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Occupational Safety, Health & Environmental Management Fundamentals

Production Management Planning Grade 3 生産管理プランニング (BC検定) · ビジネス・キャリア検定 生産管理プランニング3級 · Written by Tokutei Pass based on the official study texts; not copied verbatim.

1. Purpose of the Industrial Safety and Health Act, Definition of "Worker," and Management Organization

The "Industrial Safety and Health Act," in conjunction with the Labor Standards Act, aims to secure the safety and health of workers in the workplace and promote the "formation of a comfortable working environment" by establishing hazard-prevention standards, clarifying responsibility structures, and encouraging voluntary safety activities.

The term "Worker" under this Act has the same meaning as in the Labor Standards Act (any person employed at an enterprise who receives wages) and includes not only regular full-time employees but also "short-term part-timers, temporary/arubaito workers, and contract employees" (Note: the statement "short-term part-time workers are excluded from 'workers'" is a frequent FALSE exam trap).

A manufacturing workplace regularly employing "50 or more workers" must appoint a "Safety Officer," a "Health Officer," and an "Industrial Physician," and establish a "Safety and Health Committee (meeting at least once a month)" (10–49 workers require a "Safety and Health Promoter"; 300 or more workers require appointing the plant manager as "General Safety and Health Manager").

Mandatory workplace patrol frequencies are: Safety Officer as needed; "Health Officer" "at least once every week"; and "Industrial Physician" "at least once every month (or once every two months if specified conditions are met and the employer consents)."

1. Purpose of the Industrial Safety and Health Act, Definition of "Worker," and Management Organization

Key points


  • Purpose of the Industrial Safety and Health Act = securing worker safety and health + promoting the "formation of a comfortable working environment" (Note: "Worker" includes short-term part-timers and arubaito!).

  • Manufacturing workplaces with 50 or more regular workers = mandatory appointment of "Safety Officer, Health Officer, and Industrial Physician" and establishment of a "Safety and Health Committee (meets ≥ once/month)."

  • Mandatory workplace patrol frequency: Health Officer = "at least once a week" / Industrial Physician = "at least once a month."
WordMeaning
Industrial Safety and Health Act (formation of a comfortable working environment)
definition of Worker (includes part-timers and arubaito)
Safety Officer, Health Officer, and Industrial Physician (50 or more workers)
workplace patrol (Health Officer = weekly; Industrial Physician = monthly)

2. Heinrich's Law (1 : 29 : 300) and Occupational Accident Statistics (Frequency Rate, Severity Rate, Annual Rate per 1,000)

The empirical rule stating that behind 1 major accident (fatality or serious injury) lie 29 minor injury accidents and 300 no-injury near-miss incidents (Hiyari-Hatto) is called "Heinrich's Law (the 1 : 29 : 300 Law)"; eliminating major accidents requires addressing the 300 near-misses as well as unsafe acts and unsafe conditions.

First among occupational accident statistical indicators, the "Frequency Rate (Dosuuritsu)" represents the number of casualties per 1,000,000 total actual working hours, expressing accident "frequency." Its formula is "Frequency Rate = (Number of Casualties ÷ Total Actual Working Hours) × 1,000,000" (for casualties requiring 1 or more days of absence, excluding no-lost-time injuries).

Second, the "Severity Rate (Kyoudoritsu)" represents lost workdays per 1,000 total actual working hours, expressing accident "severity." Its formula is "Severity Rate = (Total Lost Workdays ÷ Total Actual Working Hours) × 1,000" (fatality or permanent total disability = "7,500 days"; temporary disability = "Days of Absence × (300 ÷ 365)").

Third, the "Annual Incidence Rate per 1,000 Workers (Nen-sennin-ritsu)" indicates annual casualties per 1,000 workers, calculated as "Annual Rate per 1,000 = (Annual Casualties ÷ Average Number of Workers during the Year) × 1,000."

Key points


  • Heinrich's Law = "1 major injury : 29 minor injuries : 300 no-injury near-misses (Hiyari-Hatto)."

  • Frequency Rate (frequency) = (Casualties ÷ Total Actual Working Hours) × 1,000,000 / Severity Rate (seriousness) = (Total Lost Workdays ÷ Total Actual Working Hours) × 1,000 (death = 7,500 days).

  • Annual Rate per 1,000 Workers = (Annual Casualties ÷ Average Annual Workers) × 1,000.

