GSS-M

4. Risk Assessment Sumitomo Riko Group

Litigation risk

PL Act（Product Liability Act）

Manufacturers are held liable for damages arising from an accident caused by the defect of their

products. As for machines:

Design defects Was safety considered enough at the design phase?

Defects of Manufacturing defects Was commissioning/work verification satisfactory?
product Notification/warning defects Was residual risk properly communicated？

PLP（Product Liability Prevention）

Design Risk Assessment

4.Risk Assessment Ｐ12/Ｐ58

Litigation risk Sumitomo Riko Group

Past lawsuit cases Comparable to a newly employed worker who
does not know how to use the machine

Lawsuit cases（source: “Current conditions of accidents and lawsuits related to PL Act” by Tokyo Marine Nichido)

Japanese only
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5. Risk Assessment Procedures Sumitomo Riko Group

5-1.Determination of the limits of machinery
Harm ＝ Hazard ＋ Person

Hazards Risks

Hazard Source

No injury occurring when no one is around Possibility of an injury occurring when a person is around the hazard.
the hazard.

Illustration: Description of Risks図(Wリebスsクiteのo説f明M（in厚is生tr労y働o省f HHPeal職th場aのnd安W全サelイfaトreh:ttWp://oanrzkepnilnafco.emhslawf.egtoy.jps/riitsek/shytotkpu:h//ina0n7z.hetmnil）nfo.mhlw.go.jp/risk/syokuhin07.html)

It is important to specify the interaction between hazards and people.

Identifying all interactions improves the personnel safety in using the machine.

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5. Risk Assessment Procedure Sumitomo Riko Group

5-1.Determination of the limits of machinery

Determine the limits of the machinery

5W1H in using the machine (interaction with hazard)

Detailed machine specification is necessary

Machine Planning Section Machine Engineering Machine maker
Machine Using Section Section

Who ･･･Experienced or new employee, associate with special qualification, maintenance worker, etc.
When ･･･Constantly, monthly, part replacement times, annual inspection, etc.
Where ･･･Fixed position, machine inside, elevated place, outdoor, etc.
What ･･･Work, hazardous or heavy material, etc.
How ･･･By Setting, exchanging, touching or others

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5. Risk Assessment Procedure Sumitomo Riko Group

5-1.Determination of the limits of machinery
Consider the following items as well as usual usage

●Predictable misuse

Movement instantly taken when a person encounters machine failure
Allurement to easier ways or omissions (ignoring procedures)
Silent pressure making personnel hurry
Behavior of persons depending on their figure shapes & sizes

●Interaction with third parties

Passers-by, near-by workers, plant visitors, etc.

●Ambient conditions

Narrow space available, dark or hot environment, etc.

●Machine lifecycle

Installation, relocation, etc.

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5. Risk Assessment Procedure Sumitomo Riko Group
5-1.Determination of the limits of machinery

Machine Design Risk Assessment Procedures (Example) It is important to correctly
communicate the specification.

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5. Risk Assessment Procedure Sumitomo Riko Group
5-1.Determination of the limits of machinery

Information communication Items to be determined

Machine Planning ・Required specifications
Section ・Interaction between the machine and personnel

(applicable associates, intended use, predictable misuse, etc.)

・Installation environment

Machine Engineering ・Purchase specifications (based on required specifications
Section
from the Machine Planning Section)
Machine maker
・ Interaction between the machine and personnel

(maintenance, predictable misuse, etc.)

・Applicable laws, Machine Safety Standards

・Machine design (structure, dimension, device selection)
・Life, replacement frequency

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5. Risk Assessment Procedures Sumitomo Riko Group

5-2. Hazard Identification
Man-machine interaction determined in the previous step

Identify hazardous events that can cause harm .
(Process through which hazard causes harm)

Hazard･･･ Driving/rotating unit, high energy source,
dangerous/hazardous material, high/low temperature, noise,
vibration, heavy load, awkward posture, etc.

Hazard identification is the most important thing！

Unidentified hazards hamper correct risk evaluation/reduction, resulting in the design,
manufacture and introduction of machines with dangerous parts.

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5. Risk Assessment Procedures Sumitomo Riko Group

5-2. Hazard identification
Types of hazard

5. Risk Assessment Procedures Ｐ20/Ｐ58
5-2. Hazard identification Sumitomo Riko Group

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5. Risk Assessment Procedures Sumitomo Riko Group

5-3. Risk estimation
Identify hazardous events that can cause harm

Determine the risk severity for evaluation （quantification）

Risk･･･Combination of the probability of occurrence of harm and the severity of that harm

Factors for estimation
Estimation methods:
① Risk scoring (BS5304, Japan, method currently employed by Sumitomo Riko）
② Risk matrix (ANSI B11)
③ Risk graph（ISO 13849-1)

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5. Risk Assessment Procedures Sumitomo Riko Group

5-3. Risk estimation

① Risk scoring method

Probability of occurrence of harm and severity of that harm will be rated per the given criteria
and assigned into the given formula to estimate the risk based on the resultant score.

Present method employed by Sumitomo Riko

There are 3 parameters to estimate risk:
Probability of occurrence of harm → Frequency to approach hazard

Severity of the harm → Probability of occurrence of accident
Severity of accident
(A) Frequency of approach to hazard
(B) Probability of occurrence of accident (C) Severity of accident

Probability Rating Criteria Rating Criteria

Inevitable 6 Fear of injury with usual care 10 Death, loss of vision, loss of limbs

High 4 Carelessness may lead to injury. 6 Fracture or others requiring long-term treatment

Probable 2 Possibility of injury caused by human error 3 Laceration, burn, low back pain, etc.

Rare 1 Not zero 1 Abrasion, contusion,strain, etc.

Formula D = ( A + B ) x C

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5. Risk Assessment Procedures Sumitomo Riko Group

5-3. Risk estimation

① Risk scoring method

Formula: Ｄ＝（ Ａ ＋ Ｂ ） × Ｃ

（Ｄ）Risk level

Level Score Risk evaluation
Ⅴ 60≤ Major unacceptable risk
Ⅳ 31 - 59 Unacceptable risk
Ⅲ 22 - 30 Acceptable risk（major）
Ⅱ 11 - 21 Acceptable risk（minor）
Ⅰ ≤ 10 Acceptable risk

Case: An associate may have his/her hand pinched in loading/unloading a work on the die of the pressing machine.

Hazard: Die pinching

(A) Frequency of approaching hazard: Frequent → 4 points

(B) Probability of accident: Inevitable → 6 points (work estimation phase)
(C) Severity of accident: Hand cut → 10 points

(4 points＋6 points)×10 points＝ 100 points → Risk level V

Major unacceptable risk → Risk reduction measures are required

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5. Risk Assessment Procedures Sumitomo Riko Group

5-3. Risk estimation
② Risk matrix method

Probability of occurrence and severity of harm are combined to estimate risk

Example (Source: Literature published by the Ministry of Health, Labour and Welfare)

Probability of occurrence of harm Severity of harm

Probability Criteria Severity Criteria

Rarely Once every few or more years Minor injury Injury that heals soon
Occasionally About once in a year Slight injury
Sometimes Serious injury Injury requiring medical treatment
About once in 2 months Major event w ithout absence from w ork
Frequently At least once a week
Ansence from work,residual
Matrix table disability grade 8 - 14

Minor Death, residual disability grade 1-
Slight 7,injury/death involving 3 or more personnel
Serious
Major Probability Risk level
←Risk level 5
Rarely Occasionally Sometimes Frequently
１ ３
２ ２２ ４
３ ５
severity ３ ２３ ５

３４

４５

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5. Risk Assessment Procedures Sumitomo Riko Group

5-3. Risk estimation

③ Risk graph method

Make options from the decision tree for probability of occurrence and severity of harm,
which leads us to the risk level.

