Safety and Environment Report 2004 - Honda · Safety and Environment Report 2004 The Power of...

Safety and Environment Report 2004

The Power of Dreams

VALIDATEDENVIRONMENTAL

INFORMATIONREG.NO. UK000109

Honda of the UK Manufacturing Ltd, Highworth Road, South Marston, Swindon, Wiltshire SN3 4TZ www.mfg.honda.co.uk

1.0 Introduction

1.1 The Site Development

1.2 Company Profile

1.3 Management Standards

2.0 HUM Environmental Impacts and

Controls.

2.9 Performance Against Legal Requirements

Summary 2002 – 2004

2.10 2004 to 2005 Environmental Performance

against Objectives and Targets

3.0 HUM Safety Risks and Controls

3.6 Performance Against Legal Requirements

Summary 2002 – 2004

3.7 2003 to 2004 Safety Performance Against

Objectives and Targets

4.1 Safety and Environment Improvement

Objectives 2005/2006.

contents

2

The Power of Dreams

*2004 data refers to data from financial year April 2004 to March 2005

3

foreword

Environment and Safety remain cornerstones of Honda of

the UK Manufacturing Ltd’s (HUM) business. Supported by

management standards - EMAS, ISO14001 and OHSAS

18001 – HUM continues to set challenging standards for

continuous improvement.

Despite a record number of cars being built in 2004, improvements were

still achieved in energy and waste efficiency and an overall reduction

in the number of accidents on site. The additional impact of

new legislation has resulted in new operating permits for our

Die Casting and Painting operations. HUM is also compliant

with all the current requirements of the End of Life Vehicle

Directive and is working with suppliers to ensure full

compliance at least 6 months ahead of the requirements of

the law.

To communicate this activity HUM has produced its fourth

Safety and Environmental statement. The statement has been

simplified to focus only on HUM’s significant environmental

aspects and safety hazards. The significance of the hazards and

aspects is determined by the company environmental aspects

register, and the risk assess system. As the impact and controls

of the indirect aspects have not changed these have also not been reported.

This statement has been independently verified to confirm compliance with the Eco-

Management Audit Scheme (EMAS) and the Health and Safety Commission Guidance (HSC).

We would welcome any feedback or further questions you may have regarding this statement.

Contact details are included on the final page.

M . KatoHUM Managing Director

4

safety & environmental

1.0 IntroductionHonda established its first european car manufac-turing plant in Swindon in 1985. The site started as aPre-delivery Inspection Facility (PDI) and with theaddition of a second car manufacturing line in 2001now has the capacity to manufacture 250,000 cars.

1.1 Site Development Time line1985 Established

1986 PDI facility

1989 Engine plant started

1992 No.1 Car Plant No. 2 Engine LinePress FacilityEquipment ModificationsNew Model Developments

1998 No. 2 Car Plant New Model Production ToolingImprovements to existing Facilities.

2002 Expansion of the Logistics and Press facilities.

2003 Further Press Expansion

2004 Bumper Injection Moulding

1.2 Company profile

Honda of the UK Manufacturing Ltd is a wholly ownedsubsidiary of Honda Motor Europe Ltd. HUM currentlymanufactures the three and five door Civic and theCRV. All three vehicles are supplied to the Europeanmarket, the Middle East and Africa and some variantsexported to America, Canada and Japan.

The plant is built on a 1.5 million square meter greenfield site. The overall building area is 143,000 m2 .

1.3 Management Standards

HUM achieved certification to the international qualitystandard ISO9002 in 1994 and was recertified toISO9001:2000 in 2004. ISO14001 the internationalenvironmental standard was achieved in 1998 andOHSAS 18001 (a nationally recognised safetystandard) in June 2001.

ISO14001 and OHSAS 18001

ISO 14001 and OHSAS 18001 define formal systemsof environmental and safety management based onthe Plan, Do, Check, Action model shown overleaf. Itis not intended to establish the absolute requirementsfor environmental and safety performance but to showa commitment to the safety and environmental policy,to comply with applicable legislation and to ensurecontinual improvement.

HUM receives 6 monthly audits to confirm complianceto all three standards from an externally accreditedorganisation the Vehicle Certification Agency.

Environment and Safety Policies

Environment Policy

‘We will make every effort to protect the environmentfrom the effects our manufacturing operations and willachieve, by means of continuous improvement, theexpectation of society and our local community.’

