1、第1页，共59页。第2页，共59页。第3页，共59页。第4页，共59页。Hazard(Machine)(Lion)Human Human errorRisk Assessment（find risk by KYT)AccidentCage/FenceKYT*第5页，共59页。Difference between KY and RAKY：Kyken-Yochoi(Danger-Prediction)RA:Risk Assessment*AGC Automotive Japan/Asia Pacific 第6页，共59页。KYRAscopeSelection of dangertimeobject
2、iveALL machine,All processDaily jobBrain storming type1 min 5 min(Short-KY)Danger preventionBy personal senseSystematic searchone year and continuallyDanger preventionByGuard/fenceDifferenceRA seminar.Next time,if you need*AGC Automotive Japan/Asia Pacific 第7页，共59页。Main Safety Activity based on KY a
3、nd RAFinding risk by Patrol,Near-miss info,KY KY TrainingRA(hardware countermeasure)Short KY at TB,Self-KY(Human error prevention)To achieve“safety culture”Approach from machine-side Approach from human-side*AGC Automotive Japan/Asia Pacific 第8页，共59页。Potential risk Risk AccidentMulti-protection Make
4、 holes smaller KYManagement(policy)No-guard(hardware)No-Safety manual(software)Human error(human behavior)Make holes smaller by RA第9页，共59页。He starts to climb the ladder March 24,2007March 24,2007Laminated ARGLaminated ARGWhat happened?Can you imagine?第10页，共59页。The chain was removed from the door of
5、the stocker,and chain was long,being able to enter without pulling the safety plug out.The door of the stockerWhat happened?Can you imagine?第11页，共59页。第12页，共59页。PPM of Lost time in Japan/Asia Region(00-04)1 ppm=1/1,000,000 h第13页，共59页。第14页，共59页。Three year Safety Three year Safety plan in Asianplan in
6、AsianShare the safety information200520062007Training for safety managerIn Japan(AMG,AIGL)Training of KY,RAImplement of KYImplement of RAContinuous Communication(Safety Meeting)Patrol,near miss info,第15页，共59页。第16页，共59页。PPM of Lost time in Japan/Asia Region(05-06)0.38activity第17页，共59页。Red is in 2004第
7、18页，共59页。第19页，共59页。-ROUND KYT*AGC Automotive Japan/Asia Pacific 第20页，共59页。Content of 4-ROUND 1)Purpose of KYT KYT 2)What is the KYT the KYT 3)Procedure of（Kyken:danger/hazard）（Yochi:prediction）（Training）4)Example of KY*AGC Automotive Japan/Asia Pacific 第21页，共59页。1)Purpose of KY training To prevent i
8、njury by increasingSensibility to find potential(hidden)dangerConcentration Problem solving-mindThis is the training to prevent injury.Idea is very simple,but difficult to keep implementing.*AGC Automotive Japan/Asia Pacific 第22页，共59页。)Four Step of KYT find out potential danger/hazard in your work p
9、lace,process,machine,and material by using illustration sheet or picture select and focus the most dangerous one think the countermeasures choose the most effective countermeasure and do“pointing and calling”to remind potential risk and safety behavior*AGC Automotive Japan/Asia Pacific 第23页，共59页。3.P
10、rocedure of KYTroundroundProcessProcessKey Key pointpointContent of each roundContent of each roundMake sure the Make sure the potential riskpotential riskWhat kind of What kind of risks are risks are there?there?Look at the illustration sheet/picture by all Look at the illustration sheet/picture by
11、 all attendant and find out/imagine all potential risk.attendant and find out/imagine all potential risk.R RSelect the most Select the most dangerous onedangerous onethe most the most dangerous dangerous riskriskSelect the danger risks and put Select the danger risks and put on them.on them.Select t
12、he most dangerous one and put Select the most dangerous one and put.Make sure the Make sure the countermeasurecountermeasureWhat will you What will you do?do?think the applicable countermeasure(safety think the applicable countermeasure(safety action)to avoid the action)to avoid the risk.risk.Decide
13、 the Decide the safety actionsafety actionWe will do We will do thisthisSelect the most effective countermeasure Select the most effective countermeasure(safety action)and put(safety action)and put*.And “pointing and calling”And “pointing and calling”*AGC Automotive Japan/Asia Pacific 第24页，共59页。Why“
14、Pointing and Calling”?*AGC Automotive Japan/Asia Pacific 第25页，共59页。Pointing and calling(Data from railway research center)nothingcalling pointing pointing&callingError incident rate2.381.000.750.38Error index100423216Effect index16385010026*AGC Automotive Japan/Asia Pacific 第26页，共59页。and calling at
15、railway27*AGC Automotive Japan/Asia Pacific 第27页，共59页。*AGC Automotive Japan/Asia Pacific 第28页，共59页。*AGC Automotive Japan/Asia Pacific 第29页，共59页。practicing Pointing&Calling at the stop mark to prevent the traffic accident.Right side OK,left side OK and front OK.Then he across the road.Stop mark30*AGC
16、 Automotive Japan/Asia Pacific 第30页，共59页。31*AGC Automotive Japan/Asia Pacific 第31页，共59页。4R-KY4R-KY at DBO furnace Job changeDBO furnace Job change Example of KY*AGC Automotive Japan/Asia Pacific 第32页，共59页。He is blowing off the cullet by using compressed air during job change*AGC Automotive Japan/Asi
