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Dialogue between Management and Plants

To monitor progress in safety issues, senior managers at Zeon visit plants to carry out regular inspections, interview workers, and brief workers on annual policies. They also visit plants on other occasions to engage front-line plant workers in direct, serious dialogue. Top management spent 61 days visiting plants in fiscal 2015.

Efforts to Promote Safety Management Led by Top Management

Every year, top management develops a "Safety Management Improvement Master Plan" and leads the company in an initiative to improve its Safety Management System based on the understanding that "safety is the highest priority."
These activities are ongoing and focused on achieving the easily understood policies shown below.

  1. Reliable operation of equipment and systems to prevent mistakes (“Never rely on ‘maybe’ or ‘should’”)
  2. Plant deterioration countermeasures and foolproofing* measures (“Good judgment saves money”)
  3. Review of past accidents and recurrence prevention (“Never rely on ‘maybe’ or ‘should’”)
  4. Review of standards (“Always follow the rules. Change any rules that cannot be followed.”)

The act of modifying a piece of equipment or a process to prevent accidents that would otherwise result from human error, such as when a new employee or someone with less knowledge or experience makes a mistake, or when someone with experience makes a mistake inadvertently.

Obtaining Safety Inspector Certification at all Sites

Safety Inspector Certification *1
Obtained at all worksites (Takaoka, Kawasaki, Tokuyama, and Mizushima plants).
Completion Inspection Certification *2
Obtained at our Kawasaki, Mizushima, and Tokuyama plants.
When renewing these certifications, evaluations are carried out not only to investigate safety inspection and completion inspection methods and inspection management implementation, but also to confirm that the Safety Management System meets the standardized requirements set by Japan’s High Pressure Gas Safety Act and that these systems are being operated properly.
In order to more reliably ensure safety at all of our worksites, we ensure operation of the Safety Management System and plan implementation of hazard identification and risk mitigation at all of our plants.

  • *1.Safety Inspection Certification
    Certification granted by Japan’s Minister of Economy, Trade and Industry in accordance with the High Pressure Gas Safety Act to allow qualified individuals to perform safety inspections to determine whether certain facilities comply with technical standards, either while the equipment is still running or while it is stopped.
  • *2.Completion Inspection Certification
    Certification granted by Japan’s Minister of Economy, Trade and Industry in accordance with the High Pressure Gas Safety Act to allow qualified individuals to perform completion inspections to determine whether manufacturing facilities or class 1 storage facilities that have undergone certain modifications comply with technical standards.
Certification Safety Inspection Completion Inspection
Takaoka Plant Obtained in 2000
(renewed in 2015)
Kawasaki Plant Obtained in 1998
(renewed in 2012)
Obtained in 2008
(renewed in 2012)
Tokuyama Plant Obtained in 2007
(renewed in 2012)
Obtained in 2012
Mizushima Plant Obtained in 2006
(renewed in 2011)
Obtained in 2006
(renewed in 2011)

Improving Plant Safety

We conduct "plant safety evaluations" and "safety diagnosis programs" to further improve the safety level at plants and prevent the occurrence of serious accidents or disasters.
Plant Safety Evaluations
We conduct evaluations to confirm plant safety at the design stage when commissioning a new plant or upgrading an existing one.
Safety Diagnosis Program
For existing plants, while checking each work area, we make sure all risk sources have been identified, and confirm whether past decisions regarding the need for safety measures were appropriate.

Accidents and Injuries in Fiscal 2015

In fiscal 2015, we experienced three security incidents (two incidents of leakage of hazardous materials, one incident of leakage of Freon refrigerant)
Although the incidents did not result in human casualties, damage to equipment, or impacts on the environment, we set up an accident investigation board and are acting to pin down the direct and indirect causes of the incident, develop countermeasures, and prevent future recurrence.

Emergency-Response Training

  • Comprehensive emergency training<br />at the Mizushima Plant Comprehensive emergency training
    at the Mizushima Plant

Each year, our worksites perform Emergency-Response Training under various hypothetical scenarios including activities such as contacting and reporting, emergency treatment, rescue, and firefighting. Comprehensive emergency-response trainings are carried out jointly with local firefighting agencies when possible.
Training activities confirm whether standards are appropriate and confirm the operability of emergency equipment (e.g., fire trucks, fire hydrants, broadcasting equipment). Problems encountered in the process of training are promptly resolved or improved upon in efforts to establish more reliable responses.

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