Toyota Construction Safety Requirements

Version 3.1

07/01/2020

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Toyota Safety Requirements for Construction, Equipment Installation,

& Equipment Decommissioning Version 3.1

2020

July 2020

Toyota Motor North America Toyota Production Engineering Safety Engineering

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Revisions:

2005-1 Mar-2005, 2006-1 May-2006, 2007-2 Mar-2007, 2009-1 Oct-2009, 2009-1.2 April-2010, 2009-1.3 July-2011, 2013-1 May-2013, 2015-1 January-2015, 2015-2.0 September-2015, 2016-2.01 January-2016, 2019-3.0 August 2019, 2020-3.1 July 2020

Details of the revisions located in the appendix.

References:

The requirements in this handbook are based on the listed references. Information for further clarification for each section or standard can be obtained from the following:

Canada

The Occupational Health & Safety Act (OHSA):

Regulation 213/91 for Construction Projects.

Regulation 851/90 for Industrial Establishments.

Regulation 632/05 for Confined Spaces.

Regulation 860/90 for Workplace Hazardous Materials Information System (WHMIS).

Fire Protection and Prevention Act:

Regulation 213/07 for the Ontario Fire Code.

Building Code Act:

Regulation 350/06 for the Ontario Building Code.

México

Mexican Federal Labor Law (“Ley Federal del Trabajo”)

Mexican Federal Security, Hygiene and Environmental Regulation

(“Reglamento Federal de Seguridad, Higiene y Medio Ambiente de Trabajo”)

United States

ANSI American National Standards Institute

OSHA 29 CFR 1910: OSHA Standards for General Industry

OSHA 29 CFR 1926: OSHA Standards for the Construction Industry

MSHA: Mine Safety and Health Administration

NFPA: National Fire Protection Administration

NIOSH: National Institute of Occupational Safety and Health

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Introduction

Welcome to Toyota Motor North America, Inc. (“TMNA”). Our ultimate goal is for everyone to leave work each day as healthy (or healthier) than they were upon arrival. For that reason, ensuring safe working conditions and safe work practices are top values at Toyota.

This TMNA corporate document has been created as a reference to assist Toyota members and contractor companies. Our expectations are that we all create a workplace free of hazards and potential injury while working at our Toyota North American Manufacturing Company (“NAMC”) facilities. It is intended to help identify the basic safety standards and best management practices that shall be observed by Toyota members and Contractor companies and their workers while working on Toyota projects. It contains both mandatory requirements and recommended practices.

This document shall be applied to the following activities:

• Construction, remodeling, or modification of buildings and facilities; • Installation or relocation of machinery and equipment, and; • Decommissioning of machinery and equipment.

This includes Prime or General Contractors, Subcontractors, and any company providing workers for purposes stated above. (Note: depending upon the type of work done this may include machine vendors, installers, and companies that decommission, reclaim, and/or remove equipment.)

This document is not intended for companies solely providing administrative or maintenance services such as: janitorial or cleaning services, secretarial services, inspection services, contract engineering, forklift repair, machine/equipment preventive maintenance, landscaping services, food services, and other similar services.

This document describes only the minimum Toyota safety standards along with references to applicable law or governing authority. Additionally, in Mexico and Canada, the Contractor shall comply with the applicable law or governing authority of that jurisdiction. NOTE-(In Canada, Ont. Reg 213/91 is the minimum standard that must be followed for construction safety laws and regulations.) Therefore, the information contained in this document shall in no way be considered a complete listing of all necessary safety standards to be observed by the Contractor. The Contractor shall be aware of all applicable standards, enforce them, and ensure they have been met in all aspects of their work. The most stringent standard shall be enforced where a conflict arises. The Contractor shall assume full responsibility and liability for the actions of its workers, Subcontractors, Subcontractor workers, agents, material suppliers, visitors, etc., with no limitations. This document shall in no way be interpreted to mean that Toyota assumes direct responsibility for safety compliance of any Contractor working on a Toyota project. Each Contractor is responsible for the safety and health of its own employees.

The publication of this document shall in no way be interpreted as the assumption of responsibility or liability by Toyota Motor North America, Inc. Contractors shall be responsible for following applicable laws, codes, standards, regulations, etc. If a conflict between this document and any code, standard, regulation exists, it is the Contractor’s responsibility to bring it to the attention of Toyota Safety or the designated Toyota contact in charge of the project for resolution.

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Table of Contents

Section A 1.0 – Purpose and Scope

1.1 Safety Rules 10 1.2 Construction Safety Representation 10

1.3 Contractor’s Responsibility 10 1.4 Acting as (General Contractor/ Contractor) 10

1.5 Monitoring of Construction Site 10 1.6 Safety Training and Education 11

1.7 Contractor Safety Representation 12 1.8 Required Documentation 13 1.9 Apprentice/Journeyman Ratio 13

Section B 2.0 – Glossary of Terms Used/Interpretations 13

Section C 3.0 – General Safety Requirements 21

3.1 Safety and Health Program 21 3.2 Safety Policy, Procedure, and Organizational Charts 21 3.3 Site Specific Safety Plan 21 3.4 Environmental Policy 21 3.5 Hazard Communication/WHMIS 22 3.6 Emergency Action Procedures 22 3.7 Substance Abuse Control Program 22 3.8 Job Safety Analysis (JSA) 23 3.9 CPR and First Aid Trained Resource Requirement 23 3.10 Proof of Insurance 23

3.11 Project Coordination/Notification of Work 24 3.12 Toyota Safety Orientation 24 3.13 Coordination Meetings 24 3.14 Contractors’ Tool Box Talks 24 3.15 Site Visual Control 25 3.16 Means of Egress 25 3.17 Emergencies: Evacuation/Severe Weather/Spills/Fires 25 3.18 Incident Reporting Procedures 25 3.19 Housekeeping/5S 25 3.20 Commissioning 26 3.21 Handover to NAMC 26 3.22 Safety Violations 27

