO Group

□ Contents -1 ～Machine design risk assessment manual part～

□ Foreword -2 -177

□ (Safety-04)Rules for Machine Safety □ (GSM-00-003) Machine Design Risk

Management -5 Assessment Procedures -178

□ (GSM-00-001) Standards for Machine □ Machine Design Risk Assessment manual

Safety Certified Associates System - 11 -189

□ Table of contents for R.A -190

～Machine safety inspection guide part～ - 13 □ Concept of Safety -192

□ (GSM-00-004)Machine safety □ Risk Assessment Procedures -196

inspection - 14 □ Specific Examples -207

Eight Safety Rules for a - 25 ～Construction Safety Work Guide part～
Machine/Equipment Trial Run -219

(GMS-00-006)Work Safety Inspection

Standards - 31 □ (GSM-00-007) Safety Standards for

□ Safe introduction of Machinery - 37 Machine Construction -220

□ Table of contents for inspection - 39 □ Safety Guideline for Construction Works
□ Related Documents - 83
-223

～Machine operations safety guide part～ - 95 □ TBM Check Sheet (to be filled in by
□ (GSM-00-005)Machine operations safety
Contractor) -237
- 96
□ Lateral Development Case of Accidents □ Hot Work Permit Application -241

-101

～Machine Safety Design Manual part～ -103

□ (GSM-00-002)Machine safety design -104

□ Machine safety design manual -107

□ Table of contents for Safety design -108

□ Introduction System of Safe Machines

～ 3 Step method -109

□ Inherently Safe Design Measures -124

□ Safeguarding -155

□ Complementary Protective Measures

-164

□ Information for use -168

Foreword: Global Safety Standards for Machinery – SUMITOMO RIKO Group
Background of Establishment 1

Global Safety Standards for Machinery to be established and communicated
throughout the entire Sumitomo Riko Group

1. Machine Safety Status at Sumitomo Riko (till 2014)
（1）Immature awareness of machine safety

●Lack of knowledge of relevant personnel
●Machine safety specifications inconsistent across divisions

（2）Insufficient machine safeguarding measures; countermeasures taken after accidents
happen

●Lack of consideration for machine safety at the design phase

（3）Machine safety standards not shared by group companies
●Safety rules based on Japan’s domestic safety or accident prevention statutes
●Difficulty in responding to foreign local laws and regulations

Foreword- 1/6

Foreword: Global Safety Standards for Machinery – SUMITOMO RIKO Group
Background of Establishment 2

Global Safety Standards for Machinery to be established and communicated
throughout the entire Sumitomo Riko Group

2. Purpose of Establishing Common Global Standards
To protect employees and assets of group companies by:
● Preventing machine-caused industrial accidents employees may be involved in;
● Establishing labor-friendly work environments; and
● Preventing machine fire/explosion, hazardous substance leakage and other
accidents.

3. Basic Policy for Global Safety Standards for Machinery
To enhance machine safety.
● Requirement to conform to local laws/regulation with the Sumitomo Riko Global
Safety Standards for Machinery as machine safety principles.
● Sumitomo Riko Global Safety Standards for Machinery conform to the
international standards for safety of machinery.

Foreword- 2/6

Foreword: Scope and Timing of Application SUMITOMO RIKO Group

Global Safety Standards for Machinery taking effect in April, 2015

1. Scope of Application
The Global Safety Standards for Machinery are applicable to Sumitomo Riko and its
subsidiaries.

2. Timing of Application
April 1, 2015

● Newly introduced machines are to be governed by the Global Safety Standards for
Machinery.

● Machine design risk assessment is to be conducted at the design phase.

●Existing machines also undergo improvement in accordance with priorities and
deadlines

●Local statues as well as the Standards are to be followed as to machine
introduction/maintenance and industrial accident prevention.

Foreword- 3/6

Foreword: Relevant Standards and Documentation System SUMITOMO RIKO Group
(Global Safety Standards for Machinery)

Com pany Rules for Machine Safety Management

GSS Guide Global Safety Group Rules for Occupational Safety and Health
book Standards for
Machine Safety Design Manual
M achine ry
Safety Standards for Machine design
Alr e ady
de ve loped Machine Design Risk Assessment Manual

In preparation Safety Standards for Machine Design RA procedures

Machine Safety Inspection Guide

Safety Standards for Machine Safety Inspection

Construction Safety Work Guide

Safety standards for Machine Operations

Safety Standards for the Machine Safety System
of Certified Associates
Safety Standards for Global Safety Standard Management

Safety Standards for Work RA procedures
Safety standards for Work Safety Inspection