Example of risk graph

Figure: Example of risk graph from the nursing-care robot portal site (risk assessment sheet explanation: Hiroyasu Ikeda)

Ｐ26/Ｐ58

5. Risk Assessment Procedures Sumitomo Riko Group

5-3. Risk estimation Judgment criteria
③ Risk graph method

Example of risk graph

Risk graph

Risk level

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5. Risk Assessment Procedures Sumitomo Riko Group

5-3. Risk estimation
Characteristics of each method

Method to be employed by Sumitomo Riko → Risk graph method

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5. Risk Assessment Procedures Sumitomo Riko Group

5-3. Risk estimation

In the case of the risk scoring method

Example: Hand may be pinched in loading/unloading a work on the die of the pressing
machine

Measures to take: Install light curtain. Stop the machine while loading/unloading the work.

Before Frequency: 4 points (frequent) （4＋6）×10＝100 points
Probability: 6 points (inevitable) → Level V
Severity: 10 points (cut)

After Frequency: 4 points (frequent) （4＋1）×10 ＝50 points
Probability: 1 points (almost never) → Level IV
Severity: 10 points (cut)

Level V→ Level IV (unacceptable risk)
Measures having been taken are not reflected in the results.

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5. Risk Assessment Procedures Sumitomo Riko Group

5-3. Risk estimation

Case of risk matrix method

Probability of harm

Rare Occasional Sometimes Frequent
１ ３
Minor ２ ２２ ４
Slight ３ ５
Severity of harm Serious ３ ２３ ５
Major
３４

４５

Low work frequency results in low risk level even if there may be a possibility of deadly
accidents occuring.

5. Risk Assessment Procedures Ｐ30/Ｐ58
Sumitomo Riko Group
5-3. Risk estimation
リInスthクe cグaseラoフf th法e risk graph method

Risk level 5 → Risk level 2

Measures having been taken are reflected in the results.

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5. Risk Assessment Procedures Sumitomo Riko Group

5-4. Risk evaluation
Risk estimation to quantify the risk level

The result shows whether or not risk is acceptable or risk reduction is necessary.

Example of risk evaluation sheet

Threshold of acceptable risk level (machine introduction is allowed).

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5. Risk Assessment Procedures Sumitomo Riko Group

5-5. Risk reduction
Risk reduction is required if the resultant risk level is unacceptable.

Risk reduction by means of the 3 step method Consider in this order
(detail will be separately
Priorities are set on risk reduction measures. provided)

Step 1: Inherently Safe Design Measures

Risk elimination/reduction

Step 2 (1): Safeguarding
Step 2 (2): Complementary protective measures

Containment, protection

Step 3: Providing information for use

Calling for attention

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5. Risk Assessment Procedures Sumitomo Riko Group

5-6. Risk reevaluation
Risk reduction through the 3 step method

Reevaluate the results of risk reduction.
Has the risk been reduced to an acceptable level?

5-7. Documentation
Risk has been reduced to an acceptable level.

Document the procedures and results of risk assessment successfully implemented.

Purpose

- To provide the information about risks that could not be eliminated (residual risk information)

- To provide the applicable public authorities with evidence of safety

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5. Risk Assessment Procedures Sumitomo Riko Group

5-7. Documentation
Items to be documented as records

・Date and responsible person of risk assessment

・Name of machine, machine using section

・Materials based on which risk assessment was conducted (e.g. machine
specifications)

・Result of hazard identification

・Risk estimation/evaluation results

・Risk reduction measures

・Residual risk information

To be communicated to the machine using section

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5. Risk Assessment Procedures Sumitomo Riko Group
5-8. Risk assessment flow
Repeated until the risk is reduced to
an acceptable level

Preliminary design phase

・Clarify the machine using manner
・Consider inherently safe design

At the time of
commissioning

Before use

・Provide residual risk information

Precise design phase
・Consider safeguarding

6. Specific Examples Ｐ36/Ｐ58
6-1. Determination of the limits of the machine Sumitomo Riko Group

Ｐ37/Ｐ58

6. Specific Examples Sumitomo Riko Group

6-1. Determination of the limits of machinery

Source: Machine Design Risk Assessment Procedures
Form for communicating required spec (Machine Planning Section→Machine Engineering Section

Employ formatting convenient for each
applicable section

Precise communication is important!

Ｐ38/Ｐ58

6. Specific Examples Sumitomo Riko Group

6-2. Hazard Identification

Source: Machine Design Risk Assessment Procedures

Format: Design risk assessment sheet Employ the format convenient for

each applicable section

Fill in the blanks
・As to large equipment,
complete the form for each
component machine.

Ｐ39/Ｐ58

6. Specific Examples Sumitomo Riko Group
6-2. Hazard identification

Listing hazards

・Insert the machine illustration
・Clarify hazards (assigning numbers)

人依存

・Fill in the field (numbers must correspond to those in the figure on the right)
・List all the hazards including thermal and electrical hazards, hazardous substances as
well as driving unit. (Refer to the list of hazards.)

Ｐ40/Ｐ58

6. Specific Examples Sumitomo Riko Group
6-2. Hazard identification
・Machine illustration
Example of filling in the hazard fields ・Hazard locations (numbered)

・List hazards Kind of hazard

P in ch in g Elect rical hazards

Shearing T hermal hazards

Lacerat io n Noise

Cat ching Vibr at io n

Mechanical Shock（hitt ing, collision） Radiation
hazards

St abbing Mat erial hazards

Abrasion Ignorance of ergonomic principles

High-pressure fluid blowout Environmental hazards

Ot hers Combinat ion of hazards

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6. Specific Examples Sumitomo Riko Group
6-2. Hazard identification

Example of filling in the hazard identification field

List hazardous events expected from the
identified hazards.

6. Specific Examples Ｐ42/Ｐ58
Sumitomo Riko Group
6-2. Hazard identification

Example of filling in the hazard identification field

Hazard No.

Kind of hazard

Phase of life, operation, applicable
personnel (when, who, how)

Hazard identification

Ｎｏ． Hazard Type of Life cycle Work Hazardous state
No. hazard (related Applicable Hazardous event
section) person

Hazardous event: 1 1,2 An operator puts the hand in the running machine
….will result in …. Pinching Operation Production Operator and has it pinched by the crusher cyl.

Ins pec ti on, While servicing with control panel door opened,
Mai ntenanc e
2 3 Electrical s ervi c i ng Technician an associate touches the energized part and gets

an electrical shock.

Ｐ43/Ｐ58

6. Specific Examples Sumitomo Riko Group

6-3. Risk estimation/evaluation

Example of documenting risk estimation/evaluation results

Severity of accident (degree of harm caused by hazard）

Exposure frequency (frequency of approach to hazard)

Avoidance probability (possibility to avoid hazard)
Probability of occurrence of hazardous event (before risk
reduction)

Determine the risk level for each hazardous event, referring to the risk
judgement criteria sheet.