3.23 Smoking and Tobacco Products Policy 28 3.24 Recording Devices 28

3.25 General Security Rules 28 3.26 Work Hour Restrictions 28

Section D 4.0 – Environment/Site Conditions 29 4.1 First Aid 29 4.2 Sanitation 29 4.3 Noise Exposure 29 4.4 Illumination 29 4.5 Ventilation 29 4.6 Dust Control 30 4.7 Radiation 30

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4.8 Heat Illness Prevention 30 Section E 5.0 – Personal Protective Equipment 30

5.1 Requirement 30 5.2 Foot Protection 30 5.3 Hand Protection 31

5.4 Head Protection 31 5.5 Hearing Protection 31 5.6 Eye and Face Protection 31 5.7 Respiratory Protection 31 5.8 Protective Clothing 32 Section F 6.0 – Fire Protection/Prevention 32 6.1 Requirement 32

6.2 Fire Extinguishers 32 6.3 Flammable and Combustible Liquids 33 6.4 Fuel Storage 33 Section G 7.0 – Signs/Barricades 33 7.1Requirement 33

7.2 Barricades 33 7.3 Signage Tape 33 7.3.1 Yellow Caution Signage Tape 33 7.3.2 Red Danger Signage Tape 34 7.3.3 Red and White Candy Stripe Tape 34

Section H 8.0 – Materials/Handling and Storage 34 8.1 Requirement 35

8.2 Trip Hazards 35 8.3 Liquid Spills 35 8.4 Rigging Equipment for Material Handling 35 Section I 9.0 – Tools/Hand and Power 35 9.1 Requirement 35

9.2 Condition 35 9.2.1 Cut Off Wheels 36

9.3 Guarding 36 9.4 Powered Tools 36 9.4.1 Operating Controls and Switches 36

9.5 Identification 36 9.6 Powder Actuated Tools 36 9.7 Securing Tools/Material 37 Section J 10.0 – Welding and Cutting 37 10.1 Requirement 37

10.2 Clothing/PPE 37 10.3 Protection 37

10.4 Storage 38 10.5 Restricted Hot Work 38

Section K 11.0 - Electrical 39 11.1 Requirement 39

11.2 Cord Sets (i.e., Extension Cords) 39

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11.3 GFCI 39 11.4 Cable/Wire Stripping Safety 40

Section L 12.0 – Scaffolding 40 12.1 Requirement 40

12.2 Erection/Dismantling/Access 40 12.3 Scaffold Tags 40 12.4 Falling Object Protection 40 12.5 Rolling Scaffolds 41 12.6 Scissor Lifts 41 Section M 13.0 – Fall Protection 41 13.1 Requirement 41

13.2 Fall Protection Plan 41 13.3 Fall Protection Equipment 42 13.4 Walking Working Surfaces 42

13.5 Leading Edges 42 13.6 Warning Lines 42 13.7 Horizontal Life Lines 42 13.8 Floor Openings 43 13.9 Covers 43 13.10 Roof Work/Access 43 13.11 Controlled Access Zone (CAZ) 43 13.12 Working over Water 44 13.13 General Equipment Use 44

Section N 14.0 – Helicopter Lifts 44 14.1 Requirement 44

14.2 Notification 44 14.3 Governing Authorities, Laws 44 14.4 Pre-Lift Meeting 45 14.5 Operator Responsibility 45 14.6 Static Charge 45

Section O 15.0 – Motor Vehicles/Mechanized Equipment 45 15.1 Speed Limits 45 15.2 Equipment 45 15.3 Operation 46 15.4 Inspections 46

15.5 Forklifts 46 15.6 Aerial Lifts 46 15.7 Aerial Lift Operation 47 15.8 Duties of a Spotter 47 15.9 Safe Work Practices for Fueling Equipment 47

Section P 16.0 – Excavations/Trenching 48 16.1 Requirement 48

16.2 Protection 48 16.3 Inspections 49 16.4 Access 49 Section Q 17.0 – Concrete and Masonry 49 17.1 Personal Protection/Sanitation Requirements 49

17.2 Concrete Buckets/Working Under Load 49

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17.3 Other Equipment/Tools 49 17.4 Masonry Construction 49 17.5 Concrete Formwork/Column Erection 50 17.6 Respirable Crystalline Silica 50

Section R 18.0 – Steel Erection 51 18.1 Project Management Responsibility 51

18.2 Requirement 51 18.3 Site Specific Erection Plan 52 18.4 Erection Stability Plan Requirement 52

18.5 Protection from Falling Objects 52 18.6 Multiple Lift Rigging Procedure 52 18.7 Steel Erection Kanban 53 18.8 Inclement Weather 53 Section T 19.0 – Demolition 53

19.1 Building or Structure 53 19.2 Machines and/or Equipment 54 19.3 Handover to NAMC 54

Section V 20.0 – Energy Control Policy and Program 54

20.1 Lockout 54 20.2 Lockout Training 55 20.3 Group Lockout 55 20.4 Lock Abandonment 56 Section X

21.0 – Stairways and Ladders 56 21.1 Requirement 56

21.2 Mobile Ladder Stands 56 21.3 Ladder Use 56 21.4 Job Made Wooden Ladders 57

Section Z 22.0 - Toxic and Hazardous Substances 57

22.1 Requirement 57 22.2 Material Usage Request 57 22.3 SDS Sheets 58

22.4 Storage/Labeling/Use 58 22.5 Emergency Response 58 22.6 Disposal 58 22.7 Exposure 58

Section AA 23.0 – Confined Spaces 58 23.1 Requirement 58

23.2 Confined Space Procedures 59 23.3 Responsibilities 60

Section CC 24.0 – Lifting Requirements 60 24.1 General Requirement 60

24.2 Riggers 60 24.3 Rigging Equipment 61

24.4 Cranes and Derricks 61 24.5 Conditions 61

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24.6 Operations 62 24.7 Qualifications 62

25.0 – Safety Qualifications for Contractor Safety Representation 65 25.1 Supervisors/Project Managers 65 25.2 Designated Construction Safety Coordinator 65

25.3 Workers 66 25.4 Designated Safety Representative 66 Appendix 67

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Section A

1.0 Purpose and Scope 1.1 Toyota Safety Expectation

All contractors are to ensure their workers are given free access to the Toyota Construction Safety Requirements and the host plant Security Requirements. Documents are to be available for review and their location shall be conspicuous.