Safety Policy

‘We will ensure a safe and healthy workingenvironment by building safety into our process andequipment and by achieving the highest level of safetyawareness in our associates.’

‘There shall be no production without Safety ‘

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report 2004

Plan, Do, Check Action

Plan

Safety & Environmental policy

Identification of Environmental

aspects/safety risks

Identification of legal and otherrequirements

Setting objectives and targets

Action

Managment Review

Do

Structure & responsibility

Training, awareness & competence

Emergency preparedness & response

Operational Control

Communication

Documentation

Document control

Check

Monitoring and measurement

Non-conformance andcorrective/preventive action

Records

Audits

2.0 HUM Environmental Impactand Controls

2.1 Air and Odour

Description of environmental impact

Types of emissions to air include VOC’s and particulatesfrom the painting process and from the application ofsealers and adhesives in a number of locations, andfoundry emissions from the Die Casting process.

All of these processes are regulated by licences issuedby Swindon Borough Council (SBC) as part of either thePollution Prevention and Control Act or theEnvironmental Protection Act.

How is the impact managed/ controlled?

The SBC licences set limits on specified emissions fromstacks and require controls to be put into place tominimise the processes impact on the environment.

Emissions from the Painting processes are controlledthrough the following methods:-

• Calculate a monthly mass emission showing thegrams of solvent (VOC) released per square metre ofvehicle surface area or per bumper.

• Annual stack testing to a pre-determined standardby an external company.

• Checks to ensure there is no offensive odour at theboundary or dark smoke from the stacks.

• The use of waterborne primer, surfacer andbasecoat.

• The use of thermal oxidisers to reduce VOC’s fromthe vehicle curing process.

• The use of high efficiency paint transfer systems.

Emissions from the Die Casting process arecontrolled by:-

• Dust suppressers on all the furnaces to reduce theparticulates being emitted to the environment.

• A fume scrubbing system to minimise emissionsfrom the sand molding process.

• The use of low resin sand to minimise odour fromthe process.

• Daily visual inspections and continuous particulatemonitoring.

• Regular odour checks at the boundary.

36


2.2 Water Management

Description of Environmental ImpactThere are two types of water discharged from HUM,storm and foul water. Foul water is dischargedthrough the public sewers and contains water fromour domestic facilities and effluent from our productionoperation. Storm water is discharged from the roofdrainage systems and car parking areas.


All water from this process has to meet the dischargeconsent limits set by Thames Water for foul water andthe Environmental Agency in terms of storm water.

To ensure the trade effluent achieves the dischargeconsents HUM operates an onsite Waste WaterTreatment (WWT) facility and an Engine EffluentTreatment (EET) Facility. Waste water from the Paint,Bumper Paint and Underbody Protection processesare sent to WWT for additional treatment in a batchprocess. Sampling to confirm compliance todischarge consent takes place throughout theprocess, to achieve optimum treatment and guaranteedischarge levels.

The EET facility is an Ultra-filtration process, whichseparates oil from water using a membrane. Thewater is discharged to foul and the oil is stored on-siteand later sent for recycling at a licensed wastetreatment facility.

All storm water from the site is discharged through anon site lagoon, which is a single point of discharge forthe site. The lagoon is an engineered structure with aconcrete interceptor at the discharge point to the offsite brook which is designed to regulate the flow ofwater to prevent flooding down stream and preventany petroleum based contamination entering thebrook. The quality of the water is periodically checkedto ensure compliance with the discharge consent.

Throughout site there are extensive systems in placeto reduce the potential for contamination enteringeither storm or foul drains. Examples of this include,bunding of all storage tanks to 110% of their capacityand controlled delivery and unloading of all liquidmaterials.

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report 2004

2.3 Waste Management

Description of Environmental Impact

Every department generates waste at HUM. This mayrange from non-hazardous office wastes to hazardoussolvent wastes. HUM sets a target for reducing thequantity of waste landfilled on an annual basis. This isin line with the Honda Motor policy of achieving zerowaste to landfill by 2010.

How is the impact managed/controlled?

Waste Management

HUM utilizes the following waste hierarchy as thebasis for its waste management strategy.Minimise, Re-use, Recycle and then Controlleddisposal.HUM combines this technique with the “ProducerResponsibility” principle. This requires eachdepartment to be responsible for the management ofits own waste from generation to final disposal. It alsomeans that departments need to segregate wastetypes as far as possible and ensure that waste isstored and labelled correctly.