Ｐ44/Ｐ58

6. Specific Examples Sumitomo Riko Group

6-3. Risk estimation/evaluation Option before risk reduction

Example of documenting risk estimation/evaluation Initial risk

Example of risk judgement criteria sheet Common sheets shall be used within each section.

Ｐ45/Ｐ58

6. Specific Examples Sumitomo Riko Group

6-3. Risk estimation/evaluation

Example of documenting risk estimation/evaluation

Example
Hazardous event:
During robot teaching, the machine abruptly
moves and its arm hit trainees.

Probability Ｓ３ Major (death)
Severity of Exposure Avoidance of Ｆ１ Rare (maintenance)
Ａ２ Impossible (high speed)
harm frequency probability hazardous Ｏ３ No measure (initial risk)
event

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6. Specific Examples Sumitomo Riko Group

6-3. Risk estimation/evaluation

Example of documenting risk estimation/evaluation

After estimation of each item, determine the
risk level for hazardous events referring to the
risk evaluation sheet.

Ｐ47/Ｐ58

6. Specific Examples Sumitomo Riko Group

6-3. Risk estimation/evaluation

Example of documenting risk estimation/evaluation

Ｓ３ High
Ｆ１ Rare
Ａ２ Impossible
Ｏ３ No measure

Risk level: 5

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6. Specific Examples Sumitomo Riko Group

6-3. Risk estimation/evaluation

Example of documenting risk estimation/evaluation
Risk level this time

Risk reduction is
required

Unacceptable risk

Ｐ49/Ｐ58

6. Specific Examples Sumitomo Riko Group

6-4. Risk reduction

Example of filling in the risk reduction field

Write risk reduction Ｐ50/Ｐ58
measures Sumitomo Riko Group

6. Specific Examples
6-4. Risk reduction

Example of filling in the risk reduction field

Classification of measures
(3 step method)
↓

人依存

Ｐ51/Ｐ58

6. Specific Examples Sumitomo Riko Group

6-5. Reevaluation of risk

Example of filling in the risk reevaluation field

Review the risk reduction measures→Reevaluate the risk (using the same
evaluation criteria)

Reevaluation results shall be verified with the actual machine.
→Failure of risk reduction is indicated by no lowering of “probability of hazardous event.”

Example: Installation of guarding fence→Not enough to prevent hand from reaching hazard. Result: NG

Ｐ52/Ｐ58

6. Specific Examples Sumitomo Riko Group

6-5. Reevaluation of risk

Example of filling in the risk reevaluation field

Inherently Safe Design Measure
Reduction in energy consumption may lessen the “severity of accident” and improve the
“possibility of avoidance.”
“Probability of occurrence of hazardous event” goes down to 01.

Safeguarding, complementary protective measures, information for use
No change in “severity of accident,” “exposure frequency,” and “avoidance probability” (no change in
operation and hazard exists）
“Probability of occurrence of hazardous event” goes down to 01 or 02.

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6. Specific Examples Sumitomo Riko Group

6-5. Reevaluation of risk

Example of filling in the risk reevaluation field

New risk identified In implementing further risk
(Added item has become a new hazard.) reduction, enter the number for
the description field.
Date of identification

If the risk could not be reduced to an acceptable level even after risk reduction
measure(s), describe the result of discussion on it.

Ｐ54/Ｐ58

6. Specific Examples Sumitomo Riko Group

6-6. Residual risk information

Example of documenting the residual risk information

Risk that could not be eliminated with risk reduction measures→Residual risk

For safe usage, machine users must be properly provided with the residual risk information ！

Ｐ55/Ｐ58

6. Specific Examples Sumitomo Riko Group

6-6. Residual risk information

Example of documenting residual risk information

List the residual risks. Informing manner. Explanation to the machine using
section

→Record the notification result
(done, date, marking, etc.)

6. Specific Examples Ｐ56/Ｐ58
6-7. Authorization Sumitomo Riko Group

Authorization timing

Authorization field (to be checked by a
designated person of each section)

Verified through machine Before the machine safety
safety check check
→Authorized after safety has
been confirmed.

Ｐ57/Ｐ58

7. Practice Sumitomo Riko Group

To be presented in the
explanation session

Ｐ58/Ｐ58

GSS-M

Construction Safety Work Guide part

Format 1 GSR-0Z-001
Page 1/2

Sumitomo Riko Safety Standard Classification㻌 GSM-00-007-
Number

Name Safety Standards for Machine Construction Established Jan. 12, 2016
Last Revised Jan. 12, 2016

1. Purpose
These standards stipulate matters concerning the duties and responsibilities of construction
managers and supervisors in order to ensure the safety in construction work and prevent fires and
accidents.

2. Scope of Application
This applies to all the construction work done at Sumitomo Riko and its subsidiaries.

3. Definition
(1) Construction Work
All outsourced construction work done within the premises such as building construction,
equipment and utility work, repair, inspections, greening, and sign board installation.

(2)Construction Management Department
Departments that have a construction management function at each Sumitomo Riko Group
company including Equipment Engineering, Equipment Maintenance, Plant Engineering, General
Affairs, Information System and Production Engineering.

(3)Construction Manager
Associates in the construction management departments at each Sumitomo Riko Group company
who have been educated and trained for the safety of construction work at the safety training
sessions held by their own departments

(4)Construction Supervisor
Persons who are responsible for the construction work awarded to the Contracting Companies
and have participated in the construction safety training sessions held by Sumitomo Riko Group
companies and bases.

(5)Construction Worker
Workers from the Contracting Companies engaged in said construction work under the supervision
and instructions of the construction supervisor

4. Safety of Construction Work
(1)Safety Guidelines in Sumitomo Riko Group are stipulated in Sumitomo Riko “Safety Guideline

for Construction Works.”

(2) When relevant regulations and standards of countries or regions in which Sumitomo Group
companies are based are different from the contents of the Standards herein and Sumitomo Riko
“Safety Guideline for Construction Works,” stricter requirements shall be met. However, if the
requirements in said relevant regulations and standards are contradictory and not compatible with
those of the Standards herein and Sumitomo Riko “Safety Guideline for Construction Works,”
such requirements in said relevant regulations and standards should be prioritized.

(3)Conditions to be complied with that are unique to Sumitomo Riko Group companies and bases
located in Japan and overseas may be independently stipulated at each location in addition to
Sumitomo Riko “Safety Guideline for Construction Works.”

Approved by Person Responsible

Drafted by Chair of Machine Safety WG General Manager of Safety Safety and Health Officer
Yoshinobu Isobe and Health Dept.

Hiroshi Noso Ken Kono Tsukasa Oshima

Classification Number GSM-00-007 Format 1 GSR-0Z-001
Page 2/2

5. Responsibilities of Construction Manager
(1)The Construction Manager shall place a construction work order in consideration of safety in regard
to construction work methods and period.

(2)The Construction Manager shall be responsible for the overall management of construction work.

(3)The Construction Manager shall have the Contracting Companies understand and comply with the
“Safety Guidelines for Construction Work” in Sumitomo Riko “Safety Guideline for Construction
Works.”

(4)The Construction Manager shall provide information to the Construction Supervisor in advance in
regard to handling hazardous materials and working at hazardous places in order for the
Construction Supervisor to take necessary measures.

(5)The Construction Manager shall permit the start of construction work only when he or she can
confirm safety by implementing risk reduction measures at the actual process with the actual part.

(6)The Construction Manager shall provide instructions necessary to ensure safety through the overall
construction work.

