Safety

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Safe, Stable Operations

The Tosoh Group recognizes that ensuring the safety and stability of its operations for the health and well-being of its employees and for the sake of maintaining a reliable flow of products to its customers are its most important management issues. It therefore implements diverse safety initiatives to strengthen its safety infrastructure and to foster a culture of safety. The Tosoh Group aims to achieve a zero-incidence rate for accidents, including occupational accidents requiring time off work. We are also working on a business continuity plan (BCP) to prepare for various business risks, including natural disasters.

Safety and Disaster Prevention Management Promotion System

In July 2013, the Japan Petrochemical Industry Association (JPCA), of which Tosoh Corporation is a member, formulated its Action Plan for Industrial Safety and released guidelines for its members to follow.

Tosoh is applying these guidelines under its RC promotional structure to promote activities that ensure safe and stable operations.

Our RC Committee formulates safety and disaster prevention policies for application throughout Tosoh. It also tracks our progress and accomplishments in this regard and promotes further activities related to process safety and disaster prevention in cooperation with our complexes and various other operations.

The Environment, Safety, and Quality Control teams at Tosoh Corporation headquarters in Tokyo and at the company’s domestic complexes collect information on accidents and work-related injuries and share this information with Tosoh Group companies globally through a database. The teams, meanwhile, also exchange opinions on overall safety and disaster prevention activities and invite outside instructors to educate employees on safety and environmental issues. The aim is to improve the level of safety management at Tosoh Group companies.

Occupational Safety and Health

The Tosoh Group is aware that safety counts as the highest priority under its Basic Principles Regarding the Environment, Safety, and Health. It therefore conducts activities to safeguard anyone involved in its business activities.

These activities center on eliminating unsafe conditions and behaviors that could lead to occupational accidents. For the Tosoh Group, this means doing the following five things: educating people on basic safety behavior, assessing risks comprehensively, avoiding repeat accidents and work-related injuries, strengthening preventive maintenance, and utilizing increasingly safe new technologies.

Fiscal Year 2020 Results

In fiscal year 2020, there were three accidents at Tosoh Group companies in Japan and one at a Tosoh Group company elsewhere. We immediately investigated the cause of these incidents and implemented countermeasures. To prevent a repeat of such incidents anywhere in the Tosoh Group, we promptly disseminated the details to our operations worldwide.

Initiatives to Ensure Safety

President’s Control Room Visits

Every year since fiscal 2013, Tosoh’s president has visited workplaces at the Nanyo and Yokkaichi Complexes to share ideas on safety with employees. The president’s visits and direct dialogue with employees lead to the sharing of issues between management and employees and motivate employees to strive for safer, more stable workplaces.

In eight years of such workplace calls, the president has made 245 control room and office visits and interacted with over 5,500 employees.

Education and Training Upgrades

To achieve safe, stable, and efficient plant operation, the Tosoh Group provides diverse educational and training opportunities that reflect opinions gleaned from the workplace.

We hold, for example, hazard prediction training and, utilizing external trainers, follow-up sessions.^* This training enhances employee awareness of potential dangers and encourages teamwork. In fact, hazard prediction training involves small groups of participants discussing the risk factors hidden in their workplaces and the problems they may cause. Participants learn to recognize hazard points and the actions needed to counter them.

Tosoh Group technical education involves the use of risk experience equipment and of simulator- and experience-based learning equipment. Risk experience equipment enables users to experience firsthand falling and being caught or entangled and exposed to liquids, static electricity, and other dangers in the workplace. Simulator- and experience-based learning equipment allows users to experience the principles and characteristics of distillation towers and basic operating equipment in chemical plants. Employees learn how to start and stop tower operation and to respond to abnormalities. We’ve offered this training format since fiscal year 2018. In fiscal 2020, we introduced three pieces of equipment to enhance our hazard simulation training.

Tosoh is forever upgrading its education and training. We are always looking to better our knowledge and skills related to safe, stable operations and heightened workplace capabilities.

 * The hazard prediction training course includes a follow-up course by an external trainer.

Disaster Preparedness Training

Tosoh conducts disaster drills to raise employee awareness of the importance of their role in and of developing their abilities for emergency response. In Japan, we regularly hold comprehensive joint disaster drills to prepare for contingencies, including with government agencies. We held a joint drill in fiscal 2020 between our headquarters and our Nanyo Complex to connect them online and exchange information in real time. We also conducted a blind disaster drill to test our ability to respond to emergencies.

In addition, we conduct ongoing types of training in Japan in collaboration with the residents near our facilities and with government agencies.