HUM has taken steps to minimise waste generated atsource. One of the main areas of minimisation hasbeen the use of returnable packaging. This takes theform of metal stillages with a lifetime of about 7 yearsand plastic boxes with a lifetime of about 3 years.Returnable packaging is used on the majority oflocally (European) supplied parts to replace cardboard,polythene and polystyrene. A similar approach hasbeen taken with parts supplied from Japan (known asKD or “Knock Down” parts). These are transported inreturnable metal modules. Honda has introducedreturnable plastic boxes to be used in these modulesfor some parts in order to minimise the quantity ofpackaging entering the factory.

If waste cannot be eliminated at source HUM will tryto re-use any waste materials in the process. Anexample of this is the re-melting of reject aluminiumheads and blocks to make new heads and blocks inthe die-casting process. This concept has recentlybeen applied in the bumper injection moulding areawhere reject bumpers are chipped and re-melted tomake new bumpers.

HUM is committed to the recycling of waste materials.Cardboard and polythene from both car plants arebaled using the onsite-recycling centre located in theMaterial Logistics (ML) area and then sent off site forrecycling. Other projects include the recycling of usedcoolants and oils to make heating and fuel oils, woodto make chip board and solvents for re-use in carbody shops. Metals from the press shop are baled atHUM before being recycled by a local metal recycler.Aluminium not suitable for re-introduction into the Die-Cast process is returned to the aluminium supplier forre-processing. A recent improvement uses watertreatment sludges from the paint and water treatmentareas as a raw material for cement manufacturing.

An on-site waste broker organises the disposal routeson behalf of HUM for all waste excluding aluminiumand steel which is managed by HUM. The wastebroker also monitors the quantities of wastegenerated by the site on a monthly basis. This data isused by departments to identify improvement areas.

The Duty of Care regulations state that a wasteproducer must verify the legal compliance of its wastecontractors. Waste site Duty Of Care audits arecarried out by both HUM and the waste broker forthose contractors that they control. HUM also has anobligation under the Producer Responsibility(Packaging Waste) Regulations and is required torecover and recycle a percentage of its packagingwaste. HUM has achieved its obligation to date bybuying the required number of packaging wasterecovery notes.

Total Waste to Landfill (T/ Year):- 2000 to 2005 Target

2.4 Energy Management


HUM supports the continuous drive for CO2 reductionby analyzing every opportunity to reduce theconsumption of energy. Energy includes gas, waterand electricity use. The measurement of energyincludes base energy used to operate the buildings,such as heating and lighting, and process energy tomanufacture the product.


HUM manages energy based on the ‘user responsi-bility’ principal. Targets are set on an annual basis andaction plans developed by departments to achievetheir targets. Representatives from each of the maindepartments meet on a monthly basis at the siteenergy committee. The Paint, Bumper Paint, and DieCast departments are also required to meet ClimateChange Levy targets set by the government andagreed through our trade association the Society ofMotor Manufacturers and Traders (SMMT).

The majority of electricity usage on site is metered andactual time data can be accessed by departmentsfrom the intranet. They can use this data to implementimprovements immediately.

2.5 Noise Management


Noise is generated from HUM from a number ofprocesses (internal and external), for example, thePress department, air conditioning systems andcontractor operations.

How is the impactmanaged/controlled?

Internal noise iscontrolled primarilythrough safetylegislation and internalsafety standards toensure the protectionof our associates. Allexcessive noise isengineered out of theprocess wherepractical at the design and development stage. HUMexternally sited equipment is regularly maintained tominimise noise levels and contractor work is carriedout with the aim of minimising the impact on the localcommunity.

Noise modelling has been carried out across the siteto confirm noise levels at the boundary and that HUMare in compliance with our planning consent. For allnew developments where noise is likely to be a issuethe noise model is updated to assess the impact ofthe new development so that mitigation measures canbe implemented if required.

2.6 Traffic Management


There are three main causes of traffic into HUM:-

• Transporters taking cars to the ports or dealers

• Parts deliveries

• Associates driving to and from work.

Each of these impacts has an effect on the localcommunity, on air quality and noise.


Transporters taking cars to the ports or dealers – thereare over 1500 transporter movements per month. Alltransport companies are instructed to use the mainroutes (M or A roads) where ever possible. Morerecently HUM have asked all transport companies toensure that their vehicles run on low sulphur diesel andthe scheduling of the trucking pattern has beendesigned to reduce the impact during peak traffic times.