Toyota Contractor Safety management is built around the principle of Find It, Fix It, No Repeat.

• Find It – TOYOTA expects our contractors to find safety hazards and behavioral issues by themselves before TOYOTA. This represents that the contractor management and safety representatives have a critical eye for safety. The ability to find and address problems proactively is essential for success at TOYOTA construction sites.

• Fix It – TOYOTA expects our contractors to show the importance of safety through rapid resolution of issues identified on audits or raised by their members. By stopping and addressing safety hazards quickly and communicating with the members, the contractor establishes the expectation that safety is the highest priority.

• No Repeats – Sustained success at TOYOTA requires contractors to demonstrate PLAN-DO-CHECK-ACT, reflect on lessons learned and prevent reoccurrence of safety issues. When safety hazards reoccur, it represents a failure of management to implement effective countermeasures.

1.2 Construction Safety Representation (CSMS 3.8, 3.9)

All contractors are responsible to have safety representation on all Toyota construction projects as described in Section 1.7 of this document. The level of safety representation shall be determined by the exposure or risk associated with the scope of work for the project. The safety representation qualification requirements are in Section 25 of this document.

1.3 Contractor’s Responsibility – REFERENCE (OSHA CFR 1926.16)

Contractors have responsibility for the safety of their personnel and shall be responsible for compliance with all Toyota standards, regulations, and accredited consensus standards applicable to their scope of work, as well as Toyota requirements. The General Contractor assumes the overall responsibility under the contract and the subcontractor assumes responsibility with respect to his portion of the work. With respect to subcontracted work, the General Contractor and any Subcontractor(s) shall be deemed to have joint responsibility. Where joint responsibility exists, both the GC and the Subcontractor(s), regardless of tier, shall be considered subject to the enforcement provisions of all applicable laws, codes, standards and the requirements contained herein.

1.4 Toyota Acting as General Contractor/Contractor

When an internal Toyota division, department, section, or group is acting in the role of the General Contractor/Contractor, it shall be responsible for performing all required functions of a General Contractor/Contractor. This may include providing the dedicated On-Site Safety Coordinator (s).

1.5 Monitoring of Construction Site (CSMS 6.4, 6.5, 6.6, 6.7)

All Contractors shall ensure that proper monitoring of the work site and their personnel are conducted per the requirements of applicable sections of this document. The Contractor is required to implement a program of planned, regular safety inspections and meetings. Daily Safety Inspections shall be conducted to ensure compliance with the SSSP, Toyota Guidelines, and applicable law, to maintain good housekeeping of the project sites. Inspections shall be documented and submitted to the Toyota Project Leader/designee and to Toyota Safety daily. (CSF D-35)

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When Toyota Safety performs audits of work areas, the Designated Construction Safety Coordinator(s) (or designee) shall participate in the audit. The audit results shall be reviewed with the Contractor(s) managing staff and workforce, and posted on the Project Control Board daily. General Contractors shall review, monitor and document Subcontractor safety performance and make records available to the Toyota Safety Representative upon request.

1.6 Safety Training and Education (CSMS 4.2)

All Contractors shall ensure that all their workers and their Subcontractors’ workers, are properly trained, fully qualified for their work, and be prepared to provide declarations of qualification, when requested. The employer shall instruct each employee in the recognition and avoidance of unsafe conditions and the regulations applicable to his or her work environment to control or eliminate any hazards or other exposure to illness or injury. All contractors shall, upon request, provide Toyota Safety access to their training programs and personal training records for their workers on a Toyota project site. Training records will be subject to review to ensure compliance with governmental regulations and Toyota policies and procedures. All workers in the U.S. shall have OSHA1926 Construction 10 hour or equivalent (as approved by TMNA PE Safety) training and certification at a minimum. In addition, Toyota Project Leaders must also have OSHA 1926 Construction 10 hour or equivalent.

All Supervisors (Superintendents, Foremen) in the U.S. shall have OSHA 1926 Construction 30 hour or equivalent (as approved by TMNA PE Safety) training and certification at a minimum. Prime Contractors shall also ensure appropriate safety coverage and safety deliverables (e.g. a daily safety audit) for all jobs performed by ensuring an appropriate span of control.

Examples of specific training that Contractors shall provide (confirmed by ISN) include but are not limited to:

• Aerial Lifts • Confined Spaces • Cranes • Electrical Safe Work Practices • Elevated Work Platforms • Fall Protection/Fall Protection Systems • Fire Prevention and Fire Extinguisher Use • First Aid/CPR • Forklift Operation • GFCI Use and Testing • Hazard Communication • Hot Work Permit System • Lockout • Powder Actuated Tools • PPE • Respiratory Protection • Rigging • Signaling • Use of Power Tools

If a person is not trained, competent, or qualified for the task or activity he/she is performing, Toyota Safety will require that work task to cease until corrective actions have been implemented by the Contractor. No person shall be allowed to perform any work at any time without the required qualification or training.

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1.7 Contractor Safety Representation (CSMS 3.8, 3.9)

Prime or General Contractors shall provide an on-site Dedicated Construction Safety Coordinator, on all shifts, who shall be responsible for general site safety. This requirement shall be enforced regardless of the number of workers on site. This person(s) shall confirm and enforce all aspects and requirements of the Site Specific Safety Plan and all Toyota requirements, applicable laws and/codes, and consensus standards that are considered to be best practices in the scope of work. This person shall be qualified and knowledgeable in safety and how it applies to the construction industry (Section 25).