6. Responsibilities of Construction Supervisor
(1)The Construction Supervisor shall be responsible for the safety and health affairs and preventing

accidents in the awarded construction work.

(2)The Construction Supervisor shall engage in construction work in compliance with the “Safety
Guidelines for Construction Work” mentioned in Sumitomo Riko “Safety Guideline for
Construction Works.”

(3)The Construction Supervisor shall educate construction workers about the “Safety Guidelines for
Construction Work” mentioned in Sumitomo Riko “Safety Guideline for Construction Works” at
least once a year.

(4)If the Contracting Companies in charge of construction work have their own safety rules for
construction work, the Construction Supervisor must comply with them in addition to the
Standards herein and Sumitomo Riko “Safety Guideline for Construction Works”

(5)As for the contracts for construction work concluded between Sumitomo Riko Group
companies and the Contracting Companies, if said Sumitomo Riko Group companies do not engage
in all the contracted construction work at all, the Contractors in charge of the entire construction
work shall lead the safety and health control over the overall construction work. In such case, said
Sumitomo Riko Group companies as contractee shall make their utmost effort and provide as much
support as possible in order to prevent any accidents and injuries. Both parties shall abide by rules
and regulations of the countries they are based in and the matters stipulated in their contracts for
construction work.

7. Documents
The formats and storage life of documents relevant to the Standards herein may be determined by
each Sumitomo Riko Group company and base independently except for the ones prescribed in
Sumitomo Riko “Safety Guideline for Construction Works” and those stipulated by Sumitomo Riko
Safety and Health Department. Also, document formats adopted by the Contracting Companies may
be utilized as well.

Additional Provisions
(Supplementary Provisions)
1. The Sumitomo Riko Safety and Health Department shall be the Department responsible for the

Standards herein.

2㸬The Standards herein shall be effective from January 12th of 2015.

3. Specific implementation methods of the matters prescribed in the Standards herein shall be based on the
classification number GSM-0G GSS-M “Safety Guideline for Construction Works.”



Safety Education Seminar Material

Safety Guideline for Construction Works

Sumitomo Riko Company Limited

Material for Safety Safety Guideline for Construction Works Date: January 1, 2015
Education By Sumitomo Riko Co., Ltd.

1. Introduction

Safety first! Thank you for your usual cooperation to comply with our safety rules.

This Guideline for Work Safety presents requirements to be followed by Contractors to carry out the work safely preventing accidents. Please

read this Guideline carefully before starting the contracted work on our premises. If you have any uncertainty, contact the Department in charge

of equipment at Sumitomo Riko and perform the work with confidence.

This Guideline is distributed to the Department in charge of equipment at Sumitomo Riko and our contractors. Each contactor who intends to

outsource part of the contracted work is required to make the sub-contractors fully understand and follow this Guideline too.

We hope this Guideline is fully understood and obeyed to attain favorable working environments free of accidents and disasters.

Nothing is more important than health and safety.

Slogan

̌Safety is our top priority.” Let's work together to achieve Zero Accidents!

2. Safety Guideline for Construction Works 1…Read carefully 2…Read at least once 3…Reference

Safety Materials Sumitomo Riko Contractor Description

Page
Equipment

(1) Safety Guideline for Construction Works 1 1 1 Introduction

(2) Safety Rules for Work 21 1 Safety requirements to follow in working on the Sumitomo

Riko premises

(3) TBM Check Sheet (face side) 13 1 1 Hazard anticipation activity through TBM and safety check

Work Safety Checklist (back side) before, during and after the work. Submit this sheet after the

work.

(4) How to Complete TBM Check Sheet 15 1 1 Instructions for filling in TBM Check Sheets and KY

and KY Signboard Signboards

(5) Hot Work Permit Application Form 16 2 2 The application form against which actual conditions are

(front side) checked at the site.

Precautions in Construction Work

(back side)

-1-

Safety Rules for Work Prepared by Sumitomo Riko Co., Ltd.

Contractors are required to read and follow the following
rules to carry out the work safely.

Safety Rules Note (additional information/past close call events)

1. General

(Prior permits) (1) “Fire Permit Application Form” must be filed beforehand by

(1) It is required to submit “Fire Permit Application Form” or the Work Manager on the applicable date. “In-plant Road

“In-plant Road Use Permit Application Form” to use fire or Use Permit,” which will be applied for by the Sumitomo Riko

block the road in the premises to carry out the work. Work at representative, takes 3 to 7 days before issuance. Submit

dangerous material handling sites require permit of application form, if necessary, well in advance. Application

competent fire department. with the fire department is the responsibility of Sumitomo

Riko. Prior discussion with Sumitomo Riko is required as

(Work clothes) some 30 days are required for such proceedings.

(2) Wear clothes appropriate for work. Be sure to properly fasten(2) There was an accident where a worker had his unbuttoned

cuff and neck buttons. cuff caught by a machine.

(3) Put on a helmet, adjusting chin strap so that it won’t come off in(3) There happened an accident where a worker without a helmet

case you may tumble or fall down during work. (Wear Helmet) on fell down and died. Many close call events have been

(4) Use safety shoes. (If it is impossible to wear safety shoes due reported on hitting heads against objects.

to the situation, follow directions of the Sumitomo Riko(4) Obtain prior permission from the Sumitomo Riko

representative.ዅ representative when workers need to wear shoes other than

(5) Wear cleanroom suit to work in a cleanroom. (Safety shoes or safety shoes (i.e. jika-tabi for scaffolding work or boots for

helmet should be worn as instructed by the Sumitomo Riko earth work).

representative.) (5) Use helmets within their useful life as per the instruction

(6) As for work in a quasi-cleanroom, follow directions of the manual provided by the Japan Helmet Manufacturers

Sumitomo Riko representative. Association.

(Work Manager)

(7) The Work Manager is required to wear arm band or decal to(7) Any site must have a dedicated Work Manager deployed.

identify managerial position. The Health and Safety Manager is The Work Manager must be readily identified as such with

required to be legally qualified or have been finished the specific arm band or decal.

training course for health and safety promoter (or education per̪Those who finished the work safety training course held from

Article 60 of the Industrial Safety and Health Act or Article 40 of 2002 onwards are supposed to possess a decal to prove it.

the Ordinance on Industrial Safety and Hygiene in Japanዅ. Affix the decal on your helmet.

(8) The Work Manager is responsible for ensuring all workers wear

appropriate protective gear.

(Protective gears)
(9) Each worker must bring their own protective gear appropriate(9) Contractor is responsible for preparing proper gear unless

for the work (e.g. helmet, safety shoes, safety glasses, otherwise specified.
protective gloves, face shield, safety mask, safety belt). Use
protective gear which is free from such damages adversely
affecting function and is within its useful life.

-2-

(Smoking)

(10) Smoking is only allowed at an area designated by the(10) Ask the Sumitomo Riko representative for the smoking

Sumitomo Riko representative. Do not smoke while working or areas/rules. Follow the representative’s instructions as to

walking, or any space other than designated place. smoking at rest rooms or other places. Make sure that your

cigarette is completely put out before discarding it into

(KYK(kiken yochi katsudo (hazard anticipation activity)) ashtray.

(11) This is a self-motivating activity to raise safety awareness(11) Ask the Sumitomo Riko representative about any

among workers. Before starting any work, irrespective of its uncertainties about KYK. We have the KY signboard ready

duration, conduct KYK with the presence of all workers and for use, or the contractor may prepare it on their own. Safety

fill in the KY signboard to be posted at a prominent place. point field should contain concrete measures that are

feasible.