Parts Deliveries - The majority of HUM’s partssuppliers deliver into warehouses operated by aHonda subsidiary SDC or their own local warehouses.

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Power Logic Screen Print

9

report 2004

A large percentage of deliveries from the warehousesare carried out via an internal road to minimise theimpact on the local residents. To minimise the impactof those deliveries that have to use the public routessuppliers are required to use M and A roads whereverpossible and maximise parts loading.

Associates driving to and from work – Due to thelocation of HUM and the lack of public transportopportunities the focus of our green travel initiative,has been to increase the number of associates whocar share. An informal scheme is in place. Althoughcycle sheds and cycle paths on site are provided, alack of cycle tracks on the main roads onto site makeit unsafe to encourage associates to cycle to work.

2.7 Visual Impact

Description of Environmental Impact

Visual impact is a term used to describe the effect onthe landscape caused by buildings and theirassociated facilities. The current site buildings coveran area of 143,000 m2. In addition to the building areaHUM has extensive car parking areas for product andassociate cars.


Colour – All buildings on site are consistently colouredto minimise the visual impact and to blend in with thelandscape.

Size – Buildings are constructed using the principle ofminimum space in order to maximise efficiency,resulting in the least visual effect on the landscape.

Land Management – The site is surrounded by aseries of tree belts incorporating English Nativespecies, such as English Oak, Beech and the

Hawthorn, that are regularly maintained in accordancewith the site planning consent. The last major plantingtook place in 1997 and 1998 when over 2700 treeswere planted along the South Marston fence line.Additional planting took place in 2002 following theexpansion for the second car plant.

Lighting – Lighting in the operational areas of site iscontrolled by Vehicle Logistics and Facilities. Lightsare directional and are aimed away from SouthMarston village. The lights are controlled to ensurethat 2 out of 3 perimeter lights are off at night andtherefore the night light is substantially reduced, alsoresulting in energy savings.

2.8 Supplier Management


HUM has over 220 parts and direct consumablesuppliers in both Europe and the rest of the world.


The environmental performance of suppliers isassessed on an annual basis using the supplierEnvironmental Management Survey issued byPurchasing. The purpose of the survey is to verify whichof HUM’s suppliers have achieved IS014001 or EMAS.

All Civic suppliers are required to achieve ISO14001 oran equivalent standard by September 2005 and CRVsuppliers must achieve by September 2006.

HUM will support supplier environmental improvementactivities if requested.

All other environmental impacts are managedthrough the site environmental management system.

2.9 Performance against Legal Requirements Summary 2002 – 2004

10


Air and Odour• Paint Mass emissions (g/m2) (total)

• Bumper Paint VOC Stack emissions average(mg/m3)

• Die cast stack emissions average (mg/m3)- Particulate (mg/m3)- Fluoride (mg/m3)- Chloride (mg/m3)- Copper (mg/m3)- VOC (stack 3 only) (mg/m3)- All other results for Die Cast stack 3 were

undetectable

Water• Metals waste water stream

- Oil and Grease (mg/l)- Chemical Oxygen Demand (mg/l)- Settlable Solids (mg/l)- Nickel (mg/l)- Zinc (mg/l)- Copper (mg/l)- Lead (mg/l)- Chromium (mg/l)- PH- Phosphate (mg/l)

• Engine Effluent treatment discharge- Oil and Grease (mg/l)- Chemical Oxygen Demand (mg/l)- PH- Settlable solids (mg/l)- Nickel (mg/l)- Zinc (mg/l)- Copper (mg/l)- Lead (mg/l)- Chromium (mg/l)

• Lagoon Discharge- Oil and Grease (mg/l)

• Noise

25

13

4.80.20.860.001219

1279880.620.310.070.090.077.931

2088866.84500.052.480.080.180

1.9

23

7

3.730.022.150.00173

201027520.560.290.070.0910.0777.5431

48103706.36360.10.90.10.30.1

2.7

24

11

9.80.150.810.00263

1085080.770.140.010.010.028.96

2143106.0220.030.5 0.020.010.04

0.5

60

50

50552030

5020001000233336-11100

350300006 – 11100023333

20

Criteria 2002 2003 2004 Legal reqt

Within Planning consent limits WithinPlanningConsent

There have no breaches of existing consents and no significant statutory nuisance issues.