Contractor Safety Coordinators/Representatives must be easily identifiable by wearing green safety crosses on both sides of their hard hat. A green band stating Safety is also acceptable.

Additionally, General Contractors and Prime Contractors shall ensure appropriate safety coverage and safety deliverables (e.g. a daily safety audit of all jobs) for all subcontractors and jobs performed by ensuring an appropriate span of control based on the requirements in Table 1. This safety representation requirement can be satisfied by General Contractor or Subcontractor appointed safety representatives, or (only when directed by Toyota) a combination of safety representatives of the contracting Toyota Department, Section or Group.

When Contractors are found to be noncompliant, the Toyota Project Leader shall provide immediate direction, and suspend activities until adequate coverage is established. General and Prime Contractors shall be ultimately accountable for the safety representation, safety programs and performance of their Subcontractors. Additional Safety representation may be requested to supplement a Subcontractor’s lack of safety performance.

NAMCs shall have a designated and onsite management presence for all construction work, including weekend and shutdown work, to ensure Contractor adherence to the requirements in Table 1. Where Contractors are found to be noncompliant, it is up to the NAMC designee to provide immediate direction, and to suspend activities until adequate coverage is established.

See Section 25 for reference to contractor safety representation qualifications.

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1.8 Required Documentation

Contractors shall maintain a daily roster of all workers on site for accountability purposes. In addition, contractors shall submit Weekly Manpower Reports to Toyota Safety. (CSF D-07) The Toyota Safety Cross (CSF D-09) shall be maintained by the Contractor and displayed on the Contractors’ site visual control display. The minimum required documentation that shall be submitted prior to beginning work, are the following; (CSF D-01, CSF D-08), a Site Specific Safety Plan and a completed JSA (forms and samples located in the appendix).

1.9 Apprentice/Journeyman Ratio

The combined employment of apprentices and non-journeyman classifications in a craft may be up to 40% of a craft’s work force.

Section B

2.0 Glossary of Terms Used/Interpretations

Three (3) point ladder contact: When climbing or working, the requirement of having 2 feet and 1 hand on the rungs or 2 hands and 1 foot on the rungs.

5S: Toyota’s principal that guides us in maintaining a neat and organized workplace. The 5 S’s are; Sort, Straighten, Sweep, Standardize, and Sustain

Affected Worker: (US/Canada) A worker whose job requires him/her to operate or use a machine or equipment on which service or maintenance is being performed under lockout, or whose job requires him/her to work in close proximity to the device under the lockout.

ANSI: American National Standards Institute

Applicable Law: Refers to any acts, regulations, codes, or standards applicable in the jurisdiction where the work is being performed. The Contractor shall be aware of all legal requirements that apply to its work.

ARSC: Association of Reciprocal Safety Councils

Atmospheric Hazard:

1. The accumulation of flammable, combustible or explosive agents, or 2. An oxygen content in the atmosphere that is less than 19.5% or more than 23% by volume, or 3. The accumulation of atmospheric contaminants, including gases, vapors, fumes, dusts or mists

that could: a. Result in acute health effects that pose an immediate threat to life, or b. Interfere with a person’s ability to escape unaided from a confined space.

Authority Having Jurisdiction (AHJ): (US/Canada) The governmental agency or sub-agency which regulates a construction or installation process and provides final approval of the finished construction project or equipment installation. The AHJ may be a state or local inspector or a representative from the NAMC.

Authorized Worker: A person who has the training, knowledge, and experience to lockout machinery or equipment to perform service or maintenance on the machine or equipment.

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CCO Card: Certification card issued by the National Commission for the Certification of Crane Operators

Certified Rigger: A person who has passed stringent written and practical exams related to rigging from an accredited organization.

CFR: Code of Federal Regulations. The OSHA Standards are contained in 29 CFR 1910 (General Industry) and 29 CFR 1926 (Construction).

CHST: Construction Health and Safety Technician

Commissioning: The progressive process utilizing the Toyota Kanban system of installing, testing, and buy-off, for equipment installations and initial start-up. Commissioning typically occurs after white Kanban is signed but before pink Kanban is signed.

Commissioning Zone: The area established around the commissioning process, defined by red and white candy-striped tape. Please see TMNA PE Commissioning Training for additional specifications and requirements.

Competent Person: (USA) (OSHA 29 CFR 1926.32(f)) (Canada) (OHSA 1.1) One who can identify existing and predictable hazards in the surroundings, or working conditions which are unsanitary, or hazardous to workers, and who has the authorization to take prompt corrective measures to eliminate them. – See Competent Person D-01 Form and Detailed Definition in Appendix

Confined Space: A space that meets the following requirements: (See Permit Required Confined Space)

(US)

Space is large enough and so configured that a worker can enter and perform assigned work;

Space has limited or restricted means for entry or exit (example, tanks, vessels, storage bins, hoppers, vaults, and pits); and,

Space is not designed for continuous human occupancy. (Sample CSF D-19)

(CAN) Confined space means a fully or partially enclosed space:

That is not both designed and constructed for continuous human occupancy, and

In which atmospheric hazards may occur because of its construction, location or contents or because of work that is done in it.

Construction: The activity of work that is not production, maintenance, service, or administrative, that can be performed by contractors, vendors, and installers.

Construction Safety Coordinator: A person hired by the contractor that is qualified and knowledgeable in safety and how it applies to construction and the project. This knowledge shall have been demonstrated through a combination of experience in the construction field and formal safety training/education.

Constructor: (Canada) A person who undertakes a project for an owner and includes an owner who undertakes all or part of a project by himself or by more than one employer.

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Contractor(s): Any person or organization that is hired to perform or lead construction, equipment installation, or decommissioning activities. This includes, but is not limited to, companies that install machines and/or are responsible for industrial asset disposal. For the purposes of this document, the term Contractor(s) shall be interchangeable with the term General/Prime Contractor or Subcontractor and shall include their directors, officers, Supervisors, agents or workers, unless otherwise specified.