(TBMዄtool box meetingዅ) (12) Acquire the TBM check sheet from the Sumitomo Riko

(12) Conduct TBM with the presence of all workers before representative as necessary. Submit the completed check

starting work to confirm operations to be implemented each sheet to the representative after the work.

day and safety points to pay attention to. Also conduct a safety

check as per the TBM check sheet.

(Protection of facility)

(13) Finished/in-process products and equipment that are difficult to(13) Use covering sheet that is clean enough.

put away from the work site must be covered with sheets to

prevent foreign matter, dirt and dust from entering or adhering(14) In the past someone touched joint face of in-process

to them. products, causing adhesion defect that resulted in a major

(14) Do not touch finished/in-process products unless necessary. customer complaint.

(15) As for work accompanying transfer or handling of heavy(15) Care must be taken in using sheeting with eyelets, which

material, floors must be protected with appropriate sheeting or may damage the floor surface. Cart wheels with dirt on them

plywood. Follow the Sumitomo Riko representative’s directions. may also damage the floor. Clean the wheels before

(16) Long objects such as pipes and angle bars, which may damage bringing the cart into the premises.

the floor, must be placed on sheeting or cardboard laid on the

floor.

(Others)

(17) Do not enter the area other than the applicable work site unless(17) There once was a case where a person watching equipment

necessary. controlled by another department was taken for an industrial

(18) Vehicle is only admitted into the premises to load or unload spy and required to submit a written explanation.

tools/materials/equipment, otherwise it must be parked in a(18) All vehicles parked in the plant premises must have their

designated parking lot. If temporary parking of a vehicle on the door unlocked and key left inside in case they have to be

premises is inevitable, leave the doors unlocked and the key moved in emergency.

inside. Be sure to use car stop. (19) Plant’s AC100V receptacle circuit had no ELB. (Sumitomo

(19) Use cable reel equipped with ELB (earth leakage breakers). Riko makes it a rule to use ELB equipped cable on the

(20) Cable reel cord shall be fully extended when in use. equipment side to minimize damage caused by power

(21) AC100V receptacle provided within the control panel is for PLC leaks)

auxiliary devices and is not appropriate for electric tools. (20) Electric cord of cable reel with 15A capacity can supply only

Products and other items put away to facilitate work must be 5A when wound on the drum and may heat up and take fire.

replaced after the work is completed. (21) Transformer was burnt and damaged when a vacuum

cleaner was operated plugging into this receptacle.

-3-

(22) All workers are required to go through health checks to ensure

that they are healthy enough for work.

(23) Workers, contractors and self-employed persons must be

covered by appropriate industrial injury insurance.

(24) Workers must have qualifications or certificates required for(24) Workers on the job must always carry applicable

work. qualifications or certificates with them.

2. Work with Fire 2. Fire won’t occur if any one element is missing of the following:

(Preparation) ignition source, flammable material and oxygen. It is not

(1) Consider possible methods do not use fire. practical to remove oxygen (air), but eliminating the ignition

(2) Do not use spark generating tools including sanding machines source or flammable material is possible.

around equipment such as local discharging ducts or hoods as Measures to eliminate ignition sources include (a) using no fire

they may have organic solvent adhered. and (b) containing flying sparks. Measures to eliminate

(3) To use fire, conduct a prior site inspection per check items on flammables include (a) putting them away, (b) cleaning them

“Fire Permit Application Form” (with a Sumitomo Riko away and (c) covering them with fireproof sheeting. Though

representative). Obtaining approval of Sumitomo Riko fire is difficult to extinguish once it expands, it can be put out

representative and Safety, “Fire Permit” sign must be posted at easily at an early stage. It is necessary to establish systems to

a prominent location of fire place. put out fire immediately.

(4) Fire Permits may be applied for only when fire use is(4) Issuing permits for uncertain use plan may give rise to

unquestionably required. misunderstanding that fire can be freely used. Be sure to file

Applications just in case fire may be needed for work will not be the Fire Permit Application Form with the purpose

accepted. identified. Fire generating equipment not in use must be

If not constant but occasional fire use is required (planned) controlled by the Work Supervisor or the Work Manager.

during the day, application forms may be accepted upon prior (There once happened a fire due to unauthorized use of

discussion with the Sumitomo Riko representative (on pre- or equipment for a purpose other than that written in the

post-work communication manner, equipment control or other application form.)

behaviours). (5) ABC powder extinguisher scatters extinguishing agent around

Fire use in places other than the permitted fire place is when used and people sometimes seek other ways to put

prohibited. out fire, during which fire may expand. This extinguisher is

(5) Make CO2 extinguishers readily available at site. Prepare also one time use only. Therefore, CO2 extinguisher is

buckets filled with water, water hoses, water spray recommended. ABC powder extinguishers may be used as

extinguishing systems, fireproof sheets and others for use with a supplementary ones. Submitting a letter of apology may

the CO2 extinguishers. be required should fire extinguisher be used.

(6) Before using fire, check if inflammables (organic solvents) and(7) Fire spread containing sheets or plastic sheets get holes

other combustible materials are put away. when sparks drop on them and are not appropriate for

(7) Products or equipment that cannot be moved away and might repelling fire.

be exposed to flying sparks must be covered with fireproof(8) Metal powders burn fiercely once they take fire. They are not

sheet (JIS A1323A accredited sheets such as G&J Spatter non-combustible but combustible.

Sheet Gold/ Gold Alpha). (9) Carbon, additives such as sulfur, rubber powder and lint are

(8) Check shot blast machine or its dust collector for metal combustible. They may catch fire after smoldering for hours.

powders and remove them if present. (Mold release agent was once found smoldering on a beam

(9) Clean the site to make it free from carbon, chemical, rubber at a belt plant.)

powder, lint and other flammables. (10) When duct hanging bolts were cut with gas flame, the duct

(10) It is not allowed to use fire to cut, machine or otherwise process heated up and took fire inside. When fire must be used

the existing duct. around a duct, the applicable duct shall be detached, cleaned

inside and positioned at a safe place.

-4-

(11) Check the welding (or cutting) points, their back side and the(11) Flammables may be too thin to notice visually. Check for

range within which sparks may fly for flammable/combustible flammables touching with fingers, especially paying attention

materials not only visually but tactually. to backsides or other hidden areas. A small fire once

(12) Confirm that dust collector or local fan is off before using fire. experienced at the Komaki Manufacturing Plant was caused

(13) Remove the pit lid and check for solvent smell or flammables by welding conducted without knowing the existence of

before using fire in or near the pit. urethane powder containing oil mist on the backside of the

(14) Gas bomb for gas cutting (welding) must be fixed to a pole, welding point.

fence or other rigid structure or put on the dedicated bomb cart.(12) Running fans may bring in flashing matter, causing fire may

(15) Arc welder must be equipped with electric shock protector. at an unexpected place (e.g. inside the dust collector).

(16) Power supply for arc welder must be taken from the breaker(13) Solvent floating in the drain ditch once caught fire.

designated by Sumitomo Riko representative. Earth shall be(16) When the earth was connected to a building because the

connected as close to the welding point as possible. earth cable was short, electric current flew through the

conduit for wiring and melted the wire coating, causing short

(Watchman) circuit.