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report 2004

2.10 2004 to 2005 Environmental Performance against Objectives and Targets

Air andOdour

Waste

Suppliers

Traffic

Water

• Paint 1 mass emissions 20g/m2

• Paint 2 mass emissions 27g/m2

• Zero local community odourcomplaints

• In Paint 1 the emissions from

two thermal oxidisers wasplanned to be redirected to theexisting regenerative thermaloxidiser.

• In Die Cast a situation analysiswas carried out on the functionof the abatement equipment.

• 1200T to be landfilled

• Eliminate paint sludge fromlandfill.

• Improve packaging recyclingacross the Paint Division.

• 100% of first tier suppliers tohave a certificated EMS byOctober 2006.

• Reduce traffic impact on thelocal community from partsdeliveries by 10%.

• Carry out a traffic survey onassociate’s cars.

• Maintain existing waste waterprocess.

• Implement the requirements ofthe Oil Storage Implement the requirements ofthe Oil Storage Regulations intonew developments.

• Implement new PPC permitrequirements into WWTprocess.

• Investigate water recycling bydeveloping a trial unit.

• Paint 1 mass emissions20.3g/m2

• Paint 2 mass emissions28g/m2

• Zero complaints received

• Oxidisers redirected

• Situation analysiscompleted andimprovement plan in place.

•1415T to landfill

• Obsolete parts salvagescheme introduced

• All sludge’s recycled incement manufacture.

• Polythene recycling is nowtaking place

• 86% of suppliers complete

• 5% reduction in traffic byre-directing vehicles towarehouses

• Traffic survey notcompleted.

• Existing processmaintained.

• Complete.

• Draft permit in place

• Investigation complete.

• The change in paint 2from two shifts to oneshift but with no change incleaning frequency hasmeant that the targetcould not be achieved.

• Paint sludge recycling delayed

• Improved paper recyclingplanned for 2005

• Activity ongoing for 2005

• Carry out traffic survey in2005.

• Improvements to continueduring 2005.

• No concerns raised byThames Water or theEnvironment Agency.

• Activity planned for 2005.

• Polymer trials carried out.

Media 2004 Objectives End of Year Result Comments

Table continued overleaf.

12


2.10 2004 to 2005 Environmental Performance against Objectives and Targets cont.

Noise/Landscaping

Energy

Other

• Maintain current planningconditions.

• Carryout tree husbandry alongboundary.

• Zero noise complaints.• Maintain the site noise model

following significant developments.

• 3% reduction in absoluteenergy use.

• Preparation for entry into newEmissions Trading Schemethrough the installation of newmeters and remote metering.

• Implement contractor passportsystem on site.

• Complete the recyclabilitycalculation for the new Civicmodel.

• Existing maintenanceprogramme achieved.

• Tree husbandry carried out.

• No complaints received.• No significant

developments.

• 3% reduction achieved.

• Application for EmissionsTrading Scheme completeand allocation agreed.

• Incomplete

• Activity to be completed in2005.

• Noise model to beupdated in 2005.

• On-going improvementactivities in 2005 toimprove controls onboilers and compressedair generation efficiency.

• On-going activity in 2005.

• As above.

Media 2004 Objectives End of Year Result Comments

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report 2004

3.0 Plant Safety Hazards3.1 Fire

There are three areas at risk from fire within HUM.These are the Welding, Paint and Die Casting areas aseither hotwork is carried out or flammable material isbeing stored.


HUM’s fire policy focuses on the preventionof fire, ensuring effective and testedevacuation procedures are in place andfinally fire fighting but only if assessed assafe by trained and competent associates.

The plant is built on a 1.5 million m2

greenfield site. The overall building area is143,000 m2.

Fire Prevention

The most important part of managing fire isto prevent it occurring in the first place. This isachieved by both physical and management controlsincluding:-

• All new equipment is ATEX specified as

required and checks carried out following installation on site.

• A high standard of housekeeping is maintained

• Regular equipment maintenance checks on allequipment

• The controlled storage and use of flammablesubstances, particularly petrol, solvents and gases.

• The use of water based paint where possible withinthe paint shops has also reduced the risk of fire inthese areas.

• Responsibilities for fire prevention is clearly allocatedand documented.

• Designated smoking areas and a clear site smokingpolicy.

• A permanent security presence on site to reducerisk of arson.

• Permit to work system controls irregular hot workoutside of designated hot work areas.