Controlled Access Zone (CAZ): An area where the work may take place without the use of a guardrail system, PFAS, or safety net system and where access to the area is controlled by an attendant.

CPR: Cardio Pulmonary Resuscitation

Critical Lift: Any one of the following is considered a critical lift:

Exceeds 70 percent of the rated capacity of the crane or derrick. Requires the use of more than one crane or derrick or a crane and an additional hoisting

device. Requires upending or down-ending equipment that weighs more than one ton where the

center of gravity is unknown or moving. Unbalanced load of 5 tons or greater with no engineered lift points. Poor soil or unknown ground condition. (CSF D-26)

CSA: (Canada) Canadian Standards Association

CSP: Certified Safety Professional

CSMS: TMNA’s Construction Safety Management System

Dedicated Spotter: A person whose only job duty is observing a specific task or tasks. This person shall not have any other job responsibilities or perform any work not related to the observation and assistance of the work they are observing.

Emergency: A sudden, urgent, usually unexpected occurrence or occasion requiring immediate action.

Employer: A person or business that employs one or more people, especially for wages or salary.

ESA: (Canada) Electrical Safety Authority (Ontario)

Fall Arrest: A system used to arrest (stop) a worker in a fall from a working level. It consists of an anchorage point, connectors, body harness, and may include a lanyard, deceleration device, lifeline or a combination of these.

Fall Protection Plan: A written document that includes measures that shall be taken to reduce or eliminate fall hazards for workers.

Fall Restraint: Equipment that prevents a worker from reaching a point where he/she will encounter a fall hazard

Fall Zone: An area (including but not limited to the area directly beneath a load) in which it is reasonably foreseeable that partially or completely suspended materials could fall in the event of an incident.

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Fire Watch: A person whose only job duty is observing Hot Work being performed with an appropriate size and type of fire extinguisher, extending 30 minutes past the conclusion of the hot work. This person shall be trained in the use of the extinguisher and have the means to contact emergency services.

First Aid: The provision of initial care of an illness or injury, usually performed by non-expert but trained personnel, until definitive medical treatment can be accessed.

FLL: (México) Mexican Federal Labor Law

Foreman: The worker or tradesman who oversees a construction crew for the contractor.

FSR: (Mexico) Mexican Federal Security, Hygiene and Environmental Regulation

General Contractor: A construction company that is employed by Toyota that will be responsible for the day-to-day oversight of the project, management of vendors and trades, and communication of information to involved parties throughout the course of the project. Responsibilities may include, but not be limited to: managing personnel on site, monitoring schedules, maintaining accurate records, and overseeing of the project’s safety performance (see Appendix Construction v. Non-Construction).

Global Harmonization System: GHS stands for the Globally Harmonized System of Classification and Labelling of Chemicals. GHS defines and classifies the hazards of chemical products, and communicates health and safety information on labels and safety data sheets. It is an internationally agreed-upon standard managed by the United Nations that was set up to replace the assortment of hazardous material classification and labeling schemes previously used around the world.

GFCI: Ground Fault Circuit Interrupter. A device used in conjunction with a plug and cord attached cord sets (extension cord), appliance, or device. It is designed to stop the flow of electricity to the device when current from a current-carrying conductor(s) to ground exceeds a preset limit. GFCI’s are used to protect people, limiting the current to 5 ma, thereby providing protection from an otherwise potentially lethal shock, and shall be designated as a Class A device.

Governing Authority: (USA-OSHA) (CANADA-OHSA) the agency prescribed to administer and enforce compliance with applicable law.

Hazard Communication (HAZCOM): The OSHA Hazard Communication Standard, or "HAZCOM," is a set of regulations designed to inform workers of hazards, particularly chemical hazards, in the workplace and to provide information on the type of PPE required for handling chemicals. This standard is also known as the “Worker Right to Know Law.”

High Risk Activities: This includes, but is not limited to, any work that involves; fall protection, lockout, energized work, confined space, scaffolding (or overhead work), excavation, steel erection, and hot work activities.

Hot Work: Any work that produces or generates an arc, spark, open flame, or heat.

Restricted Hot Work: Hot work that is performed in an NEC Class I Division 1, or Class II Division 1 area (extremely high fire or explosion risk area)

IDLH: Immediately Dangerous to Life or Health

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Incident: An unwanted or unplanned event that could or does cause injury to people, damage to property, or loss to process

Individual: All Toyota employees and non-employees such as variable work force (VWF), contractors, temporary employees (temps), and co-ops, who are working on a project under the scope of this document.

Job Control Lock: A lock, which is placed on a group lockout box by a Lockout Job Control Leader. The purpose of the lock is to prevent a lockbox from being unintentionally opened during shift changes or other events. It is the first lock applied to the group lockbox and the last to be removed.

Job Made Wooden Ladder: A job-made wooden ladder is a ladder constructed at the construction site. It is not commercially manufactured. A job-made wooden ladder provides access to and from a work area. It is not intended to serve as a work platform. These ladders are temporary and are used only until a particular phase of work is completed or until permanent stairways or fixed ladders are installed.

JSA (Job Safety Analysis): A proactive risk assessment method for analyzing the potential safety hazards associated with a particular job or task. Each element of the task is analyzed to determine if a potential hazard exists and, if necessary, what method(s) of safeguarding shall be used to counter the risk. The findings of this analysis are used to create a document that is then reviewed with the workers involved with the task. (sample CSF D-16)

Kanban: As it applies to construction, Kanban is the “visual, efficient and orderly flow of the necessary steps or stages of a work activity to ‘safely’ install and/or modify equipment and machinery”. It is a formal project management system Toyota utilizes for building and equipment installation and modification, and hand over.

