Year 2009 1st Edition

Safety and Plant Engineering Department

Plant & Facility Engineering Section

Production Engineering Division

Toyota Motor Asia Pacific Engineering and Manufacturing Co.,Ltd.

1st Edition

Year 2009

Plant & Facility Engineering Section has many experience for construction and safety management throughout the construction of various plants.

Toyota Part Center Asia PacificBANPHO Plant

Gymnasium (TMAP-EM) Engine Plant no.2 Siam Toyota Motor Test Building no.3

TAMP-EM Office BANPHO Test course

Introduction

We are expert in domestic construction and safety management systems such as CCCF ,Tool Box meeting ,Exercise ,Morning Talk ,Safety Patrol etc.

We would like to share & suggest our all experience and knowledge to AP affiliate throughout the implementation construction systems.

Tool Box meeting Morning Talk Safety PatrolExerciseCCCF

2

3

• To share & suggest safety construction management

• To use for safety conditions in bidding document.

• To understanding the expectation of roles that have to performed following the safety standards in each stage.

• To clarify the expectation of safety standards/rules.

• To advise the contractor can following &management the work throughout the construction period.

“ ZERO ACCIDENT ”

“NO HARZARDOUS IMPACT TO ENVIRONMENT”

Propose for this manual are:

4

Index

1.Safety Requirement for Project Bidding……………………………………….....5

2.Organization setup……………………………………………………………………7

3.Site Planning and Construction Temporary work………………………….....11

8.Further Safety Prevention………………………………………………………….57

4.Management and Safety Activities……………………………………………….29

5.Monitoring and Safety Visualization………………………………………….....35

6.Construction Safety Training………………………………………………...……43

7.Particular Safety Procedure……………………………………………………....47

5

1.Safety Requirement for Project Bidding1.Safety Requirement for Project Bidding

To clearly exhibit contractor commitment towards safety and communication of “safety First” policy to all concerns

Main contractor should clearly define safety policy and commitment to activity should be inline with policy

Owner or AP affiliate should confirm safety policy to main contractor and have the agreement of commitment with the own safety policy.

6

1.Safety Requirement for Project Bidding1.Safety Requirement for Project Bidding

Organization Setup

Site Planning and Construction

Temporary work

Management and Safety Activities

Monitoring and Safety Visualization

Construction Safety Training

Particular Safety Procedure

Further Safety Prevention

Safe

ty R

equi

rem

ent

for

Proj

ect

Bidd

ing

2

3

4

5

6

7

81

First, contractor should set up organization for clearly communication.

After that contractor must provide temporary facility for construction all period.

All member have safety activities together.

In order toward truly direction, Should have monitoring by visual control.

Contractor always take safety training course for workers.

In case of special work. Must have the safety procedure.

In others prevention of description detail.

Flow chart step

72.Organization setup2.Organization setup

1.Construction Organization 2.Safety Committee Organization

3.Emergency Route (In case accident)

Contractor should have appropriate safety organization with the clearly defined role and the responsibility (including emergency)

Chairman of their organization must be the top management to drive/ and focus “Safety First”. Moreover, contractor have to train the safety officer to promote the activity.

Propose of organization is nominating the leadership in each stage of project. And integration of the owners and contractor’s safety organization including emergency route.

1 2 3

8

1.Construction Organization

Project Name

In order to clarify

Plant & Facility Engineering Section (PFE) is Project

Main of contractor name

Project SupporterTMC and other section of

TMAP-EM which support & cooperation

Project owner such as affiliate country in Toyota group

Project Owner

Project ExecutiveToyota top management

which concern in this project

Project Leader

-To control main contractor job.

-To control safety, schedule, quality & budgeting.

-To construct base on USER requirement.

-Cooperate job to all concern.

TMAP Owner

TMAP TMAP TMC

Owner


Contractor

the job’s responsibility for construction project. Flow charge as below:

Sample is TH

project

9

2.Safety Committee Organization Identify Safety committee route.

Top management

Management

Safety Leader

Safety Sub Leader

Safety member


Sample is TH

project

Organization that combined with TMAP & Owner

TMAP Owner

10

3.Emergency RouteIn case of accident ,this organization will show the route to inform the accident occurrence.