Fire Evacuation

To ensure effective, immediate and safe fire evacuation,detection systems are installed throughout. Thesesystems include: -

• Fire alarm sounders, break glasses, emergencylighting, fire exit signs and smoke detectors that arelinked to a fire management computer system.

• Fire procedures detail actions to be taken byassociates and emergency teams.

• Emergency evacuations and roll calls testedregularly.

• Trained emergency teams to investigate and ensureevacuation.

• Fire assembly points with radio communication toemergency teams.

Fire Fighting

If a fire were to take place at HUM the priority is toensure safe evacuation.

Stratton Fire station is only 2 minutes away from themain site entrance and the fire brigade regularlycarryout familiarisation tours to ensure they have athorough knowledge of the site.

The site emergency teams that investigate all fire alarmsituations are trained in fire procedures and minimisingrisk in fire situations. Additional fire extinguisher trainingis provided on site to appropriate associates.

Physical controls have also been put into place.These include: -

• All buildings except die casting have fire sprinklers.

• Fire extinguishers in all areas including large trolleymounted extinguishers in higher risk areas andwater hydrant ring main around both plants.

• Fire management computer system automaticallyshuts down high risk areas such as Paint and thepetrol delivery system. It also opens security lockeddoors.

• Specially designed solvent storage and mix rooms inPaint and Bumper Paint.

• Emergency cabinets containing equipment and toolslikely to be required in an emergency.

• All fire equipment is regularly maintained. The effectiveness of these controls is reviewed in eachdepartment through the company safety toursystem.

3.2 Plant and Equipment

Description of Safety Risk

Equipment is used to support every aspect of HUM’smanufacturing process. Equipment is defined asmachinery, appliance, tool or assembly of parts. Thetypical equipment hazards at HUM are:

• Mechanical hazards - trap or crush points; contactwith moving parts; ejected or falling parts

• Electric hazards such as shock or burns

• High or low temperatures

• Noise and vibration

• Ergonomic

• Chemicals

• Lasers

How is the risk managed/controlled?

To minimise the risk of newequipment the priority is to eradicateany hazards during the design,manufacture and installation. Allnew equipment is CE marked andpurchased according to a strictHonda specification. Once theequipment is installed an equipmentsafety check sheet is completed toensure that the equipment complieswith the HUM specification.

Other controls for equipmentinclude:-

• Operation standards, riskassessments and visual aids/signage in place to support thetraining of operators.

• Clear lock off, access and maintenance procedures.

• Regular checks on electrical distribution equipmentand portable appliance equipment.

• 110v equipment used where practical in productionareas.

• Noise and vibration surveys to highlight any areas ofconcern.

• Insurance checks carried out on all lifting equipmentand marked with the safe working load.

3.3 Vehicle Movements


Vehicle movements on site include:-

• Associates coming to work

• The delivery and movement of parts around site.

• The movement and testing of new vehicles.

• Associates business driving on public roads.

All of these activities present different hazards to ourassociates, pedestrians and other road users and needspecific controls to be appropriately managed.


Forklifts and Towtrucks

Forklifts and tow trucks are used to move parts andconsumables around the factory. The risk is increasedwhen the goods are being loaded and unloaded.Examples of process controls to minimise the riskinclude:-

• All drivers must hold an HUM licence,

• All trucks undergo regular maintenance and dailychecks are carried out before they are used by thedriver.

• Only gas and electric trucks can be used on site andthey are limited to 7mph.

• Barriers are used in front of doorways and gangwayspainted green to protect pedestrians.

• Seat Belts worn on all counterbalance forklifts.

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report 2004

Car Movements

Car movements include the movement of new vehiclesto loading areas, associates driving on and off site andthe delivery of parts and materials on site.

Where possible pedestrians and vehicles are keptseparate and a site speed limit of 15mph externally and10mph inside the building is imposed. Vehicle speedchecks are carried out to increase associate and driverawareness and enforce the speed limits. All driversmoving cars on site or driving for company business arerequired to undergo training and sign the companydriving procedures to confirm they will comply with thesite rules.

3.4 Associate Awareness


Good associate safety involvement is critical to ensurethat safe working practices are followed andaccidents are reduced. Unsafe behaviour or a poorsafety culture can lead to an increase in all types ofaccidents.


A strong safety culture and good associate safetyawareness is maintained at HUM through some of thefollowing methods:-

• Training of all levels of associates through induction,the associate development programmes for eachgrade and job specific training.