17、a Pacific 第33页，共59页。round 1Imagine the potential(hidden risk)in this picture(you can decide the situation,if not clear)write down the risks as much as possible1.Get eyes hurt by flying cullet when you blow off the cullet by using compressed air2.Hit his head against the flame and has a bruise when e
18、ntering under the blast head.3.Air nozzle hit the body and gives him a bruise because of its high pressure when opening the air valve4.Get the lower back hurt when cleaning the cullet.5.Stumble between step and step,and break the foot finger when changing your position.*AGC Automotive Japan/Asia Pac
19、ific 第34页，共59页。round 2Select the dangerous risk and put .And select the most dangerous one and put.1.Get eyes hurt by flying cullets when you blow off the cullet by using compressed air2.Hit his head against the flame and has a bruise when entering under the blast head.3.Air nozzle hit the body and
20、gives you a bruise because of its high pressure when opening the air valve4.Get the lower back hurt when cleaning the cullet.5.Stumble between step and step,and break the foot finger when changing your position.35*AGC Automotive Japan/Asia Pacific 第35页，共59页。Use safety glasses during cleaning the cul
21、let.Put on helmet for unusual work.countermeasure：think the countermeasure against the most dangerous risk round 3*AGC Automotive Japan/Asia Pacific 第36页，共59页。Use safety glasses and helmet when cleaning the cullet around blast head.Decide the safety action“pointing and calling”safety glasses and hel
22、metYOSHI(OK)round 4*AGC Automotive Japan/Asia Pacific 第37页，共59页。safety glasses and helmet YOSHI(OK)*AGC Automotive Japan/Asia Pacific 第38页，共59页。4R-KYT(basic training)Short-KYatTool Box MeetingSelf-KYIn front ofMachine orBefore action第39页，共59页。Tool box meeting KY Accident information from other plant
23、s Near miss information Quality information Production schedule40*AGC Automotive Japan/Asia Pacific 第40页，共59页。short time(1-2 minutes)KY by team at tool box meeting Short KY Round 1;OOO becomes ooo,because oooSuppose and speak out 3 5 potential dangersRound 2;choose the most dangerous oneRound 4;when
24、 we do ooo,lets do oooo.“pointing and calling”*AGC Automotive Japan/Asia Pacific 第41页，共59页。Self(one-person)KY short KY(1 minutes)by yourself before touching machine or starting action.This is the most useful method to prevent accident.42*AGC Automotive Japan/Asia Pacific 第42页，共59页。Confirm the right
25、switch,OKmis-operation*AGC Automotive Japan/Asia Pacific 第43页，共59页。Head clearance,OKNarrow area44*AGC Automotive Japan/Asia Pacific 第44页，共59页。Signal to co-worker,OKAt the team JobI cant see what my colleague is doing*AGC Automotive Japan/Asia Pacific 第45页，共59页。Not to pinch hand,OKConfirm the surroun
26、ding,OK*AGC Automotive Japan/Asia Pacific 第46页，共59页。At the stepWatch step,OK*AGC Automotive Japan/Asia Pacific 第47页，共59页。Watch step,OKAt the step*AGC Automotive Japan/Asia Pacific 第48页，共59页。Repeat and repeat KYT at your working place.increase your sensibility until you can point out the potential da
27、nger immediately.*AGC Automotive Japan/Asia Pacific 第49页，共59页。End of 4 round KY Training50*AGC Automotive Japan/Asia Pacific 第50页，共59页。The Theory of Heinrich Near-miss(Hiyari Hatto)Restricted Recordable Man-day lossDeathUn-safety action Un-safety state 12930051*AGC Automotive Japan/Asia Pacific 第51页
28、，共59页。The Theory of Heinrich Near-miss(Hiyari Hatto)Restricted Recordable Man-day lossDeathUn-safety action Un-safety state 129300Review accident.Deploy countermeasure horizontally The Hiyari Hatto campaign The Risk Prediction campaign5-S campaign Reduce hazardous situations and un-safe actions/stat
29、e to reduce fatal problems*AGC Automotive Japan/Asia Pacific 第52页，共59页。The Theory of Heinrich Near-miss(Hiyari Hatto)Restricted Recordable Man-day lossDeathUn-safety action Un-safety state 129300*AGC Automotive Japan/Asia Pacific 第53页，共59页。Japan/Asia region Safety Three Year PlanObjectiveTargetMain
30、PlanElementsStandard-080910JapanAATH,AMGAACN,AAPHAIGL,AAFNto achieve zero accident(injury)workplaceTo build up Risk-free working area(working environment andhuman behavior)utilizing OHSMS by 2010KYT,Safety Patrol,Near Miss info.,5SRisk Assessment(risk analysis and countermeasure)Internal audit betwe
31、en country,Incorporate conventional activity into OHSMSBuild up OHSMS based on OHSAS18001Establish OHSMSKYT,Safety Patrol,Near Miss,5SImprove activity(Ex.introduce BBS concept)Improve activityEstablish OHSMSKYT,Safety Patrol,Near Miss,5SAlready established*AGC Automotive Japan/Asia Pacific 第54页，共59页
32、。RAKYTo construct OHSMS based on OHSAS18001SafetyPolicyLegal requirementPDCAPatrolInternalaudit5SMR*AGC Automotive Japan/Asia Pacific 第55页，共59页。第56页，共59页。Take pictures of your Job/your site unusual job trouble shooting job change*AGC Automotive Japan/Asia Pacific 第57页，共59页。第58页，共59页。演讲完毕，谢谢观看！第59页，共59页。
