Kao Japan Company Kao Worldwide
 

HOME > Culture > Occupational safety and health, process safety and disaster prevention

Occupational safety and health, process safety and disaster prevention [LA6]

Kao conducts activities to ensure occupational safety and health and disaster prevention based on the Kao Responsible Care Policy activities in order to protect employees from accidents and disasters in the course of conducting business activities.

2015 activities
In regard to safety and disaster response, we set standard KPIs applicable to the entire Kao Group, and implement related activities in accordance with specified priority items.
When occupational accidents occur, we examine the accident or disaster carefully, and identify and analyze the causes. The results of the analysis are shared throughout the Kao Group, helping to prevent similar accidents from occurring again in the future.
Kao continues to implement training in company-wide reporting and communication assuming an earthquake scenario, and also implements various plant safety and stable production measures that include earthquake-proofing reinforcement of plant buildings and Tsunami countermeasures.

Policies/structures

Activities ensuring “occupational safety and health” and “process safety and disaster prevention” are clearly described in the Kao Responsible Care Policy.
Accordingly, when occupational accidents occur, we examine the accident or disaster carefully, and identify and analyze the causes. The results of the analysis are shared throughout the Kao Group, helping to prevent similar accidents from occurring again in the future, thereby protecting our employees while maintaining safe and stable operations. In addition, Kao provides extensive safety education to all employees regardless of their employee status at the general training sessions for new hires and training sessions organized by individual divisions in order to boost safety awareness.
Our daily activities for occupational safety and health, process safety, and disaster prevention are conducted as part of the Responsible Care promotion system. In particular, when accidents or disasters occur, we have a framework in place to keep track of them through our global emergency reporting network. In addition, when a large-scale disaster such as a major earthquake occurs, we will establish an Emergency Response Team Organization headed by the President. Together as a Group, our initial response places top priority on human life as we implement measures including our business continuity plan (BCP).

The Kao Responsible Care Policy, together with details of the implementation framework and related activities, can be found on the following page:

Global

2015 targets and results

We implemented activities in line with the three priorities of “Eradication of Occupational Accidents,” “Creating a Pleasant Working Environment and Improving Employees’ Health,” and “Maintenance of Safe, Stable Operations (Eradication of Accidents for Security, Disaster-Prevention Activities).”
Specific activities to eradicate occupational accidents have focused on equipment and operational risk assessment, equipment safety measures and prevention of equipment-related incidents by ensuring thorough awareness of and compliance with rules; activities have also focused on measures to prevent slip and fall accidents involving stairs, etc., and work-related traffic accidents, etc.
In the area of creating a pleasant working environment and improving employees’ health, we have been strengthening management of the working environment, ensuring effective implementation and follow-up of health check-ups, holding health promotion activities, and implementing risk assessment for chemical substances.
Regarding maintenance of safe, stable operations (eradication of accidents for security, disaster-prevention activities), we have given each promotion division the themes and objectives of implementing thorough Change Management,* risk assessments of chemical facilities, regular inspections, enhanced patrols, enriched disaster drills, and strengthened security; each division has been required to formulate, and put into effect, detailed implementation plans. Starting from 2014, the scope of these activities has been expanded to include subcontractors.

  • * Change Management
    Management activities anticipating and accommodating risks before changes are implemented, along with preventive measures for issues such as failure, defects, and accidents.
2015 targets and results
Category Scope Indicator 2015 2014 results
Targets Results*5
Occupational accidents All divisions inside Japan
All sites outside Japan (including both regular employees and temporary workers)
Death and Serious lost time accidents*1 (persons) Kao Group 0 0 0
Lost time accidents frequency rate*2 Kao Group 0.39 or less 0.59 0.55
Total accidents frequency rate*3 Kao Group 1.92 or less 2.02 2.67
Total accidents frequency rate*3 Kao Group in Japan 1.00 or less 1.62 1.75
All sites (subcontractors) Death and Serious lost time accidents (persons) Kao Group 0 0 0
Lost time accidents frequency rate*2 Kao Group 0.41 or less 0.82 0.45
Total accidents frequency rate*3 Kao Group 0.95 or less 2.18 2.36
Total accidents frequency rate*3 Kao Group in Japan 1.40 or less 2.09 2.41
Traffic accidents Sales, logistics 100% negligence accidents causing bodily injury (no. of accidents) Kao Group in Japan 0 14 17
Accidents other than 0% negligence per 100 vehicles*4 Kao Group in Japan 6.6 or less 7.75 8.67
Accidents All divisions inside Japan
All sites outside Japan
Fires, explosions, leaks, etc. (no. of accidents) Kao Group 0 6 6
  • *1 Serious lost time accidents: Accidents involving death or injuries which caused the loss of physical function
  • *2 Lost time accidents frequency rate: Number of persons dead or seriously injured in occupational accidents per million hours worked (including only accidents involving at least one lost work day and also loss of a part of the body or a bodily function)
  • *3 Total injuries frequency rate: Number of persons injured in occupational accidents including accidents without lost work days per million hours worked
  • *4 Accidents other than 0% negligence accidents per 100 vehicles: Number of traffic accidents other than 0% negligence / No. of vehicles in fleet × 100
  • *5 From 2015 onwards, the boundary of data collection was expanded to include all sites outside Japan; data includes all sites outside Japan that had already completed the necessary preparations for inclusion