  • Example: Average 400 workers, 800,000 total actual working hours/year, 2 casualties → Frequency rate = 2 ÷ 800,000 × 1,000,000 = 2.5; Annual rate per 1,000 workers = 2 ÷ 400 × 1,000 = 5.0

  • Example: 800,000 total actual working hours and 400 total lost workdays (including 365 absence days converted as 365 × 300 ÷ 365 = 300 lost days) → Severity rate = 400 ÷ 800,000 × 1,000 = 0.5
WordMeaning
Heinrich's Law (1 : 29 : 300 and near-misses / Hiyari-Hatto)
Frequency Rate (casualties per 1,000,000 working hours: frequency)
Severity Rate (lost workdays per 1,000 working hours: severity)
Annual Rate per 1,000 Workers (annual casualties per 1,000 workers)

3. Inherent Safety (Fail-Safe / Fool-Proof), Plan Notification, Specified Machinery, and Specified Autonomous Inspection

The two major principles of "Inherent Machine Safety" are "Fail-Safe" and "Fool-Proof." "Fail-Safe" ensures that even if a machine fails or loses power, it always defaults to the safe (stopped) state; "Fool-Proof" ensures that even if a human misoperates a control, no hazard arises (such as interlocks or two-hand press safety controls).

The Grade 3 Planning exam tests administrative filings for hazardous machinery. First, an employer planning to install, relocate, or alter a "Power Press Machine" or "Local Exhaust Ventilation System" must file the plan with the "Chief of the Labor Standards Inspection Office (Roudou Kijun Kantokusho-chou)" "at least 30 days prior to the start of construction."

For particularly hazardous "Specified Machinery, etc. (Boilers, Class-1 Pressure Vessels, Cranes and Mobile Cranes with a lifting capacity of 3 tons or more, Derricks, Elevators, Gondolas)," manufacturing requires prior "Manufacturing Permission from the Prefectural Labor Bureau Director," and installation requires passing a "Completion Inspection (Rakusei Kensa) by the Chief of the Labor Standards Inspection Office" and receiving an "Inspection Certificate."

Furthermore, for power presses and forklifts, employers must conduct a "Specified Autonomous Inspection" "at least once every year" by a qualified inspector (or registered inspection agency), affix an "Inspection Sticker," and retain records for 3 years.

Key points


  • Fail-Safe = design defaulting to the safe (stopped) side upon failure / Fool-Proof = design preventing danger even upon human misoperation (interlocks, two-hand switches, etc.).

  • Installation plan notification for power presses or local exhaust ventilation = file with the "Chief of the Labor Standards Inspection Office" "at least 30 days before construction starts."

  • Specified Machinery (Boilers, Cranes ≥ 3t, etc.) = requires "Manufacturing Permission from the Prefectural Labor Bureau Director" and "Completion Inspection (Inspection Certificate issuance) by the Chief of the Labor Standards Inspection Office" upon installation.
WordMeaning
Fail-Safe and Fool-Proof (Interlock)
Plan Notification (filed with Labor Standards Inspection Office Chief ≥ 30 days before construction)
Specified Machinery (Manufacturing Permission, Completion Inspection, Inspection Certificate)
Specified Autonomous Inspection (once a year and Inspection Sticker)

4. Risk Assessment Priority Hierarchy, Safety Education, and Restricted Work

"Risk Assessment" is the systematic process of identifying potential workplace hazards or harmful factors, estimating their risk (Severity × Probability), and implementing risk-reduction measures in order of priority.

With legal compliance as an absolute prerequisite, the priority order for risk reduction is: ① "Inherent Safety Design (eliminating or substituting hazardous work/substances)," ② "Engineering Controls (safety guards, interlocks, local exhaust ventilation)," ③ "Administrative Controls (manuals, warning signs, restricted entry)," and finally ④ "Using Personal Protective Equipment (PPE)."

Employers must provide "Safety and Health Education" upon hiring or changing job duties, and must conduct "Special Education" before assigning workers to designated hazardous tasks such as arc welding, low-voltage electrical work, or industrial robot teaching.

For higher-hazard "Restricted Work" (forklifts with max load ≥ 1 ton, slinging/Tamagake ≥ 1 ton, crane operation ≥ 5 tons (License), gas welding, etc.), only qualified personnel holding a "License" from the Prefectural Labor Bureau Director or having completed a "Skill Training Course" may be assigned (and an "Operations Chief" must be appointed for hazardous work).

