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PLANT SAFETY HAZARDS3.5 MANUAL HANDLING AND ERGONOMICSThe Use of Manual Handling Assist DevicesManual handling assists, conveyors and other mechanical aids are used when the manual handling risk can not bedesigned out of the process. Forklift trucks and trolleys may be used to move heavier irregular objects and parts aredelivered to the production line in purpose built stillages to where they are needed to reduce the amount of space online used by the parts but also to minimise the amount of manual handling.ErgonomicsHUM has a dedicated team of Associates in place to manage the ergonomic risks of building cars and engines. Theprimary role of the team is to carryout assessments of the production line processes in order to identify the ergonomicrisks and the establish countermeasure activities. The design and application of countermeasures is a complex task andinvolves consultation with engineering, quality and process functions as well as the Associates performing the task inorder to come up with the right solution.HUM has established an ergonomics policy as well as a detailed risk assessment system which is communicated to allthrough the Health and Safety manual. A monthly report is generated to keep Associates and managers appraised ofany developments regarding ergonomics as well as the progress against objectives and targets.Old Process Connecting CouplersNew Process Fitting CouplersIn 2010 there have been many improvements regarding ergonomics.• Key Associates involved in the development of new models have received basic ergonomics training. This will helpwith the design of processes and car components in order to minimise ergonomic risks.• An activity plan covering the next 3 years has been developed that includes all aspects of ergonomics managementfrom new model introduction to plant layout issues, policy development, Associate recruitment and rehabilitation.• The ergonomic risk assessment method has been revised to ensure that HUM focuses on the most significantergonomic risks by introducing an enhanced rating system. This rating system has been developed with the help ofthe onsite physio provider, Rehab Works, who have provided information on the types and severity of injury. Thenew system also allows the effect of process rotation to be accurately determined.• All of the ergonomic guidelines that HUM uses to set up processes have been reviewed and updated to reflect thestature of European Associates.HUM is an active member of the Motor Industry Ergonomic Group (MIEG) which is a body made up of ergonomicexperts from UK motor manufacturers. This MIEG meets 3 times a year to share information on ergonomic concerns,issues and innovative solutions.26SE/D/G/15 - Nov 2011www.hondamanufacturing.co.uk
3.6 PERFORMANCE AGAINST LEGAL REQUIREMENTS SUMMARY 2008 – 2010Injuries as defined in The Reporting of Injuries, Diseases and Dangerous Occurrences Regulations 1995 (RIDDOR)occurring to HUM employees.*per 100,000 employees as defined in HSE publication Successful Health and Safety Management (HSG65)Description of Major InjuriesThere were 8 serious accidents during 2010.1. Associate was repairing an engine with the wrong drill bit which shattered and went into his eye. The Associate wasnot wearing safety glasses and was using the incorrect drill type. Increased signage and training in the area wascarried out.2. Associate was unloading parts at his work station when the cylinder head he was moving slipped out of his righthand and transferred the full weight through his left hand resulting in a dislocated shoulder. Permanent slide tableintroduced3. Associate had been recently transferred to the area and was picking up a parts box and struck his elbow on a girderresulting in a fractured elbow. The layout was improved to allow easier access to parts.4. Associate was pushing a stack of boxes. As she turned away she felt pain in her back and legs. The Associate was inhospital for several days. The subs assembly area layout was changed to remove the need for boxes being pushed.5. Associate broke a bone in his hand as a result of forcing the parts into place. Associate was using incorrect fitmenttechnique. Correct technique confirmed with other Associates. Additional PPE made available.6. Associate cracked a rib when he fell into a shallow pit he was cleaning during production downtime. As he steppedinto the pit he slipped on some spilt brake fluid. Risk assessment and visual aids created.7. Associate tripped on broom stand or parts boxes and fell, resulting in a broken elbow. The Associate was in theproduction area before shift and lighting levels were lower than usual. Broom stand moved and 5S improved.8. Associate broke a bone in his hand as a result of forcing a part into place. Incorrect technique used. Improvedcorrection technique information to be added to operation standard and supported with additional on thejob training.Improvements in accident reporting and investigation procedures have been implemented (see section 3.4).Description of firesThere were 12 minor fires during 2010.Measure 2008 2009 2010Fatal accidents 0 0 0Major injuries 1 6 8Dangerous occurances 0 0 03 day reportable accident rate * 816 1049 734Reportable disease 0 0 0First aid accident and ill health rate * 6560 8813 10277HSE enforcement notices 0 0 0Convictions of HSE offences 0 0 09. Weld Metal Inert Gas (MIG) unit caught fire. MIG gun sent for analysis but root cause not fully understood.10. Smoke from the conveyor due to incorrect cable tension which led to a short circuit. New cable fitted with thecorrect tension11. Aluminium leak from DC due to the core not being correctly closed due to sand build up. Associates reminded tomaintain 5S and operation standards updated12. In the Engine control centre a spark from grinding and welding ignited the dust and debris under the floor support.The area is now damped down prior to any welding or grinding and the importance of a fire watch reconfirmed.13. A box for purging weld sealer caught fire on hood line. Box removed and replaced with lidded metal container.Container emptied on a daily basis.14. Rectifier fire on Paint equipment. Equipment sent for analysis but cause unknown.15. In the repair area an Associate was MIG welding under the car and the interior melt sheet, harness and carpetcaught fire. Associate training improved and fire watch put in place for similar processes.16. Small fire in Weld Spot Robot line 2nd station due to sealer build up. Rear Right (RR) wheel arch area robotsre-taught to minimise sealer waste.17. Fire on side panel mezzanine due to sealer dripping onto sheeting. More regular changing of plastic sheeting tominimise sealer build up.18. Electrical panel fire in the impregnation area in Engine plant due to fan overheating. Panel isolated and fanremoved. Fan overload de-rated. Fed forward to other departments.19. Robot cables caught fire due to material contamination. Deep clean schedule in place.20. Fire on flexi truck in Engine Plant. Truck in question removed from service and repaired. Other flexi –trucks areunder review.All of these fire incidents have been investigated and root causes established (see section 3.1)SE/D/G/15 - Nov 2011www.hondamanufacturing.co.uk27
Page 1 and 2: Safety and Environment Report 2010H
Page 3 and 4: HONDA OF THE UK MANUFACTURING LTDSA
Page 5 and 6: INTRODUCTION1.0 INTRODUCTIONHonda
Page 7 and 8: HUM SIGNIFICANT ENVIRONMENTALIMPACT
Page 9: 2.2 WATER MANAGEMENTDescription of
Page 20 and 21: PLANT SAFETY HAZARDS3.0 PLANT SAFET
Page 22 and 23: PLANT SAFETY HAZARDS3.2 PLANT AND E
Page 24 and 25: PLANT SAFETY HAZARDS3.3 VEHICLE MOV
Page 28 and 29: PLANT SAFETY HAZARDS3.7 2010 SAFETY
Page 32 and 33: LOCAL COMMUNITY ACTIVITY5.0 LOCAL C
Page 34 and 35: VERIFICATION STATEMENT7.0 VERIFICAT

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