Earthquake and Tsunami Countermeasures

Seismic reinforcement work on high-pressure gas storage tanks at the Nanyo and Yokkaichi Complexes is scheduled to be completed in fiscal 2021.

We are also seismically reinforcing such vital areas of our buildings as employee-occupied control rooms and offices, which also serve as evacuation centers during an earthquake or tsunami. This work has already been completed at the Yokkaichi Complex and at the Tokyo Research Center, and the research building and other facilities at the Nanyo Complex have been rebuilt to seismic standards.

The Nanyo Complex houses Tosoh’s permanent disaster preparedness center. The center’s range of disaster readiness information equipment has been improved and expanded, and its initial response and information-gathering capabilities during times of emergency have been significantly upgraded. We have, for example, added equipment to enable exchanges of information with disaster sites via live chat. We have also constructed a communication system that ensures the rapid relaying of instructions.

The Yokkaichi Complex, meanwhile, prepares for disasters by conducting system confirmation tests in the event of a blackout. It also displays flood maps and flood level indicators at its workplaces.

Business Continuity Planning Initiatives

Business continuity planning (BCP) offers an action plan for sustaining business operations as long as possible in the event of a disaster, accident, or other unforeseen event. A BCP also ensures the rapid restoration and resumption of operations following any interruption by such events.

The Tosoh Group’s priority is the safety of its employees amid such events, including the recent novel coronavirus pandemic. We continue to review and improve our disaster countermeasure regulations to ensure business continuity and the early recovery of facilities while minimizing the impact of any shutdowns to the extent possible that we can maintain a stable supply of products and services to our customers.

As we expand our global operations, opportunities for employee postings and travel increase. This, in turn, increases the vulnerability of employees to global events, such as wars, earthquakes, terrorist acts, rebellions, and infectious diseases. We are therefore implementing overseas risk management measures for the safety of our employees.

Risk Communication Activities

Tosoh is enhancing its internal and external communication, reporting, and public relations (PR) systems for implementation amid emergencies. This involves holding disaster readiness drills at our business locations with local governments and residents’ associations.

We have improved our PR system based on the guidelines in Japan’s public information handbook for coping with disasters at petrochemical complexes. We have also produced a pamphlet summarizing precautions for handling and emergency responses to the mishandling of each of our products and distributed it to local government agencies and residents throughout Japan.

Every year, moreover, we invite media representatives to conduct mock press conferences and practice lectures to strengthen our risk communication capabilities.

Accident Case Study Research

Tosoh Group believes that preventing the repeat of problems has two facets. First, causes must be determined in accordance with fundamental rules and principles governing the determination of causes. Second, solutions must be devised and implemented to tackle the causes permanently, not temporarily.

Tosoh delves into the essence of a problem by asking repeatedly why the problem occurred and by comparing and analyzing it in detail against other, similar problems. We also share information and utilize accident case studies for educational and training purposes through the operation of our groupwide accident and disaster information database, which centrally manages accident information.

Information Communication Technology Use

To ensure plant safety, we are advancing our use of information communication technology, or ICT. We have introduced

• a monitoring system for shared use by complexes;
• an operational support system;
• an abnormalities detection system;
• digitalized daily operational handover logs;
• telecommunications tablets for on-site use;
• an instrumentation diagnostic, smart valves system;
• wireless gas detectors;
• wireless vibration and temperature sensors;
• drones; and
• a gas turbine energy management system.

Accident Remembrance

So that we never forget the November 13, 2011, explosion and fire at our No. 2 Vinyl Chloride Monomer Plant at the Nanyo Complex, we’ve erected a safety monument at the complex. We also display documents related to the accident.

In addition, we’ve designated November 13 Safety Day. And on that day, we invite safety experts to speak to our employees. We also host safety activity conferences at the Nanyo and Yokkaichi Complexes.

Preventive Maintenance Efforts

We have invested approximately ¥16 billion since fiscal 2015 to restore the health of our facilities and to promote measures to strengthen them. The result is evident in a reduction in our number of accidents and other problems. Beginning in fiscal 2019, moreover, we launched an initiative to strengthen our preventive maintenance.

We are also taking measures to deal with accidents and work-related injuries among our many subcontractors, such as construction companies. To reduce the risks of construction work at our facilities, we have enacted measures to strengthen (1) education for construction companies, (2) the identification of and countermeasures for sources of danger, and (3) compliance with work procedures.

We have been testing our new preventative maintenance system through a series of trials over two years, ending in fiscal year 2020. Going forward, we will operate this system as a normal part of our business and strive to further improve safety through its application.