Accident occur !!!

OwnerTMAP

TMAP

Owner

TMAPOwner

Top management

Top management

WorkingTeam

Management

Contractor

Project Name


Sample is TH

project

11

3.Site Planning and Construction Temporary work3.Site Planning and Construction Temporary work

1.Main Gate 2.Wheel Cleaning Station

3.Temporary Road 4.Morning Talk Stage

5.Morning Talk Area 6.Photo Tower

7.Material Storage 8.OBEYA room

9.Toyota Construction Site Office 10.First Aid Room

11.Training Room 12.Smoking Area

13.Electical box 14.Gas Welding & Cutting Devise Set

15.Garbage Bin 16.Labor Camp

Before the construction start. Contractor should planning and provide construction temporary work. In order to manage in overall construction period throughout to prepare the facility and necessity equipment which base on the owner’s safety control requirement.

The lists below are necessary for the temporary work that should be manage and control. (You can see the details of each items in next page)

12NORTH

Construction AreaConstruction Area

Temporary Site Control

1.Main Gate 6.Photo Tower

Temporary Fence 2.Wheel Cleaning Station

3.Temporary Road

5.Morning Talk Area

4.Morning Talk Stage

Around area

8.OBEYA rm.

7.Material Storage

Enclose area

15.Garbage Bin

10.First Aid rm.

11.Training rm. WWTPrimary water treatment before discharge

12.Smoking Area (More than 1)

Canteen

16.Labor Camp

Setup outside Construction site area

This layout show the location of necessary construction for the temporary work .


9.Toyota Construction

Site Office

13.Electical Box

For workers ,Labors and Staffs eating

area

14.Gas Welding & Cutting Devise Set

Can movable & (More than 1)

13

1.Main Gate

Propose to control In and Out of the person , vehicle, machine and equipment. Include Guard man for security monitoring.

Fence at least 2 m. high.

Canvas sliding gate

Safety sign board

Small guard box

Access road have stability

Prohibit Signs

Mandatory Sign

Warning Signs

Safe condition signs

Temporary fence must resistant strong wind

Detail are shown….

Construction site indication sign


With guard man all time.

14

2.Wheel Cleaning

Station

To prevent the soil stick on the truck wheel. Before truck go out of construction area.

Rough surface

Basin

Incase of civil work. Should have heavy spray water under the vehicle.

Vehicle from in site

Go to outside


In many case. If you don’t care the environment of the outside area which close to our construction. The nearly resident will complain to our company which it may be the environment’s dispute.

15

3.Temporary Road

Width at least 6 m.

In order to avoid unsafe from vehicle and Keep 4’S toward.

Show limited high

Crush stone / Soil compaction

SlopeTemporary drainage

w/slope Slope

Boundary line to separate man & vehicle

Traffic sign control

Speed < =30 km/hr

Grading Compaction

Spray water for Dust Protection

Provide Guardrial when cross gutter


4.Morning Talk Stage Layout work doing Safety Symbol

Safety Rule

Daily safety activities

President wording Attendant board Safety declaration Safety statistic

Stage for head man or group leader announcement. You should to provide the board

of Safety rule to remind all workers.

Visual board to monitor amount of worker everyday.

Daily cycle activities.

To record safety hour.To remind safety awareness. By contractor management.

Location of each job.

Every worker must follow the rules.


16

17

5.Morning Talk Area

Assembly point or Muster point for all workers make a row in front of Stage.

Stage

Row of worker

To identify subcontractor name


18

6.Photo Tower

The foundation must stability and strengthen with correctly install scaffolding by fixed support around the structure.

Safety symbol control

Highest stage have safety prevention

Net dust protection cover

Fixed end support

Sign warning

Support all around

3.Site Planning and Construction Temporary work3.Site Planning and Construction Temporary workIncase of large area. should provide 2 location.

(If any)

19

7.Material Storage

Plastic sheet cover

Pallet floorBarricade

Support to prevent moisture from soil

Separate by function

Special material keep indoor areaHazard material must have containment

Boundary FenceIn area Keep 5’s

<=1.5 m.

Store keeper to control

3.Site Planning and Construction work3.Site Planning and Construction work

Contractor must take care all material and always keep 5’S rule for easy to use.