Global

Targets for 2016

Of the targets set for 2016, with the exception of the work-related traffic accident target, all other targets have been set on all Kao Group basis, and we are working to prevent the occurrence of accidents and disasters throughout the Kao Group.
Traffic accident targets will also be set on a global Kao Group basis in the future once we have a grasp of the current situation in Kao’s sites outside Japan in this regard.

Targets for 2016
Category Scope Indicator 2016 targets
Occupational accidents Regular employees and temporary workers (Kao Group) Death and Serious lost time accidents*1 (persons) 0
Lost time accidents frequency rate*2 0.31 or less
Total accidents frequency rate*3 1.60 or less
Subcontractors (Kao Group) Death and Serious lost time accidents*1 (persons) 0
Lost time accidents frequency rate*2 0.34 or less
Total accidents frequency rate*3 0.88 or less
Traffic accidents Sales, logistics (Kao Group in Japan) 100% negligent accidents causing bodily injury (no. of accidents) 0
Accidents other than 0% negligence per 100 vehicles*4 6.1 or less
Accidents Kao Group Fires, explosions, leaks, etc. (no. of accidents) 0
Logistics-related leakage incidents (no. of incidents)*5 0
  • *1 Serious lost time accidents: Accidents involving death or injuries which caused the loss of physical function
  • *2 Lost time accidents frequency rate: Number of persons dead or seriously injured in occupational accidents per million hours worked (including only accidents involving at least one lost work day and also loss of a part of the body or a bodily function)
  • *3 Total injuries frequency rate: Number of persons injured in occupational accidents including accidents without lost work days per million hours worked
  • *4 Accidents other than 0% negligence accidents per 100 vehicles: Number of traffic accidents other than 0% negligence / No. of vehicles in fleet × 100
  • *5 Logistics-related leaks: Accidents involving leakage while products etc. are being transported

Global

Status of occupational accident occurrences

In 2015, 150 employees were involved in accidents across the Kao Group, of whom 44 lost work days as a result (including temporary workers).
Across the Kao Group in Japan, a total of 93 employees suffered occupational accidents, up by five compared to the previous year. This total included 16 employees who suffered injuries resulting in lost time (of whom four lost time due to traffic accidents in which they were 0% negligent), up by two compared to the previous year. As in 2014, the most common types of accident were fall and slip accidents (38 employees), accidents involving cuts and scratches (16 employees), and accidents involving reactional action (10 employees); these three types of accident combined accounted for over 60% of all occupational accidents. Measures are being taken to reduce the number of fall and slip accidents.
In the Kao Group outside Japan, a total of 57 employees suffered occupational accidents (including 28 who suffered injuries resulting in lost time), down by 14 compared to the previous year. The most common causes included coming into contact with hazardous materials etc. or with substances at very high or very low temperatures (17 employees), cuts and scratches (9 employees) and accidents involving reactional action (9 employees); these three types of accident combined accounted for over half of all occupational accidents. Operational risk assessment is being carried out.
As regards occupational accidents involving subcontractors, the number of persons affected in 2015 was 45 (of which 17 suffered injuries resulting in lost time), an increase of eight compared to the previous year.
The number of people in our SCM and R&D divisions worldwide involved in operating production equipment who were victims of occupational accidents fell by 11 from 2014 to 78 in 2015 (with 30 employees losing time as a result of accidents). For the Kao Group in Japan, the corresponding figure was 24 (of which five involved lost time), down by six compared to 2014.

Lost time accident frequency rate in the SCM and the R&D divisions★

Lost time accidents frequency rate: Number of persons dead or seriously injured in occupational accidents per million hours worked (including only accidents involving at least one lost work day and also loss of a part of the body or a bodily function)

  • * Figures for manufactures and chemical industry are based on data from Ministry of Health, Labour and Welfare in Japan “Survey on Industrial Accidents 2015.”

Severity rate in the SCM and the R&D divisions

Severity rate: Number of working days lost per thousand man-hours actually worked

  • * Figures for manufactures and chemical industry are based on data from Ministry of Health, Labour and Welfare in Japan “Survey on Industrial Accidents 2015.”

Japan

Drills to prepare for large-scale disasters

In addition to the fire prevention training and emergency evacuation training conducted at the level of the individual workplaces, the Kao Group as a whole has been conducting the following training activities aimed at being prepared for a large-scale disaster.

