trainingDate July 2008Environmental & Safety management officeEnvironmental & Safety management officeJapan/Asia Pacific general divisionJapan/Asia Pacific general divisionAGC AutomotiveAGC AutomotiveHisashi NishiyamaHisashi Nishiyama1 1 CONTENT 1.General information about KY2.Safety activity in Japan / Asia3.4 round KYT4.Taking picture of your Job5.Short KY at your shop floor2 21. General information about KY Kiken Yochi TrainingKiken is “Danger or Risk”Yochi is “Anticipation or Prediction”What is KYT ?What is KYT ?3 3history of KYT in JapanStarted zero- accident activity in 1973 because of lots of accident in JapanKYT started in 1978New KYT started in 1982 with “pointing and calling” 4 4Hazard(Machine)(Lion)Human Human errorRisk Assessment （find risk by KYT)AccidentCage/FenceKYT5AGC Automotive Japan/Asia PacificDifference between KY andRAKY：Kyken-Yochoi(Danger-Prediction)RA : Risk Assessment6AGC Automotive Japan/Asia Pacific KYRAscopeSelection of dangertimeobjectiveALL 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 need7AGC Automotive Japan/Asia Pacific Main Safety Activity based on KY and 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-side8AGC Automotive Japan/Asia Pacific Swiss Cheese ModelPotential risk Risk AccidentMulti-protection Make holes smaller KYManagement(policy)No-guard(hardware)No-Safety manual(software)Human error(human behavior)Make holes smaller by RA9 9He starts to climb the ladder March 24, 2007Laminated ARGWhat happened?Can you imagine?1010The chain was removed from the door of the stocker, and chain was long, being able to enter without pulling the safety plug out.The door of the stockerEmergency Emergency stopstopWhat happened?Can you imagine?1111 CONTENT 1.General information about KY2.Safety activity in Japan / Asia3.4 round KYT4.Taking picture of your Job5.Short KY at your shop floor1212PPM of Lost time in Japan / Asia Region(00-04)1 ppm = 1/1,000,000 h1313Safety record of 2004 AAJPAATHAMGAACNAIGLAAPHtotalPPMof lost-time004.22 3.3611.6503.30Lost-time(requiring leave)009636051Restricted(not requiring leave)3201736058Recordable(minor)5243000321414Three year Safety plan in 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,1515Result of safety activity in Asia in 20061616PPM of Lost time in Japan / Asia Region(05-06)0.38activity1717Safety record of 2006 AAJPAATHAMGAACNAIGLAAPHtotalPPMof lost-time0.4200.410.650.2800.38Lost-time(requiring leave)3012107Restricted040311018Recordable418121012157004.223.3611.6503.30Red is in 20041818 CONTENT 1.General information about KY2.Safety activity in Japan / Asia3.4 round KYT4.Taking picture of your Job5.Short KY at your shop floor1919- ROUND KYT20AGC Automotive Japan/Asia Pacific Content of 4-ROUND 1) Purpose of KYT 2) What is the KYT 3) Procedure of （Kyken: danger/hazard） （Yochi: prediction） （ Training）4) Example of KY21AGC Automotive Japan/Asia Pacific 1) Purpose of KY training To prevent injury 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.22AGC Automotive Japan/Asia Pacific ) Four Step of KYTfind out potential danger / hazard in your work place, process, machine, and material by using illustration sheet or pictureselect 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 behavior23AGC Automotive Japan/Asia Pacific 3. Procedure of KYTroundProcessKey pointContent of each roundMake sure the potential riskWhat kind of risks are there ?Look at the illustration sheet/picture by all attendant and find out/imagine all potential risk.RSelect the most dangerous onethe most dangerous riskSelect the danger risks and put on them.Select the most dangerous one and put .Make sure the countermeasureWhat will you do ?think the applicable countermeasure (safety action) to avoid the risk.Decide the safety actionWe will do thisSelect the most effective countermeasure (safety action) and put *.And “pointing and calling”24AGC Automotive Japan/Asia Pacific Why “Pointing and Calling” ?25AGC Automotive Japan/Asia Pacific Pointing and calling(Data from railway research center)nothingcalling pointing pointing & callingError incident rate2.381.000.750.38Error index100423216Effect index16385010026AGC Automotive Japan/Asia Pacific and calling at railway27AGC Automotive Japan/Asia Pacific 28AGC Automotive Japan/Asia Pacific 29AGC Automotive Japan/Asia P