EX: Cement EX: Safety equipment

EX: Steel

EX: electrical wire

20

8.OBEYA Room

The place to presentation & meeting.

Layout plan For explain to Top Management

For explain to Guests or Visitors

Visualization boards around the room


Movable

hanging hanging

21

9.Toyota Construction Site Office

The place for site management and construction controlling.

For construction working team

For Toyota internal meeting


22

10.First Aid Room

Primary curing when accident happen.

Doctor or nurse stand by Medicine cabinet Bed


23

11.Training Room


The place for training new workers and meeting for safety knowledge distribution.

Welding maskHelmet GloveSafety Belt Leather glove Ear plug

Training new workers Special work training

Information boardSafety devise model

Equipment KY Sheet

Daily Safety MeetingSafety Unsafe

Example equipment for use :

goggle

24

12.Smoking Area

In doorOut door

Rest area for workers should to install on the flow freshening area. Have chairs with roof, cigarette bin and fire extinguisher.

Cigarette binSmoking sign

Fire extinguisher

Bin

Inside smoking area should have provide of…


25

13.Electrical Box

Detail of Elec. Box

QC Check ,ok!

Person in charged

RST. Phase

fire extinguisher separate of here plug

Main Elec. Box

Guard rail

In / Out

Number Box in work site

Propose for temporary use connecting with electrical equipment.

Cover around to prevent vehicle to cash or make it

stand out point

The person who can control and daily check it

Lock out system

Water proof prevent the rain


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fire extinguisher and at least 2 full water

buckets to closely it.

QC Check flash back arrester

pressure reducing valve

pressure gageQC Check flash back arrester

pressure reducing valve

pressure gage

14.Gas Welding & Cutting Devise Set

2.Gas cylinder tank

1.Oxygen cylinder tank

Equipment set use for Welding & Cutting of steel work. Compose of oxygen and gas tank.

The equipment must have daily check of pressure gage, pressure reducing valve, connecting point and wire for safety using.


The kart can movable

The kart can movable

Bind tanks with chain

27

White RedGreenBlack Brown Blue

15.Garbage Bin

For plastics garbage such

as bottle

For Aluminum, Stanless ,Steel scrap

For paper rubbish For toxic and dangerous garbage

For general garbage

For oil contaminate

material garbage

Install on easy visual and separate garbage for environment keeping as color below.


28

Canteen

Adipose prevention

Car Parking

Main Door for security and aluzinc

fence all around

Camp for sleeping Gutter for drainage

Septic tank

Cleaning Toilet

Shower RoomWaste water treatment

16.Labor Camp Provide for workers long stay. Everyone must follow the camp strict rule that concern with safety and environment procedure.

3.Site Planning and Construction Temporary work3.Site Planning and Construction Temporary work28

29

1.CCCF Activities (Completely Check Completely Find out)

2.Daily Patrol 3.Weekly Patrol

4.Monthly Patrol

In order to clearly exhibit contractor management towards safety and activities of “Safety First” policy to contractor ,subcontractor and Toyota member.

CCCF is proactively find out hazard in all area of construction and develop construction management before develop to accident by “GENCHI GENBUTSU” of Toyota way concept.

4.Management and Safety Activities4.Management and Safety Activities

Concentrate on safety patrolby use CCCF as a tool.

(See next page.)

Make countermeasure action planMake countermeasure action plan

Classify these hazard into 3 Level, Rank A, B, and C

Classify these hazard into 3 Level, Rank A, B, and C

Find a hazard from all working area especially low

frequency work

Find a hazard from all working area especially low

frequency work

11

Maintain safety operation standard and 5S and training all concern

Maintain safety operation standard and 5S and training all concern

22

33

44

Rank A : Death, Severe

CCCF Activities Procedure as sequences.