Lay-down Area: The area provided to contractor Companies for the temporary storage of equipment, tools, materials, and supplies, etc. while performing construction work.

Limited Access Zone (LAZ): A defined area, which shall be established whenever a masonry wall is being constructed to prevent injury in the event of collapse during construction. The zone shall be restricted to entry by employees actively engaged in constructing the wall. No other employees shall be permitted to enter the zone.

Lockout: (LO) Placement of a lock on an energy-isolating device in accordance with an established procedure, thereby preventing the energy-isolating device from being operated until removal of the lock or in accordance with established procedures.

Machine(s): An assembly of linked parts or components, at least one of which moves, with the appropriate machine actuators, control and power circuits, etc. joined together for a specific application, in particular for the processing, treatment, moving or packaging of a material.

Major Project: Any project that is involved in working with high risk activities (elevated work, confined space, excavations, Lockout, etc.), or has a duration of 14 or more working days. (Note: working Saturday and Sunday for 2 weekends equals 4 working days.)

MOL: (Canada) Ontario Ministry of Labour

MSHA: Mine Safety and Health Administration

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NAMC(s): Toyota North American Manufacturing Company(s)

Near Hit: A near miss involving a moving object. (See Near Miss)

Near Miss: An unplanned event that did not result in, illness, injury, or damage but had the potential to do so. (See Near Hit)

NEC: National Electrical Code

NFPA: National Fire Protection Association

NIOSH: National Institute for Occupational Safety and Health

OCIP: Owner Controlled Insurance Program

OHSA: (Canada) Occupational Health and Safety Act

ORO: (CSMS item 0) Owner’s Representatives Office – a project management organization, usually located on the site of the construction project for major project. It functions as a representative and/or agent of Toyota for the project, and normally includes Toyota and/or contract project leaders, safety representatives, and other technical support staff.

OSHA: (USA) Occupational Safety and Health Administration

Owner: (Canada) (CSMS 1.8) includes a trustee, receiver, mortgagee, in possession, tenant, lessee, or occupier of any lands or premises used or to be used as a workplace, and a person who acts for or on behalf of an owner as an agent or delegate.

Permit Required Confined Space: A confined space that has one or more additional life-threatening hazard(s) (e.g. hazardous atmosphere, risk of engulfment, entanglement, or drowning) (See Confined Space), (Sample CSF D-19)

Non-Permit Required Confined Space: A confined space that does not present an additional life-threatening hazard. Documented testing shall be on file certifying that the Confined Space meets the requirements of a Non-Permit Required Confined Space as defined by governing agencies. (Sample CSF D-19)

PFAS: Personal Fall Arrest System. A system designed to prevent a worker from falling to a lower level. As a minimum for the Toyota site, it consists of a full body harness, lanyard, and an adequate anchorage point (capable of supporting 2 times the maximum anticipated load or 5,000 lbs). (See Fall Arrest & Fall Restraint)

PLHCP: Physician or Other Licensed Health Care Professional

Prime Contractor: Any contractor on a project having a contract directly with the owner.

Project: Any work, or group of work that is performed during construction, installation, and/or decommissioning.

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Project: (Canada) A construction project, whether public or private, including;

(a) The construction of a building, bridge, structure, industrial establishment, mining plant, shaft, tunnel, caisson, trench, excavation, highway, railway, street, runway, parking lot, cofferdam, conduit, sewer, watermain, service connection, telegraph, telephone or electrical cable, pipe line, duct or well, or any combination thereof.

(b) The moving of a building or structure.

(c) Any work or undertaking, or any lands or appurtenances used in connection with construction; The constructor must provide a Notice of Project to the Ministry of Labour prior to starting projects that meet the standards set out in Section 6(1) of the Regulation for Construction Projects, O. Reg 213/91.

Project Leader: Project Leaders can be anyone who has the authority to make decisions on the Construction project. Typically, this could be Team Leaders, Specialists, Group Leaders, Asst. Managers, Managers. Project Leaders are required to have at least the OSHA 10 Hour Outreach Course for the Construction Industry, CSMS Project Leader training, and JSA Guidelines Training.

Qualified Person: (USA-OSHA 29 CFR part 1926.32(I)) A person, who by possession of a recognized degree, certificate, third party training, professional standing, or by extensive knowledge, training and experience, can successfully demonstrate the ability to solve/resolve problems relating to the subject matter, the work, or the project.

Qualified Rigger: A person who is competent (See Qualified Person) in the lifting and moving of extremely large or heavy objects and meets the criteria for a qualified person.

Qualified Signal Person: A person who understands the operations and limitations of crane equipment, including the crane dynamics involved in swinging, raising, lowering and stopping loads and boom deflection from hoisting loads. The person shall be trained and competent to effectively communicate signals through voice, audible, or standard method hand signals.

Recordable: Any injury or illness which meets the requirements of 29 CFR 1904, used in reporting to OSHA.

Rigging: Any type of ropes, cables, hooks, clamps, slings, or other lifting accessories, used for lifting of materials and equipment.

Scaffold Tag: A colored label(s) (green, red, or yellow) that is hung near the scaffold access ladder to identify the safety status of the scaffolding. (See Appendix Scaffold Tags)

SDS: (Formerly Material Safety Data Sheet (MSDS)) These documents include several important pieces of information/instructions regarding the safe handling, first aid, required PPE, firefighting and chemical properties of a product.

Shall: Without exception; a requirement.

Shutdown: The period of time when production has stopped and Construction projects are performed at Toyota facilities. (Refers to Winter Shutdown and/or Summer Shutdown time frame). Determine coverage considering overall scope of project including size of site, shifts, number of personnel, and risk level of work.

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Site Visual Control: A visual display (solid board, vinyl pouches etc.) placed so the contractors and subcontractor’s workers have direct and immediate access to information for the safe operation of the project site. (Example in Appendix)

Site Specific Safety Plan: A written plan that contains safety procedures for the specific job hazards that the contractor anticipates on the project site.