(17) Allocate at least two workers for work using fire, one of whom(17) In using fire on the deck/second floor, ceiling or rooftop, a

shall be a watchman. watchman must stand downstairs or in the next room.

(18) The Watchman is responsible for watching fire, extinguishing Sparks may go through the narrow clearance temporary fire

fire at its initial stages if necessary and keeping unrelated walls, causing fire at an unthinkable location.

persons from the work area. (19) When fire broke out on a ceiling beam, fire extinguishing

(19) For overhead work using fire, deploy another watchman agent did not reach the fire and initial fire fighting was

carrying an extinguisher at the work site in addition to a delayed.

watchman on the ground. The watchman deployed at the

elevated place is responsible for early fire extinguishing.

(Worker)
(20) Only legally qualitied person can conduct gas/arc welding.

Depending on the nature of work, those who have finished skill
training or special education may do such work. (Refer to the
separate sheet, “List of Dangerous /Toxic Work
Qualifications.” )

(Precautions)

(21) Use fireproof sheet to prevent sparks from setting fire at the

site.

(22) The Watchman must always check for flammables in the(22) Fire spread containing sheet or plastic sheet get holy when

direction toward which sparks may fly. Fire must be suppressed sparks drop on it and are not appropriate for fire repelling.

while it is as small as a match flame. When using iron plate, trace sparks may bounce on the plate

(23) As to work section A, fire shall be used under the and fly in unexpected directions.

supervision of the Sumitomo Riko representative. ዆ During cooling tower removal, sparks generated by pipe

(24) In welding, be sure to wear heat shield (protective goggles) and cutting set fire on noise insulating mat inside, causing small

safety gloves. fires. Identify spark flying range to take satisfactory

protection.

(23) Fire may not be used at A rank sections without supervision

by a Sumitomo Riko representative.

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(Post-work check)

(25) Confirm that the area is free from fire at the end of work and 1(25) Check for abnormal smell, smoke, flame or temperature of

to 2 hours later again. The site must go through the final check heated parts using the five senses. In February, 2003,

by the Sumitomo Riko representative. when duct was cut with flame, the heat insulating material

(26) Leave the site for intermission or meal with a watchman inside began to burn after a few hours. (Post-work check

allocated or if safety is ensured more than 1 hour after fire was was insufficient.)

put out. (26) In leaving the fire place, checking equivalent to the

post-work inspection is required.

3. Overhead Work

(Prior preparation)

(1) As to work at places 2m or higher, “MEN WORKING ABOVE”(1) Work at 2m or higher falls into the category of “overhead

banners must be hung so that people below can easily notice. work.”

(2) Install rigid and stable scaffold and confirm safety before(2) Consider employing a rolling tower, cherry picker (to be driven

starting work. by a qualified person) or other means to assure safety.

(3) Be sure to wear helmets and safety belts. (3) Tighten the chin strap of helmet so that they won’t come off in

(4) Use fireproof sheet to prevent welding sparks falling down. case of accident. Safety belts must be secured to a stable

(5) Use curing sheet to prevent dirt and dust falling on equipment structure such as pole, beam or safety line. Safety belts must

below. be used correctly in line with the instruction manual.

(6) Use rigid scaffolding board to work on the slate roof or(4) Select fireproof sheet large enough to allow for unexpected

Gyptone ceiling. Work without scaffolding board is prohibited. flight-paths of sparks.

(7) Scaffolding board, mesh road, safety net installation and other(5) Curing sheet also facilitates post-work cleaning. There was a

measures must be taken to walk on slate roofs. case where all the rubber tape palletainers had to be

(8) When small chips are expected to fall in a vast area due to slate checked to find a fallen tapping bolt, which could have been

roof exchange or painting, protective netting or sheeting must caught by curing sheet.

be installed. (6) There are many reports on serious injury or extreme close

call events caused by falling or crashing through ceilings

(Measures during work) because scaffolding board was not installed. Do not

(9) When overhead work takes longer than 1 hour, applicable area over-trust your capacity.

must be enclosed with tiger-striped fences, safety poles and/or(7) Time and cost are required to install safety nets, but safety

barrier rope to keep away unrelated persons. should be prioritized over everything else.

(10) For short overhead work within 2 hours, deploy a watchman to

prevent unrelated persons from entering the work area. (9) Guard fencing should be installed for fixed location.

(11) Overhead work must be conducted by at least two persons,(10) Ordinary people are not aware of risk. A watchman is

signaling or communicating with each other. required to keep them away without using rough words.

(12) Ladders and trestles must be secured to some rigid structure at

the top or bottom. If it is impossible, allocate a person to(12) Feet of ladders/trestles must be non-slip. Wipe off water or

support it at the bottom. slippery fluid from the floor where ladder/trestle will be set.

(13) Jigs, tools, materials and parts must be brought up or down with Do not stand, sit or ride on the head step.

bag or basket tied to the rope. Take care not to drop them. (13) Do not put or leave jigs, tools, materials or parts on unstable

(14) It is strictly prohibited to work standing on the forks of forklift places such as beams and equipment. We once saw an

truck. empty can falling from a beam next to the contracted work.

(15) In carrying pipes, ducts or other long materials at elevated(14) There were cases where a person standing on the forks fell

places, both ends must be held by two persons or suspended down or had their finger pinched by the mast.

with rope. (15) A person carrying a long pipe once lost balance and

dropped one end, making a hole on the ceiling. (It costs

much to repair ceiling.)

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(16) Should roofing or ceiling be damaged, follow the direction of the(16) Leaving the site without reporting on the damage is subject
Sumitomo Riko representative to take appropriate measures. to punishment.

(End of work)

(17) Roof or ceiling must be cleared of materials, tools and refuse,(17) Material left on the roof once clogged the rain water gutter,

which are supposed to be taken away by the contractor. causing rain to outflow from the gutter and flood the plant

(18) Place tiger-striped fence at the opening of the deck/second premises.

floor.

4. Heavy Material Handling

4-1. Crane operation/slinging work

ጟCrane operation/slinging work must be conducted by a qualified

person (legal certificate or special education is required) (refer to

the separate sheet, “List of Dangerous/Hazardous Work

Qualifications”). Obtain prior permit of the responsible department

and the Manager .

(Working state)

(1) Helmets and safety shoes must be always worn.

(2) Cranes (or tow trucks) must be operated with a watchman

deployed to keep away unrelated persons from the working(2) To close in-plant road from traffic, “In-plant Road Use Permit”

area. is required. A watchman must keep other people away from

(3) Allocate a person who gives operation signals to the driver. the work area, taking care not to use violent wording.

(4) No one shall be under the hoisted load.

(5) Slinging work shall be conducted by a person who has finished

the applicable training, except for assistant work.

(6) Use wire rope and auxiliary items corresponding to the weight

of the load. (6) Wire rope ends must have eyebolts, which must be inserted

(7) Take care not to have a finger pinched between the rope and as far as they go. When using a shackle, ensure that it is

the load. attached securely.

(8) Lower the load slowly to prevent injury.

(9) Sling angle must be 60 degrees or smaller. (8) Lower the load considering the center of gravity/ balance and

(10) Never ride the hoisted load. signaling each other.

(11) Hoist the load with 4 wire ropes in principle. Hoisting with one

rope is not allowed.

(12) Never lift the load over the rated capacity.

(13) In hoisting the load, suspend lifting when the rope gets tight to(13) Prepare special lift fixture if required depending on the

verify slinging condition and balance, and then resume lifting to equipment configuration and weight balance.

avoid shock to the load.