Key points


  • Risk Assessment reduction priority: ① Inherent safety (elimination/substitution) → ② Engineering controls (guards, safety devices) → ③ Administrative controls (procedures, training) → ④ Personal Protective Equipment (last resort).

  • Safety & Health Education = education upon hiring or job change, plus "Special Education" when assigning specific hazardous tasks.

  • Restricted Work (requires License or Skill Training Course) = Forklifts ≥ 1 ton, Slinging (Tamagake) ≥ 1 ton, Crane operation ≥ 5 tons, Gas welding, etc.
WordMeaning
Risk Assessment and priority hierarchy of risk-reduction measures
education upon hiring and Special Education
Restricted Work (License and Skill Training Course)
appointment of an Operations Chief (Sagyou Shuninsha)

5. Three Managements of Occupational Health, Working Environment Measurement (Classes 1–3), and Health Exams (Overseas Dispatch)

The "Three Managements of Occupational Health" are: ① "Working Environment Management (enclosing hazard sources, installing local exhaust ventilation, optimizing lighting/temperature/humidity)," ② "Work Management (shortening hazardous exposure time, ergonomic posture, proper PPE use)," and ③ "Health Management (medical examinations and follow-up care)."

In hazardous workplaces handling dust, organic solvents, specified chemicals, or noise, employers must periodically (typically once every 6 months) conduct "Working Environment Measurement" and evaluate results into three "Control Classes": "Class 1" is appropriate (maintain); "Class 2" requires improvement efforts; and "Class 3" is inappropriate—requiring immediate equipment inspection/improvement and mandatory respiratory PPE.

"General Health Examinations" include exams upon hiring, periodic annual exams (once every year), and exams for night-shift/specified workers (upon reassignment and "once every 6 months"). Hazardous work involving organic solvents, lead, or dust requires "Special Health Examinations (generally once every 6 months)."

Furthermore, the Grade 3 Planning exam frequently tests "Health Examinations for Workers Dispatched Overseas for 6 Months or More." Employers must provide a physician's medical examination both "before dispatching" a worker overseas for 6 months or more AND "after returning" to domestic duties from an overseas assignment of 6 months or more.

Key points


  • Three Managements of Occupational Health: ① Working Environment Management (local exhaust ventilation, enclosure) + ② Work Management (hours, posture, PPE) + ③ Health Management (health exams).

  • Working Environment Measurement: Control Class 1 (good), Control Class 2 (strive to improve), Control Class 3 (inappropriate → immediate equipment improvement and PPE mandatory).

  • Overseas Dispatch Health Exam = mandatory both "before dispatch" and "upon return" when dispatching a worker overseas for "6 months or more."
WordMeaning
Three Managements of Occupational Health (Working Environment, Work, Health)
Working Environment Measurement (Control Classes 1, 2, and 3)
General Health Examination and Special Health Examination (once every 6 months)
Health Examination for Overseas Dispatched Workers (≥ 6 months: pre-dispatch and post-return)

6. History of Industrial Pollution (Ashio Copper Mine, Four Big Pollution Diseases) & Basic Environment Act Principles / Typical 7 Pollutions

Japan's history of industrial pollution began in the Meiji–Taisho eras with mining and industrial growth—such as the "Ashio Copper Mine Mineral Pollution Incident (Watarase River basin, Tochigi)," the "Besshi Copper Mine Smoke Pollution Incident (Ehime)," and the "Osaka Alkali Incident"—followed during the post-war rapid economic growth era (1950s–1960s) by the severe "Four Big Pollution Diseases."

The "regions and causative substances" of the Four Big Pollution Diseases are: ① "Minamata Disease (Kumamoto)" and ② "Niigata Minamata Disease (Agano River, Niigata)" caused by "Methylmercury compounds" in factory effluent; ③ "Itai-itai Disease (Jinzu River, Toyama)" caused by "Cadmium" in mine wastewater; and ④ "Yokkaichi Asthma (Mie)" caused by "Sulfur Oxides (SOx)" from petrochemical complexes.

Enacted in 1993, the "Basic Environment Act" sets forth "Three Basic Principles": ① Enjoyment and inheritance of environmental blessings for future generations, ② Building a sustainable society with reduced environmental load, and ③ Actively promoting global environmental conservation through international cooperation (Watch out for a frequent exam trap: "Formation of a comfortable working environment" belongs to the Industrial Safety and Health Act, NOT the Basic Environment Act!).