STOP 6 Incident: An incident that falls into one of categories defined by TMC as the top six causes of fatal incidents.

A - Pinched/caught/other by powered machine

B - Contact with/caught in heavy objects

C - Contact with Vehicles

D - Fall from height

E - Electric shock

F - Contact with hot objects- Burn (Thermal or Chemical)

STPS: (Mexico) Mexico’s Ministry of Labor, authority in charge of enforcing the labor legislation in Mexico.

Subcontractor: A contractor that signs a contract with a General Contractor to perform all or part of the obligations of the General Contractor’s contract. The Subcontractor has all the same safety obligations and responsibilities as that of the General Contractor.

Supervisor: Member of management or person responsible for providing direct oversight or job specific direction. (See Foreman)

Supplier: Someone who, via business arrangements such as award of a bid or specific service, work on Toyota premises to complete the requirements of the specified task or job. The terms of what they supply specify their task, responsibilities, and duration of the work.

TMNA: Toyota Motor Engineering & Manufacturing North America, Inc.

Toyota Safety: A team member from the TMNA PE Construction Safety group, a TMNA PE Construction Safety Representative (contracted), or an authorized designee (e.g., an NAMC Safety representative).

Toyota: A reference used within this document, which includes Toyota Motor North America, Inc. (TMNA), Toyota Owner’s Representative’s Office (ORO), Toyota Motor Corporation (TMC), and any of the North America Manufacturing Companies (NAMCs).

Vendor/Contract Employer: Someone who has a business purpose to be on Toyota premises to perform a specific task.

Visitor: A person who is on Toyota premises for a purpose other than performing any work on equipment or systems.

WHMIS: (Canada) Workplace Hazardous Material Information System.

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Worker: A person who performs work or supervises work as part of a Toyota construction, equipment installation, or decommissioning project.

Work Rule: Recurrence prevention method implemented in response to an incident or best practice required by TMNA PE Safety. The work rule supersedes any text in the TCSR.

Section C

3.0 General Safety Requirements

3.1 Safety and Health Program (CSMS 3.10)

All Contractors shall create, implement and maintain a Safety and Health Program that demonstrates a level of control by the Contractor over their workers and Subcontractors and addresses all items listed in this document. A copy of the Contractors’ Safety and Health Program shall be submitted to Toyota Safety, or its designee, at least two weeks (determination based on the size, scope, and risk) prior to the contractor beginning work on the project.

3.2 Safety Policy, Procedure, and Organization Charts

General/Prime Contractors shall obtain, review, and have available Subcontractor safety policies and procedures along with their own to provide to Toyota Safety when requested. General/Prime Contractors are required to obtain an organization chart from each of their subcontractors along with their own, and post it on the Site Control Board. All Supervisors and Safety representatives shall be identified on each chart.

3.3 Site Specific Safety Plan (CSMS 3.22, 3.25)

All General and/or Prime Contractors shall create, implement, and maintain a Site-Specific Safety Plan, designed specifically for the work for which they have been contracted. This plan shall contain safety procedures for the specific job hazards that the contractor plans to encounter on the project site. The contractor shall identify all tasks associated with the project and then describe the risk reduction methods being taken. The SSSP shall be submitted to Toyota Safety for review and approval before the job begins. Toyota Safety reserves the right to reject any portion of the Site Specific Safety Plan. (Sample available upon request)

3.4 Environmental Policy

Contractors shall comply with all requirements published by the Toyota Environmental Engineering Department. It is the Contractors’ responsibility to recognize and comply with all necessary NAMC, local, State, Provincial, Site Specific Environmental Guidelines, and Federal environmental laws and requirements. Required forms may be obtained from the host NAMC.

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3.5 Hazard Communication/WHMIS (CSMS 3.11)

Contractors using potentially hazardous or restricted substances on the project site shall ensure that the proper Toyota forms have been submitted. Approval from the local NAMC shall be required prior to bringing these substances onto the project site. The forms are available from the local NAMC. Contractors shall be responsible for preparing an inventory and maintaining an SDS file in their office for all approved hazardous chemicals used and documentation of worker training in the hazards and use of these chemicals. SDS files shall be current, per applicable law, and in a location, such that they are readily available for inspection.

3.6 Emergency Action Procedures – (OSHA 29 CFR 1926.35, CSMS 3.10)

Contractors shall develop an emergency action plan to be used in the event of a fire, explosion or natural disaster such as a severe thunderstorm, tornado, or earthquake. The emergency action plan shall be in writing and shall cover those designated actions Contractors and their workers shall take to ensure worker safety from fire and other emergencies. The Contractor shall designate and train a sufficient number of persons to assist in the safe and orderly emergency evacuation or shelter in place event. The Contractor shall review the plan with each worker covered by the plan prior to worker commencing work, when the worker’s responsibilities or designated actions change, and when the plan is changed. The plan shall be kept in the workplace and available to the worker.

Emergency action plan shall include the following elements at a minimum:

• Emergency escape procedures and emergency escape route assignments • Locations of and routes to shelter in place areas • Procedures to account for all employees after the emergency evacuation or shelter in place

event has been completed • Preferred means of reporting fires and other emergencies

3.7 Substance Abuse Control Program (CSMS 1.6)

Toyota is a drug free workplace and insists that its contractors maintain the same. Drug screening is required for all workers on Toyota properties (except in Canada). Proof of current 10 panel drug screening (Taken within previous 30 days prior to arrival on site, unless specified otherwise) shall be provided for each worker. Prior to the worker being issued, or reactivating a badge, workers shall be required to provide proof of all 10 tests showing negative test results at the time of orientation, unless otherwise specified by the local NAMC. Toyota shall not be liable for any delays caused through the drug screen process prior to the receipt of negative test results. The contractor shall implement an effective substance abuse control program that shall include “post-accident,” and “for cause” testing, while under contract at Toyota. Toyota has zero tolerance for drug and alcohol use/possession at all sites.

