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About the Safe Sanitation of WorkplaceBy Yukio Ando

V. Chair of JDRA Business & Planning Committee　I am Ando of Business & Planning Committee of JDRA (Japan Drum Reconditioners’ Association).This time, I talk about the safe sanitation activity at the workplace that JDRA coped with.

When the Japanese encountered the dangerous scene which led to a great accident & disaster from old days, the feeling of the heart might burst was expressed “Hiyari” (frightened experience) and of the brain might explode instantly was expressed “Hatto” (startled experience). In most cases, a lot of sweats were flowing under the back and arms afterword.

In 1928, Mr. Herbert William Heinrich, who was a deputy director of the research & technical department in an American nonlife insurance company, announced an interesting thesis (The Heinrich Law or the 1:29: 300 Law) about the disaster prevention. He checked the work-related accidents more than 5,000 and showed the law characteristics that “29 slight accidents" happened to the background of one “serious accident” and that further “seedlings of 300 accidents" were lurking to the background.

The law of Heinrich is called "the law of near-miss" from the contents in Japan and is known widely as the index of disaster prevention.

1 serious accident/disaster

29 slight accidents/disasters

300 near-misses

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(The Heinrich Law)

At this time, we called for providing near-miss examples which occurred actually at the production site to the 68 member companies of JDRA, and were able to get replies from 37 members actually. Let’s try to observe the totaled results.

Query 1: Were there work-related injury and accident within the past 3 years?

It is an estimate, but is assumed the numerical value of 47% with work-related accident of several times becomes fairly high, if include the 45% of nonresponse companies.

Query 2: Is your company doing the safety & sanitation education for employees?

Although the findings are as per the graph, the safety & sanitation education may not be performed satisfactory with other than 38% performing periodically and yearly.

Query 3: Is your company doing any action about the safety & sanitation?

Specific examples of the action

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・ A study meeting in group activity・ The factory meeting coping with “the Report of Near-miss experience & KY

(dangerous prediction) " carries out improvement activities・ Performing Safe patrol, Site maintenance on Saturday attendance, Recruiting of

safety markings, Commendation and Chorus・ Making the worker report a near-miss wearing the helmet & mask and improve

each time.・ Carry out safe patrol every month・ Carry out safety education & safety week event・ Confirming the precautions at the each meeting of morning, noon and evening・ Establishment/holding of the Safety & Sanitation Committee, and monitoring

activities by the committee・ Performing a study meeting on the safety examples together・ The correction confirmation work of the risky spot in the company・ Reporting the indication, precaution, awakening and improvement at the

Environmental Safe Sanitation Committee (once a month)・ Performing safety patrol・ Recruitment of the slogan and summarization of the work-related accident examples ・ Performing safety & sanitation meeting monthly・ 5S (tidying, order, cleaning, cleanliness & discipline) activity・ Performing morning meeting etc.・ Clarification of the indication, mark and the passage・ Performing the morning gathering and meeting・ Risk assessment

We understand that all activities, such as quality control, the cost reduction as well as the safety & sanitation, can be unfolded to the improvement activity, when we see the 19 specific examples coping with.

Let’s see a few actual examples.＜Example 1> Occurrence place: The site of factory Circumstances: When coming back to my post after a break. Summary: Because it was raining and wind blew, I pulled down about half of the

shutters. I struck my head when returning to my post, even though I was watching it visually. It’s my carelessness.

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Future measures: Never keep closing the shutter in odd height. If needed to keep it halfway opening, keep more than 2 meters in height.

A problem (unstable action was taken?) of yourself: I took a rest relaxing too much and was upset.

Applicable mind and body analysis: I was upset. I was in a hurry.

＜Example 2> Occurrence Place: Drum stock yard Circumstance:　Stock confirmation Summary: In the drum stock yard where drums were kept with three-stacked, I

climbed onto the 3rd of unstable stack to confirm the stocked drums and then I lost the balance and almost dropped.

The problem of the work method: Having climbed onto the third of unstable stack. Future measures: Prepare stepladders and never climb up onto a drum. A problem (unstable action was taken?) of yourself: I did not wear a helmet. Applicable mind and body analysis: I did not think deeply. I thought it was safe. I

lost the body balance.

＜Example 3> Occurrence Place: Remanufacturing line Circumstance: When cutting off a top head Summary: The work gloves were caught by the cut edge while cutting off a top

head at remanufacturing line, and my hand was almost caught in the cutter blade.

The problem of the facilities apparatus: There was no safety cover on the dangerous place of rotary power if touched with a hand.

The problem of the work method: Having touched with a rotating object. Future measures: (1) Adhering to not touch with the rotating drums while cutting

the top heads, I posted warning at the workplace. (2) The change of work groves (from the work gloves made of cotton to rubber ones).

A problem (unstable action was taken?) of yourself: Having touched with an object while cutting top heads.

Applicable mind and body analysis: I did not think deeply. The hand worked unconsciously.

The applicable three cases of the body and mind analysis, saying "I was in a hurry, I did not think deeply, and the hand worked unconsciously," are viewed as

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the person-like careless mistakes. However, it may be thought that there is the essence of problems such as not having a rule for the workplace or not being able to manage and control the rule.

The room for improvement seems to be in here.

The important thing of near-miss activity is to share examples at least one or more. It is important to praise the employee and the site if reported without hesitation, and to scold severely if being hidden.

To perform "improvement" of many near-miss examples one by one will prevent 29 slight accidents, and further this will lead to prevent one serious accident.

The demand to the safe sanitation from customers has become stronger and stronger in recent years.

I think it is the indication of the evaluation that a company which cannot manage the safe sanitation might be inferior in the quality and cost, in addition to the reason that the stable supply will be threatened by an accident disaster.

The JDRA’s activity to edit "The Samples of Near-Miss" was the trial to raise the control level each other by sharing the valuable “failure examples”, without hiding the actual cases of the member companies which are the competitor usually.

It is my pleasure if this presentation serves you as some kind of references.

Thank you for your attention.

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