Group-wide training in the use of the system for reporting the safety of Kao employees

In both March and September 2015, Group-wide training was held over two days on inputting data into the employee safety confirmation system for use in confirming the safety of all Kao Group employees following a serious natural disaster. In both training instances, the successful data inputting rate was 100%. Given that a 100% successful inputting rate was also achieved in the September 2014 training exercise, this means that a 100% score has been achieved three times in a row. We will continue to implement this type of training in the future.

Earthquake scenario company-wide reporting and communication training
Recognizing the possibility that a major earthquake may occur in the Tokyo metropolitan area where the Kao head office is located, the Kao Group has adopted an organizational structure that permits the establishment of a disaster response headquarters either in Eastern Japan or Western Japan as appropriate.
In May 2015, we implemented training that assumed that establishment of a disaster response headquarters in Eastern Japan following a hypothetical major earthquake on the Sea of Japan coast, and in October 2015 we implemented training that assumed the establishment of a disaster response headquarters in Western Japan following a hypothetical major earthquake with its epicenter directly under the Tokyo metropolitan area.
During these training exercises, communication with regard to the data collected from the employee safety reporting system and with regard to information concerning on-site roll-call and damage assessment was undertaken by means of a meeting system that utilized satellite phones and Kao’s internal disaster response bulletin board and website. The training method used is currently being reviewed in light of the lessons learned from past training exercises.

Global

Safety and disaster prevention audits

As a general rule, safety and disaster prevention audits are implemented once every two years at Kao chemical plants in the Asia region (six plants in five countries).

In 2015, audits were carried out at Fatty Chemical (Malaysia) and Pilipinas Kao. Both plants were deemed to have made improvements in regard to the issues that were pointed out in the previous audits. In the future, we will continue to implement follow-up audits on an ongoing basis.
Auditing staff from Thailand and Indonesia participated in the audit at Fatty Chemical (Malaysia), and staff from Malaysia participated in the audit at Pilipinas Kao, with the aim of enhancing the overall level of safety and disaster response capabilities at all plants in the region.

Global

Occurrence of small-scale accidents (fire, leaks)

A total of six small-scale accidents occurred in Kao worksites.

Five small-scale fires occurred
  • ・A fire involving an electrical component that had suffered deterioration
  • ・A fire caused by a charging cord shorting out after being accidentally cut
  • ・A fire caused by earth leakage from a power cable that had suffered deterioration
  • ・Smoke emission caused by a leak from a tank piping connector which caused raw material to seep into insulating material, oxidize, and give off heat
  • ・A fire that occurred when insect pest extermination equipment was being used on an area of green space
One leak occurred
  • ・A leak caused by accidentally opening a valve

Regarding the small-scale fires, Kao has strengthened its procedures for regular replacement of electrical components and for regular inspections; and regarding the leak, Kao has tightened up its implementation of equipment management and work management procedures.

Japan

Strengthening safety and disaster prevention

The SCM Division is working to identify latent risks and implement suitable measures in response, and is continuing to promote earthquake response measures, as part of the strengthening of chemical equipment risk assessment.

In 2015, regarding the identification of latent risks, we have implemented measures to prevent fires involving low-flash-point substances, measures to prevent dust explosions, measures to prevent spontaneous combustion, and measures to ensure the safety of equipment used for polymerization and exothermic reactions.
With regard to earthquake response measures, we have implemented building seismic resistance diagnostics and reinforcement, liquefaction prevention measures, measures to strengthen protection against tsunamis, measures to ensure that equipment is automatically switched off in the event of a major earthquake, and measures to prevent leakage from tanks.

Japan

High-pressure gas safety inspection, auditing and verification

Wakayama Plant has been designated an Accredited Safety Inspection Executor* pursuant to the High Pressure Gas Safety Act. Wakayama Plant’s certification came up for renewal in 2015 (renewal is required every five years). Under the direction of the President, who also serves as head of safety management, starting from January 2015 the Safety Management division and Wakayama Plant began the preparations for applying for certification renewal. Following a field survey in September that was attended by the President, renewal of Wakayama Plant’s certification as an Accredited Safety Inspection Executor was granted by the Ministry of Economy, Trade and Industry (METI) on December 9, 2015.
The high-pressure gas equipment at other Kao sites has safety inspection performed by external inspection bodies; safety auditing and safety verification are carried out in-house, and a serious effort is being made to ensure safe equipment operation.

  • * Accredited Safety Inspection Executor
    An Accredited Safety Inspection Executor is a company or organization authorized by the Minister of Economy, Trade and Industry to perform self-inspection, either while equipment is in operation or while it is out of operation, to verify whether the safety of specified items of equipment conforms to the relevant technical standards pursuant to the High Pressure Gas Safety Act.
Copyright © Kao Corporation. All rights reserved.
Kao Group