The Basic Environment Act also defines the "Typical 7 Pollutions": ① Air Pollution, ② Water Pollution, ③ Soil Contamination, ④ Noise, ⑤ Vibration, ⑥ Ground Subsidence, and ⑦ Offensive Odors.

Key points


  • Meiji–Taisho industrial pollution = Ashio Copper Mine & Besshi Copper Mine incidents / Rapid growth era = Four Big Pollution Diseases (Minamata & Niigata = Methylmercury, Itai-itai = Cadmium, Yokkaichi = SOx).

  • Three Basic Principles of the Basic Environment Act = ① Enjoyment & inheritance of environmental blessings, ② Sustainable society with low environmental load, ③ Global conservation via international cooperation (Note: "comfortable working environment" is the Industrial Safety and Health Act!).

  • "Typical 7 Pollutions" of the Basic Environment Act = ① Air pollution, ② Water pollution, ③ Soil contamination, ④ Noise, ⑤ Vibration, ⑥ Ground subsidence, ⑦ Offensive odors.
WordMeaning
Ashio Copper Mine incident and the Four Big Pollution Diseases
Methylmercury, Cadmium, and Sulfur Oxides (SOx)
Three Basic Principles of the Basic Environment Act
Typical 7 Pollutions

7. Pollution Control Laws (Air, Water Pollution Harmful Substances & 3-Year Record Retention, Waste Manifest)

The "Air Pollution Control Act" regulates "Soot and Smoke (SOx, dust, NOx)" from boilers/incinerators, "Volatile Organic Compounds (VOCs)" from painting/cleaning processes, and "Specified Particulates (Asbestos)" during building demolition.

The "Water Pollution Prevention Act" regulates "Harmful Substances (human health items)" in effluent such as cadmium, cyanide, organic phosphorus, lead, hexavalent chromium, arsenic, mercury, PCBs, and trichloroethylene (Watch out for a classic exam trap: "Sulfur (Iou)" is NOT included among the Harmful Substances of the Water Pollution Prevention Act!). Organic water pollution indicators are "BOD" for "Rivers" and "COD" for "Lakes/Marshes and Sea Areas."

The Grade 3 Planning exam also tests Water Pollution Prevention Act procedures: anyone installing a Specified Facility must file a notification with the "Prefectural Governor (or designated city mayor)" (subject to a 60-day construction restriction from receipt), and must measure effluent pollution levels, record the results, and "retain the records for 3 years" (Note: "20 years" is FALSE).

Under the "Waste Management Act," "Industrial Waste" is the "responsibility of the waste-generating business," which must issue a "Manifest" when outsourcing disposal and retain copies for 5 years. Furthermore, the "Basic Act for Establishing a Sound Material-Cycle Society" sets the priority order: ① Reduce → ② Reuse → ③ Recycle (material recycling) → ④ Heat Recovery (thermal recycling) → ⑤ Proper Disposal.

7. Pollution Control Laws (Air, Water Pollution Harmful Substances & 3-Year Record Retention, Waste Manifest)

Key points


  • Harmful Substances under the Water Pollution Prevention Act = cadmium, cyanide, lead, hexavalent chromium, arsenic, mercury, trichloroethylene, etc. ("Sulfur" is NOT included!). Rivers = BOD; Lakes & Sea = COD.

  • Specified Facility installation under the Water Pollution Prevention Act is notified to the "Prefectural Governor" / Water quality measurement records must be "retained for 3 years" (NOT 20 years).

  • Sound Material-Cycle priority order: ① Reduce → ② Reuse → ③ Recycle → ④ Heat Recovery → ⑤ Proper Disposal (outsourced industrial waste requires a Manifest).
WordMeaning
Water Pollution Prevention Act Harmful Substances and measurement records (3-year retention)
BOD (Rivers) and COD (Lakes/Marshes and Sea Areas)
Industrial Waste and the Manifest System (5-year retention)
3Rs (Reduce, Reuse, Recycle) and Heat Recovery (thermal recycling)

8. ISO 14001 (Environmental Management System & Internal Environmental Audit) and the SDGs (The 5 Ps)

The international standard for an "Environmental Management System (EMS)" enabling organizations to voluntarily and continually reduce environmental impact and prevent pollution is "ISO 14001."