4-2 Forklift operation
ጟForklift shall be operated, in principle, under the direction of a signal
person.
(Working state)
(1) Only a qualified person shall drive a forklift truck.
(2) The driver and the signaling person shall wear helmets.
(3) Do not exceed the recommended load limit of the lift truck.
(4) Two persons shall not ride at a time.
(5) No sudden starts, stops or turns.

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(6) Always stop at intersections with limited view and building

entrances to confirm safety.

(7) No one shall ride the forks or pallet on the forks.

(8) Fork extension sleeves, when used, must be securely attached

not to come off.

(9) In lifting the load, initially raise it by 5 cm above the floor to

check for a stable and centered load and stack. (10) Signal person shall provide correct signals.

(10) In inserting forks under the load or releasing it, follow the

directions of the signal person. (11) Signal person shall stand where a driver can see well.

(11) To carry the load under poor visibility, deploy a signal person(12) Wire rope may slip off if directly tied to the forks,.

and follow his/her directions.

(12) In lifting the load with wire rope, use dedicated lift fixture so that

load is evenly distributed between the 2 forks. (13) Cover the forks with cloth, wood or rubber plate, if

(13) Careful handling of loads is always required to avoid accidents. necessary, not to injure the equipment or load.

4-3 Relocation /Installation

(Working state)

(1) In relocating the object slightly with a crow bar, lay wood or

rubber under the support point in order not to damage the floor.

(2) Engage the crow bar with the base or frame so that it won’t slip(2) Position yourself so that the crow bar won’t hit you if it slips.

off.

(3) In raising/lowering equipment with a jack, care must be taken in

order not to topple it by slowly moving it up/down paying

attention to its inclination. Support the equipment with wood

plating in case of sudden drop due to jack operation error.

(4) In using plural jacks, deploy a signal person to give directions

and signals to keep the equipment to be moved up/down level.

(5) Take care not to strain your back in lifting heavy items. (5) In lifting heavy items, lower the waist bending the knees

(6) Watch out for your foot steps in carrying heavy material. When slightly, grasp the load securely and lift it stretching the

carrying with another person, call out to each other. knees with the back as straight as possible.

(6) It is important for two persons to move in harmony.

5. Electrical Work

ጟElectrical work shall be conducted by a person legally qualified to

do the work. (Refer to the separate sheet, “List of Dangerous/Toxic

Work Qualifications.”)

(1) Turn off the circuit breaker, verify there is no voltage and post(1) Use a voltage detector/tester. Do not forget to remove the

the MEN WORKING sign (to be affixed on the breaker) before MEN WORKING sign at the end of the work.

starting work.

(2) Notify all the workers when supplying or shutting off the power. (2) In stripping cable end coating, take care not to strip too much

(3) Primary wiring (between distribution panel and equipment control and expose inner electric wires. The connected portion must

panel/outlet) shall have corresponding distribution panel and breaker be properly insulated.

numbers.

-8-

6. High Voltage Handling Work
ጟ Electrical work handling high voltage shall be conducted by a
person legally qualified to do the work. (Refer to the separate
sheet, “List of Dangerous/Toxic Work Qualifications.”)
࡮Shut-off of or work in proximity of high voltage shall be done by at
least two persons.
(1) In the work meeting, the Work Manager and the Sumitomo Riko

representative shall confirm which switch to turn off, where to
inspect voltage and where to attach earth hook referring to the
electrical check list.
(2) The switch shall be turned off in 2 steps. (If 2-step method can’t
be employed due the applicable electrical system, shut off the
substation circuit breaker.)
(3) Wear insulating gloves to perform electrical testing of all the
connections of supply line to the applicable high voltage
receiving and transforming facility, attach earth hook, and then
start the work.
(4) After the completion of work and acceptance of the electrical(4) Partial supply in the middle of work is not allowed.
check list, power shall be supplied as instructed by the Chief
Engineer or his/her designee.
(5) The Sumitomo Riko representative and person in charge of
power recovery shall confirm electric supply system diagram
and the site to supply power in the presence of the Work
Manager.

7. Work at Solvent-handling Sites 7. Always follow the Sumitomo Riko representative’s directions

(1) Consider methods using no fire. without making decisions on your own.

(2) In principle, electric saws/drills and other tools generating(2) Chips from an electric saw once caused fire on an gluing

heated chips shall not be used. If using such tools is inevitable, machine that uses solvent.

follow the procedure specified in Section 2, Work with Fire.

(3) If possible, shift solvent to another location.

(4) Ventilate the site to supply fresh air. (4) Watchman shall stand outside the pit or tank. Watchman

(5) Before work in pits or tanks, solvent remaining inside shall be shall not enter the pit or tank with workers. Keep oxygen

completely discharged. Ventilate the inside with a handy fan concentration between 18% (safety limit) and 21% (normal

and deploy a watchman. Workers shall enter the pit or tank concentration).

after confirming the oxygen concentration inside is between

19% and 21%.

7-1ዊOrganic solvent handling work such as painting

(1) Carefully read SDS (safety data sheet) for an applicable solvent7-1 Solvent for floor coating once took fire due to static electricity

and handle it as per the given method. generated while agitated for mixture.

(2) Put a lid on a containers of solvent not in use.

(3) Bring in only the required amount of solvent. (4) When a drum can is used for agitation, take care not to hit the

(4) Have the wind at your back whenever possible not to inhale agitator blade against the drum can.

solvent vapor. ዆Report to the work representative or the Work Manager in

(5) Fully ventilate the painting site. starting or finishing daily work.

(6) Wear protective gear (rubber gloves, protective glasses/masks)዆Take precautions against static electricity.

as necessary. ዆Make sure fire extinguishers are ready for use.

(7) Post the “MEN WORKING” or “BLOCKED” sign.

-9-

8. Excavation
(1) Ask Plant Engineering for what may be buried near the site. In(1) A worker who accidently cut high voltage cable with a

excavating, pay attention to high voltage cable or piping which hydraulic shovel was nearly electrocuted.
may be buried.
(2) Before operating heavy equipment, check the overhead space(2) There was an accident where a hydraulic shovel hit and broke
for any obstacles the rotating arm may hit. Deploy a watchman. coolant pipe and the surrounding area was flooded. The
(3) Enclose the site with tiger-striped fences and deploy a resultant repair and cleaning delayed the work by half a day.
watchman.
(4) Excavated holes must be entirely enclosed by tiger-striped
fences and barrier rope to prevent people from falling in.
(5) Cover products or equipment nearby with curing sheet.
Excavation must be conducted whilst sprinkling water to
suppress dust.

9. Work in Underground Pits

ጟCheck the pit for oxygen shortage, toxic gas and other dangerous

elements before starting work. Work shall be done by a legally

qualified person.

(1) Work in the underground pit shall be conducted with the pit lid(1) Enclose the pit with tiger-striped fences or by other means.

removed to secure evacuation route for emergencies.

(2) Check the pit for solvent smell before entering. Deploy a(2) When there is a solvent smell, ventilate the pit before

watchman outside. Proper communication is essential between entering.

workers and the watchman during work. (3) Notice of work is essential to prevent someone from closing

(3) Notify the surrounding workers that work is underway in the pit. the pit or from activating the equipment in the pit without

(4) Working at the equipment carry-in port on the second floor, communicating it to the inside workers.

which is considered overhead work, is similar to the(4) Install tiger-striped fences around the equipment carry-in port

underground pit work and requires the same precautions as on the second floor.

those for the underground pit work.