Rank B : Injury Rank C : Small injury

Before After

30

CCCF procedure

31Work Permit

Man-Powercontrol

DailySafetypatrol

EquipmentCondition

Check(daily check)

DailyConclusion

meeting

Morning Talk,KYT

New contractorTraining,

Contractorcard

Safety Sub-

committeeMeeting

Site area cleaning

Daily Meeting(AM , PM)

Top Mgt.Safety patrol

( Steering committee)

Safety PatrolBy sub-committee

EquipmentCondition Check

(Weekly cross check)

Monthly Morning Talk

Top Mgt.Safety patrolMD/DMD’s

Safety CommitteeMeeting

(MD/DMD (chairman)

ZERO ACCIDENT

ZERO ZERO ACCIDENTACCIDENT

DAILY MANAGEMENT

WEEKLYMANAGEMENT

MONTHLYMANAGEMENT Contractor activity +

Toyota audit

Toyota Participate + Contractor activity

Top management Activity

(Advisor)

(Each Team)

Safety Culture : Safety Control Cycle & Management


Portion of safety activities to all concern during construction period.

Daily Patrol

Time : 9.00-10.00

(Morning & Afternoon)

Time : 11.00-11.30

5) Daily Safety Meeting

Time : 14.00-15.00

4) Safety Patrol

Time : 07.45-8.00

1) Daily Morning Talk

Time : 08.00-8.15

2) Tool Box Meeting

1.Exercise & enhance safety/health sense among all employee.2.To share safety information ,YOKOTEN points among all teams.

1.Daily basis discuss job allowance & overlap.2.Have common understanding roles & responsibility. Time : 08.15-8.30

3) Equipment Checking

1.Discuss & communicate problems, analysis and c/m. 2.reflect to training for unsafe act & unsafe condition.


For everyday safety activities cycle.

32

Weekly Patrol

Time : 9.00-10.00

1) Weekly Safety Patrol

Time : 16.30-17.00

3) Site Cleaning

Time : 14.00-16.00

2) Weekly Safety Meeting

Identify unsafe act, unsafe conditions with appropriate

check sheet by daily audit team


For every week safety activities cycle.

33

Monthly Patrol

Time : 07.45-08.00

1) Monthly Safety Promotion & Safety DemonstrationTime : 15.00-16.00

2) Monthly Safety MeetingBy Safety Committees

1.Standardization of contractor’s activity at site to stabilize safety condition during total project execution.

2. Main Contractor follow best practices & lead by example to his sub contractor’s.


For every month safety activities cycle.

34

Time : 9.00-10.00

2) Weekly Safety Patrol

Identify unsafe act, unsafe conditions with appropriate

check sheet by daily audit team

35

Board 1 : Project Information Board 2 : Work Progressive

Board 3 : Safety Plan Board 4 : Safety Activities

Board 5 : Safety Patrol Monitoring Board 6 : CCCF Board

Board

7 :

Job Daily Management

5.Monitroing and Safety Visualization5.Monitroing and Safety Visualization

When the construction is on the process. Everybody need to monitoring and visualization the construction work progressive and safety activities.

Contractor should provide visualization board and always update in order to present to top management and all concern to monitor and wrap up all of construction information.

36

Board 1 : Project Information

“Overview perspective picture”

To show the image project complete.

“Project Outline”To explain the

regular information of this project.

“Emergency Route Call”When accident occurrence.

This flow chart will show route line for report.

(See detail in portion 2 : Organization

“Emergency Route”)

“Safety Management”To show level of safety

concern and duty of safety member.

(See detail in portion 4 : Management and

Safety Activities “Safety Culture”)

“Contractor Organization”

To show organize all of contractor

company.

“Contractor Construction Site Organization”Show the details of

organize for smoothlyCommunicate.

“Organization Combination”

To show overall included owner, Toyota & contractor

organization level.


This board show general information.

“Design concept pictures”Detail for each view or

important area it needs more to explain.

37

“Work Progressive”To explain progressive of each work separate by layout. Easy to see

and understand.

“Overall Site Progressive Photo”

To show panorama photo every week by take photo at

“Photo Stage” for monitoring.

Ex: Roofing work show area finish and % progressive

Ex: %Floor work

Ex: % Roof steel work

“Site Plan Progressive Photo”To show photo and focus point s in each work area.

Layout show location

Photo detail

Photo detail

West view East view

Every month from started

Master schedule

3 weeks schedule

Manpower

3 month schedule


Board 2 : Work Progressive Show construction work status.