Foreword- 4/6

Foreword: GS Certification System SUMITOMO RIKO Group

Applicable departments are requested to share responsibilities to enhance and
maintain safety of machinery

Foreword- 5/6

Foreword: GS Certification System Chart SUMITOMO RIKO Group

Dept. Responsibility GS Certif ied Associates Personnel Involved Appointed by Approved by Roles
・Final responsibility for safe
Safety Manager Plant Managers and Manager of the Safety and Health
machine operations at each base
Safety and Health GSM Presidents of Department at the Head Office
Department
Subsidiaries
Safety Management
Safety Engineer Staff of the Safety and ・Education/training for machine
GSE Health Department of safety
the Head Office ・Monitoring and instructions about
safe machine operations in
Staf f of the Saf ety GSM machine safety inspections
Environment Section, the ・Safety inspection members
General Af f airs Section and
the Saf ety and Health
Sections at bases

Safety Design Head of the Machine General Safety and Health ・Responsible for machine safety
Manager Engineering Department Managersand
GSM-D of the head office Department Dept. Manager at the in each business
Managers at the
Production Engineering Head Office Head Office
Managers at bases
Business Units / R&D / Manufacturing Support Machine Design (Machine Engineering Dept. ・Responsible for machine safety
Managers at bases)
at each base

Safety Designer Staff of the Plant Engineering GSM-D ・Special ability for machine safety
ＧＳＤ ・Plan, design and introduction of
Dept. and the Machine
Engineering Dept. safe machines
・Safety inspection members
Staf f of the Production
Engineering Dept. at bases
(Staf f of the Machine
Engineering Dept. at bases)

Safety Use Manufacturing Dept. General Managers Safety and Health ・Responsible for safe machine
Manager Manager, etc. and Department Dept. Manager at the operations at each department
GSM－I Managers at the Head Office
Machine Usage Head Office

Safety Inspector Manuf acturing Section Manager GSM－I ・Basic knowledge about machine
GSI Maintenance Engineering Section safety
Manager ・Safety inspection members
Plant Engineering Section Manager

Manuf acturing Section Manager
Plant Engineering Section Manager
Machine Section Manager

Foreword- 6/6

Rule ʋ Rules for Machine Safety Management Circular ʋ
Safety᜛04 442

Chapter 1 General Provisions

Article 1 (Objective)
These rules aim to prevent physical injuries or health damage of associates and ensure safe and
comfortable work environments as well as prevent accidents that could damage company
properties and natural environment by clarifying compliance matters for safety, health, and
accident prevention required in the following operations at Sumitomo Riko Company Limited
(hereafter described as the Company) and its subsidiaries: development, purchase specifications,
design, manufacturing, purchasing, installation, modification, maintenance, and disposal of
machines/equipment.

Article 2 (Definition)
The terms used herein are defined in the following items respectively.

(1) Department
A department is the Operating Department, the Research and Development Department,
the Corporate Staff Department, or the Manufacturing Support Department.

(2) Base
A base is a plant, office, or other business facility of the Company and its subsidiaries

(3) Machine/Equipment
Machines/equipment for manufacturing, research, tests, inspections, power supply, and
generating, receiving and transforming electricity, or those provided for safety, pollution
prevention and environmental conservation with or without the Company’s specifications
and/or its involvement in their design and manufacturing processes, stipulated in the
separately-compiled Sumitomo Riko Global Safety Standards for Machinery.

(4) Safety Standards for Machinery
This includes the Sumitomo Riko Global Safety Standards for Machinery, and other
machine standards for the machines/equipment unique to each department. These
standards stipulate requirements, operation procedures, and control methods to prevent
industrial accidents and injuries, fire, explosions, and environmental accidents stemming
from machinery.
ձ Sumitomo Riko Global Safety Standards for Machinery (hereafter described as the
“Global Safety Standards for Machinery”):
A set of standards that should be applied in a universal and integrated manner across
the Company and its subsidiaries issued by the CSR Safety and Health Committee
and the Safety and Health Department.
ղ Machine standards for the machines/equipment unique to each Business Unit or
base:
These standards are Individual standards applied only in specific departments,
subsidiaries or bases, such as: the machine safety standards issued by a relevant
Business Unit, and common machine specifications. Such standards must meet the
Global Safety Standards for Machinery.

(5) Machine Design Risk Assessment
This assessment is a method to identify, analyze, and assess the risk potentials of
machines/equipment, and implement appropriate risk reduction measures at the design
phase.

(6) Machine Safety Inspection
This inspection is to confirm the safety of a machine/equipment before use, and is
conducted when it is newly built, expanded, modified, or transferred for the purpose of

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