10. Work around Blade-equipped Equipment
(1) Shut off power/air supply and discharge remaining air to ensure

that the equipment won’t move during work. Also affix “MAN
WORKING” sign to prevent other persons from turning on the
power or opening the air valve. Cover the blade to prevent
injury by contacting with sharp blade.

11. Other Dangerous Work
(1) In conducting work that may require a part of a body to reach

for pressing machines inner parts, shut off power/air supply,
discharge remaining air and engage the drop prevention lock or
insert a rigid block where there is a possibility of pinching.
(2) Working with banbury mixer drop door open requires complete
discharge of hydraulic accumulator air including remaining air.
Extract the key from the key switch and carry it with you during
work.

-10-

(3) When working on the traveling crane or its runway, carry the
switch box with you or make a watchman keep it so that other
people can’t turn on the switch.

(4) Work on an unstable position requires safe scaffolding (e.g.
gang board).

12. Commissioning

(1) Give a signal to surrounding persons and wait for the reply to(1) As to remote-control or noisy site operation, use transceivers

the signal before activating moving parts. for communication.

(2) Only a person having gone through applicable(2) A person who removed the safety cover and applied grease

education/training may deactivate safety system as required for on rotating gear got his finger pinched and lost the finger tip.

test run after installation or modification of equipment. Safety(4) It is recommended to clasp idle hands behind your back.

system deactivation requires witnessing by a Sumitomo Riko

representative.

(3) Commissioning is often conducted with safety cover removed

or safety system deactivated. Never reach for moving parts

uncovered. Use a tool if necessary.

(4) Take care not to reach for moving parts with an idle hand.

13. Post-work State of Order 13ዊEven if the contracted work has been completed with superb

(1) Remove scaffolding, ladders, tools and remaining materials. technique following the designated safety rules, evaluation

(2) Remove curing sheet taking care not to scatter dust and dirt for the workmanship will be spoiled if final cleaning and

around. commissioning are inappropriate. Post-work cleanup is a part

(3) Clean the area checking for contamination on the floor, of the work.

equipment or products. (3) Things belonging to the plant, if used, must be cleaned and

(4) Clear the ceiling or the roof of refuse or materials. returned to their original storage places.

(5) Refuse or remaining material shall be taken away unless(4) Vinyl sheet left on the material plant roof once clogged the

otherwise instructed or allowed by a Sumitomo Riko gutter and rain water flooded the area.

representative. (5) Refuse and remaining materials must be segregated into

(6) Return valves or switches to the original position. Special care combustible and non-combustible and discarded accordingly

must be taken with main piping valves or NFB circuit breakers into plant refuse bins or taken to designated places. (Follow

inside the breaker control panel for the distribution panel. the standard of Environmental Control.)

(7) Ask Sumitomo Riko representative for final check concerning(6) It sometimes happens that equipment cannot be started on

test run and cleanup. Monday morning because a contractor has failed to return

(8) When fire was used during work, receive final check and valves/switches to original positions.

inspection signature.

(9) TBM check sheet shall be submitted to Sumitomo Riko

representative after work.

-11-

Revision History Author Note
Date

9/01/1996 Ikeda, Plant Engineering safetyFirst release

member

7/31/1997 Ikeda, Plant Engineering safety Addition of measures in response to the fire in May, 1997

member

7/8/1998 Ikeda, Work Safety Committee Character size change, addition of underline

7/10/2001 Hiromura, Plant Engineering Revision according to the current state

7/15/2005 Ikeda, Plant Engineering Revision according to the current state

7/26/2006 Ikeda, Plant Engineering Addition of description about slate roof walkway

6/16/2008 Hiromura, Plant Engineering Revision per the current state and of TBM check sheet

6/26/2009 Hiromura, Esaki, Kawasaki, Plant Addition of high-voltage electric work requirement

Engineering

6/6/2010 Nouso, Noguchi, Plant Engineering Addition of organic solvent handing work description
5 / 2 5 / 2 0 11
5/29/2013 Nouso, Plant Engineering Change of fire permit application method, addition of note
12/5/2013 Hiromura, Plant Engineering for duct work
6/5/2014
10/1/2014 Revision according to the current state

2/16/2015 Hiromura, Plant Engineering Revision according to the current state (addition of
description for solvent handing siteዅ

Hiromura, Plant Engineering Revision in description for certificate/qualification
(P6),trestle(P8), scaffolding (P12) and communication in
Isobe, Global Safety emergency(P21,22)

Standards Company name change from TRI to Sumitomo Riko Co.,Ltd.

Promotion Office

Isobe, Global Safety Sta n d a r d s To b e t r a n s l a t e d i n t o E n g l i s h a n d C h i n e s e .

Promotion Office

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TBM Check Sheet፧ Sumitomo Riko representative:Sumitomo Riko personnel on
a shift:
ᯘto be filled in by Contractorᯙ
Date of work: ᡢ Equipment: Name of workers Assistants
፧ ፧ mm/dd/yyyy ᦱWork Manager
ᡣ Work description: Signal person:
Contractor: ᦮ Watchman:
᦮ Driver:
᦮

ᦄProtective gears ᦄPower Electric ᦄFluent

᦮Helmet ᦮Safety shoes testing
᦮Gloves ᦮Safety glasses
᦮Safety belt᦮Insulating gloves ᦮Power is shut off and electric testing is complete.
᦮ᯘ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ᯙ ᦪᯘ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ᯙ ᦮Main valve is closed.

ᦪᯘ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ᯙ ᦪᯘ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ᯙ

ᦄPressure ᦄHeated part ᦄFire

᦮Residual pressure is discharged. ᦮Temperature is 50ᚴ or lower. ᦮The site is checked against the hot work
ᦪᯘ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ᯙ ᦪᯘ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ᯙ
ᦄHeavy item ᦄCrane/Slinging permit application form

᦮Carried in correct manner. ᦮Signal person is allocated. ᦪᯘ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ᯙ
ᦪᯘ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ᯙ ᦪᯘ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ᯙ ᦄOverhead work
ᦄTest run ᦄEquipment out of service
᦮2 m or higher
᦮About 1 m high
᦮At least 2 persons
are allocated

᦮፧Type of scaffolding
᦮ᯘ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ᯙ
ᦪᯘ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ᯙ

ᦄEquipment in service

᦮Type of safety system ᦮Communication to relevant persons ᦮Safety system is OK
ᯘ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ᯙ ᦪᯘ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ᯙ ᦮Work with safety system deactivated

ᦪᯘ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ᯙ ᦄOther work ᦪᯘ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ᯙ
ᦄMachining/processing
Description of work: ᦮ᯘ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ᯙ
ᰋ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ᰍ ᦪᯘ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ᯙ
ᦪᯘ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ᯙ

ᯘMajor riskᯙ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧

ᯘAnticipated hazard ,KYᯙ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧ ፧
OKᯓᯓ

ᙾ፧1)ᦄ:Check the box if applicable, if not mark “ᙚ”;፧ ᦮: Check the circle and confirm risk factor
ᙾ፧2)ᦪ:Write risk factor in the blank.
Complete the form and submit to Sumitomo Riko representative (ContractorᜒSumitomo Riko representativeᜒ
Department Safety Committee Chairᯙ

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