Occupational Safety and Health Management Promotion System

The Tosoh Group is aware that safety counts as the highest priority under its Basic Principles Regarding the Environment, Safety, and Health. It therefore conducts activities to safeguard anyone involved in its business activities.

These activities center on eliminating unsafe conditions and behaviors that could lead to occupational accidents. For the Tosoh Group, this means doing the following five things: educating people on basic safety behavior, assessing risks comprehensively, avoiding repeat accidents and work-related injuries, strengthening preventive maintenance structure, and utilizing increasingly safe new technologies.

Tosoh conducts activities for occupational safety and health under its Responsible Care (RC) promotional structure. Our RC Committee is in charge of group-wide safety and security and therefore formulates the Tosoh Group’s occupational safety and health policies. It manages the progress and achievement of these policies while promoting activities related to safety and health in cooperation with the Nanyo and Yokkaichi Complexes and related departments.

It also, of course, supports the occupational health and safety activities of Tosoh Group companies globally in an effort to raise group-wide safety and health levels. To do so, the RC Committee applies a variety of methods, from conducting on-site inspections to encouraging exchanges of opinions if an occupational accident occurs.

Fiscal Year 2020 Results

The Tosoh Group has set a goal of zero incidents of work time lost because of accidents involving its employees and subcontractors. Regrettably, in fiscal 2020 we fell short of our goal, with 9 incidents in Tosoh and 16 incidents in domestic subsidiaries of time lost because of injuries to employees. The causes of these accidents were twofold: inadequate prework environments involving processes such as degassing and drainage and inadequate safety management of construction work for subcontractors. To prevent the recurrence of such incidents, we are reconfirming work environment procedures and implementing thorough construction management.

5S Activities  

To improve their workplaces, the Tosoh Group’s Nanyo and Yokkaichi Complexes and research facilities take part in the 5S’s of sort, set in order, shine, standardize, and sustain Maintaining orderly, clean work environments makes it easy to detect abnormalities. Members of our management team, therefore, are tasked with identifying superior workplaces and workplaces requiring improvement in regard to the 5S’s. And the chairman of our RC Committee conducts 5S patrols.

In fiscal year 2020, the Yokkaichi Complex held a 5S activity presentation where its superior workplaces were recognized based on an anonymous vote. The Tosoh Group also established a program in fiscal 2020 that recognizes superior workplaces eligible for the 5S Activity Excellence Award. Three Nanyo Complex workplaces, two Yokkaichi Complex workplaces, and one Tokyo Research Center workplace were the first award recipients.

Where on-site concerns are noted, we provide support for improvement. Efforts in this regard typically raise employee motivation for 5S activities in the workplace.

Hazard Prediction Activities

We regularly host hazard prediction courses taught by outside trainers. This is especially so for new employees, among whom we wish to make hazard prediction a common practice by providing them with initial and follow-up hazard prediction training.

The Nanyo Complex, meanwhile, makes it a practice to award individuals who demonstrate outstanding hazard prediction capabilities at its workplaces. Ongoing activities of this sort, we find, often improve employee attitudes regarding the importance of hazard prediction.

Nonroutine Operation and Change Risk Assessment

The Tosoh Group is undertaking “what-if” studies at the Nanyo and Yokkaichi Complexes to eliminate or reduce risks during nonroutine operations and changes. By repeatedly using the method of asking “what if,” we are better equipped to identify the sources of hazards and to propose safety countermeasures to those hazards at our operations.

Tosoh Group Initiatives

To strengthen its disaster prevention and occupational safety and health capabilities, the Tosoh Group established the Tosoh Group Safe Work Environment Network. That network enhances our sharing of legislation amendments, accident data, and other information.

In addition, the Tosoh Group holds Safe Work Environment Network Meetings. These meetings are an opportunity for Tosoh Group health and safety management representatives to get together and exchange and discuss information pertaining to occupational health and safety. Two such meetings were held in fiscal year 2020 involving 72 participants from 56 Tosoh Group companies.

Each of the meetings included occupational safety and health and environment education provided by external trainers. Those two sessions brought to four the number of occupational safety and health training sessions we hosted during fiscal 2020 using external trainers.

The Tosoh Group in Japan also has in place a program of Safe Work Environment Exchanges. The program offers opportunities for Tosoh Group companies in Japan to conduct field evaluations and to discuss evaluation results.

