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Occupational Safety and Health Management

Food Manufacturing (SSW 2) · 飲食料品製造業(2号) · Written by Tokutei Pass based on the official study texts; not copied verbatim.

Safety Basics, Heinrich's Law, KYT, and Human Error

The Industrial Safety and Health Act emphasizes proactive, preventive safety management. Industrial accidents occur when mechanical/environmental 'unsafe conditions' overlap with human 'unsafe acts,' and Heinrich's Law states that behind 1 major accident lie 29 minor injury accidents and 300 near-misses (Hiyari-Hatto).

In Hiyari-Hatto reporting, share and improve across the workplace without blaming individuals. The 4-Round Method of Hazard Prediction Training (KYT) proceeds through '1R Grasp Current Status → 2R Pursue Essence → 3R Establish Countermeasures → 4R Set Action Goals,' while Pointing and Calling raises brain alertness and cuts errors to about one-sixth.

The 12 human error classifications include 'shortcuts/omissions' to save effort and 'disregard for danger/habituation' common among veterans; countermeasures are taken across 4 aspects: software (rules), hardware (equipment safety), environment, and human (training).

Key points


  • Based on Heinrich's Law (1:29:300), improve Hiyari-Hatto near-misses by addressing both unsafe conditions and unsafe acts.

  • Conduct the KYT 4-Round Method in order (Grasp Status → Pursue Essence → Establish Countermeasures → Set Goals) and use Pointing and Calling to reduce errors to about 1/6.

  • Address human errors like shortcuts and habituation from four aspects: software, hardware, environment, and human.
WordMeaning
unsafe condition, unsafe act
Heinrich's Law (1:29:300 ratio)
KYT 4-Round Method
Pointing and Calling
shortcut and omission behavior

Risk Assessment and Machine Equipment Safety

Risk assessment is performed when installing or changing equipment or work procedures, proceeding from 'identifying hazards → estimating risk by frequency and severity → setting priorities → implementing risk reduction measures.'

The priority order for risk reduction is: (1) Inherent safety at the design stage (e.g., low voltage, rounded corners) → (2) Engineering measures such as safety guards and interlocks → (3) Administrative measures such as manuals and training → (4) Personal Protective Equipment (PPE).

A mechanism that prevents dangerous operation even if a human makes a mistake is called 'Foolproof' (such as an interlock when a cover is opened), while a mechanism that stops on the safe side during a power outage or breakdown is called 'Fail-safe.'

During inspection or cleaning, strictly enforce 'Lockout/Tagout'—turning off power, locking the switch, and displaying a tag to prevent accidental startup. Use cut-resistant gloves when cleaning slicers, use a push stick when feeding ingredients, and never wear cotton work gloves (gunte) near rotating shafts to prevent entanglement.

Risk Assessment and Machine Equipment Safety

Key points


  • Implement risk reduction in the priority order: (1) Inherent safety → (2) Engineering measures → (3) Administrative measures → (4) Personal Protective Equipment (PPE).

  • Distinguish Foolproof (interlocks against human error) from Fail-safe (stopping safely upon failure), and enforce Lockout/Tagout during maintenance.

  • Use push sticks and cut-resistant gloves with slicers, and prohibit cotton gloves when working near rotating parts.
WordMeaning
risk assessment, inherent safety design
foolproof, interlock mechanism
fail-safe mechanism
Lockout/Tagout
push stick, cut-resistant gloves

Abnormality Response, Fall & Back Pain Prevention, and Thermal Environment

When abnormalities like jams or strange noises occur, press the emergency stop button first to completely halt the machine and prevent secondary accidents, rescue injured persons, and report to superiors. Keep floors dry (dry floor) to prevent slip-and-fall accidents.

To prevent back pain, stand close to the load, bend your knees, lower your hips, and lift using leg strength; push hand trucks forward with a clear view. For freezer work, wear cold-protective clothing and pre-check the internal unlock device and alarm; in hot environments, manage WBGT (heat stress index) and replenish water and salt to prevent heatstroke.

Key points


  • In an abnormality, press the emergency stop first to prevent secondary accidents, prioritize human life, and report to superiors.

  • Prevent back pain (bend knees/lower hips, push carts forward), check internal freezer releases, and prevent heatstroke using WBGT.
WordMeaning
secondary disaster, emergency stop
dry floor, low back pain prevention
WBGT heat index, heatstroke

Noise & Chemical Control (SDS) and Mental Health Care

In noisy workplaces, conduct work environment measurements every 6 months and wear earplugs. When handling chemicals, check the SDS (Safety Data Sheet), wear PPE, and never mix chlorine bleach with acidic cleaners as toxic chlorine gas is generated.

In mental health management, notice 'different from usual' signs in workers (such as tardiness or facial expression changes) early, listen attentively while protecting privacy, and connect them to an occupational physician or specialist desk.

Key points


  • In noisy workplaces, conduct working environment measurements every 6 months and ensure workers wear earplugs.

  • Check the SDS, never mix chlorine-based and acidic agents (prevents toxic chlorine gas), and catch 'different from usual' mental health signs early to connect with an occupational physician.
WordMeaning
working environment measurement
Safety Data Sheet (SDS), chlorine gas
mental health, industrial physician

Occupational Safety and Health

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