• Safety and environmental care points are statedwithin department procedures and operationstandards.

• All departments have safety and environment noticeboards in place that include details of the companypolices and department specific activities.

• Safety patrol and safety tours carried out in allproduction areas.

3.5 Manual Handling and Ergonomics


The nature of the manufacturing operation at HUMmeans that many of the production tasks arerepetitive and may involve manual handling. Nonprocess related activities may also require manualhandling. In both cases these tasks could lead tostrain injuries. Examples of tasks that may causestrain injuries include the lifting and movement ofheavy objects and the risks of damage to hands andother parts of the body during the movement ofobjects.


The variety and nature of the risks means that themethods of control that have been implemented haveto be wide ranging.

The Use of Manual Handling Assists

Manual handling assists, conveyors and othermechanical aids are used when the manual handlingrisk can not be designed out of the process. Forklifttrucks and trolleys may be used to move heavierirregular objects. Parts are delivered to the productionline in purpose built stillages to where they are neededto reduce the amount of space on line used by theparts but also to minimise the amount of manualhandling.

Ergonomics

Ergonomics is considered when production processesare designed with the principal of ‘fitting jobs topeople’. There are trained ergonomic assessors withineach department who are involved at the new modeldevelopment and carry out process assessmentsfollowing accidents. More recently HUM has beenimplementing the Honda Global Ergonomic Standard.

On site Rehabilitation and Physiotherapy

HUM provides an on site rehabilitation, physiotherapyand chiropractic service for our associates for thetreatment of both work and non work related injuries.The associate is regularly reviewed to assess progressduring and following the treatment. The purpose ofthe facility is to ensure that associates are treated asquickly and effectively as possible.

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3.6 Performance against Legal Requirements Summary 2002 - 2004

Injuries as defined in The Reporting of Injuries, Diseases and Dangerous Occurrences Regulations 1995(RIDDOR) occurring to HUM employees.

22000022 22000033 22000044

Fatal Accidents 0 0 0

Major injuries 5 6 0

Dangerous occurrences 1 1 0

3-day Reportable Accident Rate * 1941 1767 1008

Reportable disease 1 0 0

First Aid accident and ill health rate* 16393 16602 12786

HSE enforcement notices 0 0 0

Convictions of HSE offences 0 0 0

*per 100,000 employees as defined in HSE publication Successful Health and Safety Management (HSG65)

Description of serious accidents

There were no serious accidents during 2004.

HUM does not gather specific absence data on thenumber of employee days lost due to all causes ofphysical and mental illness separate from generalabsence data.

As safety at HUM is not driven by cost but by respectfor the individual, information on the cost of safety isnot available for 2004.

Consideration will be given to providing the specificinformation in the future as requested by the HSCguidance.

3.7 2003 to 2004 Safety Performance against Objectives and Targets

17

report 2004

Fire

Plant andEquipment

VehicleMovements

AssociateAwareness

ManualHandling/Ergonomics

Other

• Comply with DSEAR requirements

• Fire Brigade familiarisation tours

• Zero major fires.

• Reduce exposure to noise and vibration

• Zero asbestos on site

• Implement lifting equipmenttagging system.

• Zero traffic related injuries.• Car park and roadway review,

• All associates who drive onbusiness to sign the businessdriving procedure.

• Improve company and departmental S&E Notice boards

• Health promotion• Safety and Environment patrols

• Database of process andindividual capabilities to bedeveloped during 2004/ 2005.

• Create robust MSD treatmentsystem.

• Complete Global ergonomicstandard training for processteams and managers.

• Implement global ergonomicstandard for design of stillages.

• Safety tours to take place in all production support areas.

• All VDU assessments to be completed for new computersystems and training of allassociates to be completed.

• DSEAR risk assessments,training, signage andintegration into companysystems complete

• Familiarisation tourscompleted

• There were no major fires.

• Monitoring and analysiscomplete. Noise andvibration procedures underreview. Departmentsworking to reduce noiseand vibration levels

• Asbestos containingequipment removed fromsite.

• Tagging system implemented.

• 2 traffic related injuries• Review completed• Speed check program started• Complete.

• Standard format created• Review completed• Health promotion delayed• Patrols completed in all areas• Process formalised in

management system• On-going process during

2005. Good progress wasmade in 2004.

• Chiropractor in place to work along side the physiotherapists.

• Training completed.