38

“Overall Site Safety and Healthy Plan”The schedule combined construction master

schedule with Safety plan.We will know when period we should

concentrate or have safety training activity. Example site safety and healthy plan such as

-Priority prevention target.- Countermeasure.

“Safety Policy”Contractor company safety

policy & Motto for motivation.

“Monthly Safety control Plan”Detail by month from “overall safety plan”


Board 3 : Safety Plan Show over all safety planning project.

39

“Safety Activity in Previous week”Training reason or photo during worker have

trained previously .Its show by topic.

“Safety Activity in Next week”Safety objective which contractor plan to

have training course in next time.

detail

detail

detail

detail

detail

detail

detail

Topic in next week

Event photo safety training in last week


Board 4 : Safety Activity Explanation safety training course.

40

“Weekly Safety Patrol Follow Up Owner Comment”Show daily safety patrol activity by contractor Toyota member.

Happen in this week

Happen in last week

1ใM/E accident

2.Heavy object falling accident

3.Vehicle accident

4.Fall down accident

5.Electric accident

6.Hot works accident

Attach photo of countermeasure Before-After of each 6 type

Accident by type

1ใM/E accident

2.Heavy object falling accident

3.Vehicle accident

4.Fall down accident

5.Electric accident

6.Hot works accident

Improvement cycle


Board 5 : Safety Patrol Monitoring

By histogram

By pie graph

By column graph

To follow CCCF activities.

“Data Summary”Show trend analysis

for project benchmarking.

41

“Completely Check Completely Find out ”Show risk highlight job,mornitoring by contractor Toyota member..

“CCCF Remark”How to separate by Type,Cause,Rank.

By Cause

By Type

By Rank

“CCCF Record”Accumulative by Type,

Cause, Rank.

CCCF List record

Layout show location

Before & After

Difference form safety patrol. Because this board it bring the unsafe highlights items only.

CCCF List record

CCCF List record


Board 6 : CCCF Board

42

“Job Daily Management ”Show construction job control by contractor.


Board 7 : Job Daily Management Contractor daily job control and management.

Layout which have construction work

Head man to control construction work

zone by zone

Date / Month/Year

Construction activities list

Safety OfficerSafety in charged

for today.

Comment by contractor

management

43

6.Construction Safety Training6.Construction Safety Training

100 % members must understand and proceed following the safety standards and safety rules which concern to his/her role.

Contractor should ensure 100 % that his employee already training & evaluation before entering site.

TMAP will check the trained members system by visual check. And the critical job will control through license system with special work training.

We separate group by 2 kind are…

1.Daily basis training 2.Weekly basis training

3.Monthly basis training

4.Speacial work training

A. Cycle road map training

B. Special work training

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Training and Evaluation

Safety Standard Training Items.1.Construction regulation2.Safety awareness3.Stop 64.Permit system5.Safety rule6.Safety audit7.Denwacho8.Risk assessment9.etc

•Contractor management

•Contractor supervisor

•Contractor safety officer

•Contractor employee

•New worker

Toyota Safety Policy

Contractor Safety Policy

+

ID card of permissionEvaluation by Safety officer license

Person should be trained

If pass training. Issue contractor card

All new employees must pass training before start work.Step for work permit

45


3.Monthly basis training

Fire freighting

Health checking

First Aid training

1.Daily basis training

Confine space trainingPPE safety training

Safety standard training

Small tool training

Common rule training

2.Weekly basis training

A. Cycle road map training

New worker training

For further detail,please see “ANZEN LEADER LISENCE TEXT BOOK” (1st Edition,1Apr’09)

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By job training High work place training Roofing safety work

Steel truss safety work

Siding safety work

Prevent falling down training

Equipment safety training Boom lift usage trainingPiling work safety training

Foundation work safety training

Column work safety training

Prevent of machine accident

Electric equipment trainingPit work safety training

A frame ladder training


B. Special work training For further detail,please see in Chapter 2 of “ANZEN LEADER LISENCE TEXT BOOK”

47

7.Particular Safety Procedure7.Particular Safety Procedure

Identify and control critical jobs through risk assessment and standardization of work procedure and confirm in the form of the work.

Contractor should prepare safety method statement and safety plan for all critical jobs and get approval and use for training before performing the job.