Fiscal 2020, meanwhile, saw Environment, Safety, and Quality Control representatives from Tosoh headquarters inspect five Tosoh Group companies and hold safety and environmental exchange meetings. Also in fiscal 2020, we continued to strengthen our guidance by calling on a third party to provide on-site advice that granted us a different perspective on safety and health at our operations.

Chemical Substance Management

Tosoh complies with domestic and foreign regulations, assesses product safety, and provides product information to customers in its efforts to ensure the safe handling of its chemical products. It also ensures sound chemical management through its entire supply chain by disclosing information about the chemical substances in its products.

Chemical Substance Management Promotion System

Tosoh activities related to chemical substance management are the purview of its RC promotion system. The Environment, Safety, and Quality Control team at Tosoh headquarters gathers information to ensure compliance with domestic laws and regulations on chemical substances. It then shares that information with the Nanyo and Yokkaichi Complexes and related departments through e-mail and other means of communication, including briefings and educational programs. That team also monitors the implementation of the various measures required by laws and regulations and strives to take timely and appropriate action if those measures are not enacted.

Enhanced Chemical Substance Management

The 2002 World Summit on Sustainable Development (WSSD) expressed its goal as “aiming to achieve, by 2020, that chemicals are used and produced in ways that lead to the minimization of significant adverse effects on human health and the environment.” In pursuit of that goal, countries around the world are enacting or revising laws and regulations concerning chemical products that require chemical manufacturers to more thoroughly manage chemical substances throughout their supply chains.

Tosoh is in response strengthening its collection of information on enacted and revised laws and regulations to better its chemical substance management and minimize risks in the whole of its supply chain.

Chemical Substance Management System

In fiscal 2016, the Tosoh introduced a chemical substance management system to centralize its management of chemicals and to ensure its compliance with all laws and regulations worldwide. That system has involved compiling a database of the chemical substances in each Tosoh product. The database makes it possible to search not just for products and their chemicals but also for the laws and regulations that apply to each chemical.

To comply with Japan’s Food Sanitation Act Positive List, we improved the search function of and added a survey function to the database in fiscal 2020. We will continue to improve our chemical substance management system overall, including adding to the functionality of its database.

The Tosoh Group, meanwhile, has certificate-issuing authority for some of its products. As with our database, this facilitates a swift response to customer requests to know the chemical content of those products.

Product Risk Management

The JCIA promotes voluntary initiatives by Japanese chemical makers to strengthen their management of chemicals. Its initiatives include the Global Product Safety strategy and the Japan Initiative of Product Stewardship, both of which aim to achieve the WSSD’s goal for 2020.

In fiscal 2020, Tosoh released 12 safety summaries of particular focus through the association. It has released 31 summaries to date. Its safety summaries present the results of risk assessments of chemical products manufactured and sold by chemical companies in an easy-to-understand format for the general public.

Safety Information Disclosure

The Tosoh Group prepares and provides safety data sheets (SDS) for all of its products. It has made some of its SDS available on its website in an effort to make sure that the particular products to which the SDS on the website apply are handled safely. The SDS detail the chemicals in each product and describe the hazards of those substances.

In May 2019, the Japanese government revised the Japanese Industrial Standards. This has occasioned the need to explain the revisions throughout the Tosoh Group and to revise our SDS. Furthermore, Japan’s Industrial Safety and Health Act stipulates that products containing chemical substances are subject to labeling. And we have duly labeled our products.

Legal Compliance

When a new product is placed on the market, it must be reported, registered, and quantified in line with laws and regulations in each country. The Tosoh Group acts on every revision to laws and regulations requiring the submission of data on its products.

In fiscal 2020, for example, a revision was made to the application system under the Act on the Evaluation of Chemical Substances and Regulation of Their Manufacture, etc. We thoroughly reviewed the new application materials and complied with their revision by reconfirming those of our products to which the revisions applied.

We also filed a prior declaration in response to South Korea’s June 2019 amendment to K-REACH, that country’s Act on Registration and Evaluation, etc. of Chemical Substances. We then began registering our products under K-REACH. We have similarly begun complying with the registration of chemical substances in Taiwan.

In fiscal 2020, the Tosoh Group experience no violations of laws or regulations related to the registration and notification of chemical substances anywhere globally.

Product Safety Audits

In Japan, Tosoh Group employees work in line with Japan’s Product Liability Act to ensure product safety. This entails providing accurate information on our products.

Our Product Safety Review Committee meets to verify the safety of our product’s raw materials and of our products and deliberates on legal regulations at each phase of product involvement within the Tosoh Group, from R&D to sales. In fiscal 2020, the committee met 46 times.

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