• Incomplete.

• Complete.

• Completed.

RRiisskk 22000044 OObbjjeeccttiivveess EEnndd ooff YYeeaarr RReessuulltt CCoommmmeennttss

• HUM are working towards achieving future legal limits fornoise and vibration

• Health promotion is a key activity for 2005/06

• Continue to assessprocesses and individuals in 2005.

• Ergonomic policyimplementation tocontinue in 2005.

• Activity to take placein 2005.

18


A

B

Safety

Environment

Reduce total site accidentsby 10%.

Formalise existing Healthpromotion system.

Reduce waste to landfillfrom 90T a month to 70Tper month by the end ofthe financial year.

Reduce absolute energy(gas and electricity)consumption by 3%.

Reduce VOC Massemissions from thepainting process by 1g/m2based on 2004performance.

100% legal compliance.

Implement associate awareness campaigns within divisions.Introduce Honda Global ergonomic standard.Encourage early reporting of Musculo- skeletal injuriesthrough associate and manager training.

Introduce voluntary medicals for all associates over 50.Implement site Drug and Alcohol Policy.Carryout ‘Stop Smoking’ Campaign.

Implement satellite collection scheme to reduce unrecyclablewaste from smaller departments to landfill.Introduce bin weighing system and zone recycling awards toincrease waste ownership and encourage good segregation.Reduce hazardous waste through improved segregationand recycling.

Further optimisation of existing building services equipment.Extension of real time monitoring to include compressed air.

Improve solvent awareness through training and in line 2modify equipment to reduce cleaning frequency.

Continue to manage through HUM management systems.

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HUM safety and environmental objectives are set onan annual basis from the company business plan withspecific action for achievement documented andmonitored on the department business plans.

Environmental Management programmes are also inplace within departments to encourage environmentalimprovement.

4.0 2005 Safety and Environment Improvement Activities - Key Themes

5.0 Local Community ActivitySchool Visits

HUMs school visit programme started in 1999 as a pilotprogramme, supported by Swindon Borough Council,with 1 school offering 25 students the opportunity totour the plant. In the past 6 years this activity hasexpanded to include 8 schools with 800 studentsvisiting site in the last 12 months. The purpose of thevisit is to promote environmental management andLocal Agenda 21 in schools in the Swindon area. Thevisit takes the form of presentations on Honda, LocalAgenda 21 and Environmental Management. This isfollowed by a plant tour and the opportunity for aquestion and answer session with HUM management.Overall these visits have proved to be very successfulfor both parties. HUM plans to continue to offer theopportunity for schools to visit for the foreseeable future.

Safety Challenge

The safety challenge is an initiative that was introducedin 1998 to help raise safety awareness with associatesand reduce accidents within the departments. This isachieved by teams of associates working towards atarget day without having an accident. When a safetychallenge team achieves their target a donation of £50will be given to a local charity of their choice. In 2004 atotal of £10750 was donated to local charities throughthe HUM safety challenge.

6.0 Verification StatementEnvironment

The information and data contained within Section 2 and 4Bhas been verified as representing an accurate statement of factand this statement has been validated as meeting therequirements of the Eco- Management and Audit Scheme(EMAS 2) (Regulation (EC) number:- 761/2001).

Signed:

VCA Accredited Verifier for EMAS 2 (UKAS Registration No. 028)Verifier Number: UK-V-0014.

Vehicle Certification Agency1 Eastgate Office CentreEastgate RoadBristol BS5 6XX

T: 0044 (0) 117 9524133www.vca.gov.uk

Safety

The information and data contained within section 3, 4A and 5has been verified as representing an accurate statement of factand the safety statement has been validated as meeting therequirements of the document ‘ Health and Safety in AnnualReports: Guidance from the heath & Safety Commission.’

Signed:

Steve SpencerClient Manager for OHSAS for OHSAS 18001 (OccupationalHealth and Safety Assessment Series Specification)Vehicle Certification Agency1 Eastgate Office CentreEastgate RoadBristol BS5 6XX

T: 0044 (0) 117 9524133www.vca.gov.uk

If you have any questions or comments with regard to this statement please contact:The Occupational Health, Safety & Environment DepartmentHonda of the UK Manufacturing Ltd, Highworth Road, South Marston, Swindon SN3 4TZ Telephone 01793 837930

Safety and Environment Report 2004 - Honda · Safety and Environment Report 2004 The Power of...

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