Toyota safety officer must check the statement, key point & Approval by safety manager of construction site by confirm during audit.

Workers should follow the procedure to avoid and control the risk due to change point and don’t change procedure without safety officer permission.

Toyota participation should to assign Toyota safety officer to strictly & follow up safety officer that available by contractor’s.

48

New Procedure requestition- Material ordering ?- Revised drawing ?- Any interference ?

Evaluation1. Workability ?2. Functional ?3. Safety condition ?

Checked &

Inspected by1. Job Controller2. Safety officer

Maker project managerapproval

Owner acknowledge or

confirm

Start to implementation

No

Yes

Yes

No

Risk Assessment

Review work procedure


49

Check sheet and driver license

Sticker of audit

Check cable and marking

Check nut bolt and marking all

Strongly supportBarricade cover piling work

1.Piling workDiesel hammer machineA-frame machine


Boundary for safety area.

Control all operation Signal man

Un concern person must avoid to nearly during piling machine operation.

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1.Provide guardrail around the pit

4.Hook pile head during pound

3.Use fiber cutting with safety 2.Use crane hook the pile

5.After cut off, worker stand off6.To remove head trim by crane

2.Pile head trimming


Mostly be careful during pile head cutting.

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Install the balustrade around foundation

Install cable support steel bar for column

Install the stair with handrail

3.Foundation work


Safety focus point are steel shaft edge and falling down to the pit.

52

Install the stair, handrail and foot plate

Install the guardrail around pit area

Install the movement meter around working area

4.Pit work


Strong barricade

Steel sheet pile to prevent soil sliding

Safety focus point are narrow space for worker and heavy machine operation.

53

Install the guardrail around pit area.

Propose the stairs and handrail

Propose the lift line

5.Sum pit work


Signal man

Beware steel bar shaft edge

Signal control is necessary .

Beware soil collapse.

54Strongly support Promise to use

Daily check sheet

Warning sign

Install cross bracing for more stronger

Install the handrail that high 90 cm.

Install the foot plate around the foot plate


6.Column work Worker always use safety belts.

55


7.Roofing work

Safety net (Prevent worker or object falling down)

Worker always use safety belts

Install life line all around

Signal man2

Signal man1

Barricade around operation area

During operation, all concern must follow safety and work procedure sequence by sequence.

56


8.Welding and hot workWorker must use correct PPE and

beware heat from welding work.

Helmet with welding maskFire extinguisher and

at least 2 full water buckets to stand by.

Barricade

Use Gas cylinder tank

Leather glove

57

8.Further Safety Prevention8.Further Safety Prevention

Temporary safety prevention and look forward in case of risk or hazard that will be occur.

Everybody must sticky the safety rule with safety awareness all of activities which construction on process.


Traffic control

Whistle

Red & Green flags

Helmet

Chinstrap

Reflective Jacket

Signal man always use PPE and control traffic at junction way.

Giving correct signal to driver

Green = Can operation Red = Stop !

1000

Sign BoardLimit Speed 30 km/hr

Warning Light

Speed Bumper Concrete Barrier

Warning light Traffic signal manHeavy machine should provide warning light

Signal manEquipment

necessary use to control vehicle

Example connection point from public road


Hard barricade and fall down protection.

Hard barricade

Hard barricade for unsafe area

Small pit cover

Handrail separate by area

Example is piling work

Grill still cover

Example is gutter work

Prevention form public


LightingMovable lighting set s

Fixed support for electrical wire

Light in high place

Make clearly of route line

QC Check ,ok!

Person in charged


Equipment checking

QC Check ,ok!

Sticker guarantee, can use it.

Every equipment must check before use

Everyday must check tools by head man


4’s and Site cleaning

In order to keep :

•Safety

•Healthy

•Clearly

•Environment

Public road cleaning Neighborhoods cleaning

On site cleaning

Safety and Plant Engineering Department

Plant & Facility Engineering Section

Production Engineering Division

Toyota Motor Asia Pacific Engineering and Manufacturing Co.,Ltd.

1st Edition

Revision Version Year 2009

Year 2009 1st Edition

Documents

Transcript of Year 2009 1st Edition