Under an "Environmental Policy" established by top management, ISO 14001 rotates the PDCA cycle: ① Plan (environmental aspects, compliance obligations, environmental objectives) → ② Do (support/operation and emergency preparedness) → ③ Check (monitoring/measurement, internal environmental audit, management review) → ④ Act (nonconformity/corrective action and continual improvement).

In particular, the "Internal Environmental Audit" checks whether the EMS conforms to standard requirements and is effectively implemented and maintained; it must be "conducted periodically at planned intervals" (Note: the exam option "internal audits can be omitted if environmental impact is small" is FALSE).

Adopted at the 2015 UN Summit for 2030, the "SDGs (Sustainable Development Goals: 17 Goals and 169 Targets)" emphasize the "5 Ps": ① People, ② Prosperity, ③ Planet, ④ Peace, and ⑤ Partnership (Watch out for a frequent exam trap: "Production" is NOT one of the 5 Ps of the SDGs!).

Key points


  • ISO 14001 = international standard for an Environmental Management System (EMS), driving continual improvement via the PDCA cycle under an Environmental Policy.

  • ISO 14001 "Internal Environmental Audits" must be conducted periodically at planned intervals and CANNOT be omitted regardless of the size of environmental impact.

  • The "5 Ps" of the SDGs (17 Goals, 169 Targets) = People, Prosperity, Planet, Peace, and Partnership ("Production" is FALSE!).
WordMeaning
ISO 14001 (Environmental Management System: EMS)
Internal Environmental Audit and Management Review
SDGs (Sustainable Development Goals: 17 Goals)
The 5 Ps of the SDGs (People, Prosperity, Planet, Peace, Partnership)

High-Frequency Exam Points and Memory Aids

In safety statistics calculations, be sure to master the multipliers (1,000,000 vs. 1,000) for "Frequency Rate (casualties per 1,000,000 working hours = frequency)" and "Severity Rate (lost workdays per 1,000 working hours = seriousness)," along with "Heinrich's Law (1 : 29 : 300)."

For Industrial Safety and Health Act traps, remember: ① "Short-term part-timers and arubaito ARE included as 'Workers'," ② "Installation plan notifications for power presses, etc. must be filed with the Chief of the Labor Standards Inspection Office at least 30 days before construction starts," ③ "Specified Machinery requires a Manufacturing Permit from the Prefectural Labor Bureau Director and a Completion Inspection by the Labor Standards Inspection Office Chief," and ④ "Workers dispatched overseas for 6 months or more require health exams both before dispatch and upon return."

For environmental law traps, remember: ① "'Formation of a comfortable working environment' is in the Industrial Safety and Health Act, NOT a basic principle of the Basic Environment Act," ② "'Sulfur' is NOT a Harmful Substance under the Water Pollution Prevention Act, and water measurement records must be kept for 3 years (20 years is false)," and ③ "Rivers = BOD vs. Lakes & Sea = COD."

Finally, lock in: "The Four Big Pollution Diseases plus the Meiji–Taisho Ashio and Besshi Copper Mine incidents," "ISO 14001 Internal Environmental Audits cannot be omitted even if environmental impact is small," and "'Production' is NOT included in the 5 Ps of the SDGs."

Key points


  • Industrial Safety & Health Act: Short-term part-timers are Workers / Plan notification = ≥ 30 days prior to Labor Standards Inspection Office Chief / Overseas dispatch ≥ 6 months = health exams before dispatch & after return.

  • Environmental Laws: "Comfortable working environment" is the Safety & Health Act (not Basic Environment Act) / Water Pollution Harmful Substances do NOT include "Sulfur," and water records are kept "3 years."

  • ISO 14001 Internal Audits cannot be omitted / 5 Ps of the SDGs = People, Prosperity, Planet, Peace, Partnership (Production is FALSE!).
WordMeaning
Frequency Rate (1,000,000 hours), Severity Rate (1,000 hours), and Heinrich's Law
Plan Notification (30 days prior), Specified Machinery, and Overseas Dispatch Health Exam (≥ 6 months)
Basic Environment Act 3 Principles and Water Pollution Prevention Act (3-year retention)
ISO 14001 Internal Audit and the 5 Ps of the SDGs

Safety, Health & Environment

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Official references

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