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3.8 Job Safety Analysis (JSA) (CSMS 3.12, 3.24, 3.26, 6.1, 6.3)

Contractors shall be required to develop an overall Job Safety Analysis (JSA) (CSF D-16) for any activities physically being performed during the project. The JSA shall be submitted to Project Management/Toyota Safety 2 weeks (recommended), but not less than 48 hours prior to the scheduled work for review. A JSA Review checklist (CSF D-17) must be submitted with the overall JSA. Toyota Project Leaders and Toyota Safety will sign the document after review. The document and the JSA will be sent back to the Contractor. The signed JSA Review checklist along with the JSA must be kept in the field and accessible. The JSA shall be communicated to all workers involved with the task, and signatures of each worker shall be acquired prior to work starting. Toyota reserves the right to request that a JSA be performed for specific activities not addressed in the project schedule. If work is discovered being performed without a Toyota Safety reviewed JSA, Toyota reserves the right to stop the work until the situation is rectified. Where the JSA content is substandard, Toyota reserves the right to reject the document at which time an additional 48 hours may be used for review (CSF D-16). A Toyota Construction Daily JSA (CSF D-18) will be required to be completed before work begins. This document is to be written by construction foremen, and/or superintendents along with input from the workers in the field and the Toyota Project Leader/designee. All workers must also sign the Toyota Construction Daily JSA before work begins for the shift.

The Contractor may use its own daily JSA form if it meets or exceeds Toyota’s requirements. The local Toyota Construction Safety Representative will review the Contractors daily JSA form to determine if it meets Toyota criteria.

3.9 CPR and First Aid Trained Resource Requirement

All Contractors shall be responsible for providing a full time, qualified First Aid/CPR person who meets all applicable training requirements, including, but not limited to, bloodborne pathogens training, as required by applicable law or contract specification. The contractor shall submit a resume and Declaration of Competency (CSF D-01) of their candidate(s) for this position to Toyota Safety or their designee for review prior to any work beginning on site. Toyota Safety reserves the right to reject any candidate who is not qualified or cannot otherwise perform the duties for the position. These credentials must be kept current and not allowed to expire while working at Toyota. The qualified First Aid/CPR trained person must be on the worksite when the work is being performed.

3.10 Proof of Insurance (CSMS 1.2, 3.7)

All Contractors shall be responsible for providing Certificates of Insurance to prove valid coverage for Automobile Insurance, Workers’ Compensation Insurance, Owner Controlled Insurance Policy (OCIP) coverage and a valid State Contractors License. When applicable, Contractors not in the Toyota OCIP program shall also provide Certificates for General Liability and Worker’s Compensation Insurance for their workers. Certificates of Insurance shall be provided to ISN, Toyota, or their designee, prior to having their workers being admitted to orientation. Contractors shall not be allowed to work on Toyota property without the required licenses and insurance coverage in place. General/Prime Contractors shall ensure that Subcontractors have proof of applicable insurance.

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(CAN)

• Contractors must have WSIB coverage and ensure their account is up to date to be eligible for clearances. Clearance must be obtained before any construction work begins and the clearance must remain in effect for the entire time the contractor is performing work on site.

• Clearance certificates must be readily available upon request.

3.11 Project Coordination/Notification of Work

All contractors are responsible for coordinating their work with all existing Toyota Engineering, Facilities, Safety and Security departments. The Contractors shall provide a CSF D-15 or Form 4.0 Notice of Work Permit (Canada), where required with a JSA to Toyota Safety, or its designee, prior to beginning on-site work.

3.12 Toyota Safety Orientation (CSMS 3.16, 3.17, 3.28)

All contractor workers, the Contractor’s management team, and anyone else, who is given authorization by the appropriate Toyota Management to enter a construction zone, shall attend Toyota Construction Safety Orientation prior to performing any work on a Toyota construction project. This orientation shall be provided by Toyota and shall be scheduled frequently enough to meet demand. This orientation is typically provided at the beginning of the work shift. Workers attending orientation shall be attired in such a manner as to be ready to begin work on the project site. Proper clothing (shirts with minimum 4” sleeves etc.), safety-toed boots, and safety eyewear shall be worn when accessing the plant/work site.

3.13 Coordination Meetings (CSMS 6.1, 7.6)

Contractors’ Supervision and Safety shall conduct daily safety coordination meetings with their workers and other Contractors to discuss that day’s work activities and their associated safety practices. These may be done as part of, or in conjunction with, the pre-shift work planning meetings. Meeting attendance shall be taken and records kept, and submitted to Toyota Safety when requested.

Coordination meetings shall include the following:

• Work coordination specific to that day’s activities • JSA’s, High Hazards and countermeasures for the day’s work • Safety Alerts, Safety Incidents • General safety practice reinforcement • Results of previous day’s safety audits

The Contractor Safety Coordinator or member of management from each contractor shall participate in a Safety Review Meeting on a weekly basis or as often as deemed necessary by Toyota Safety. The purpose of this meeting is to discuss any safety deficiencies found from auditing, provide updates on changing safety standards, and review incidents, JSAs and other pertinent safety information. The Safety Review Meeting is mandatory for all Contractor Safety Coordinators or their designees.

3.14 Contractor Tool Box Talks (CSMS 7.2)

Contractors shall conduct Toolbox Safety Meetings at least weekly with their personnel for safety awareness and discussion of special safety topics. Copies of the meeting minutes shall be available to Toyota Safety upon request.

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3.15 Site Visual Control (CSMS 4.3)

All major projects shall have a site visual control board (See Appendix). In the event there is no General Contractor or Prime Contractor for a major project, each Contractor shall maintain a Site Visual Control Board during the duration of the major project. Refer to the Toyota Construction Safety Standards Appendix (Site Visual Control), for a listing of required documents that shall be posted. For all other projects, site visual control may be maintained in a binder, protective sleeves, or other means readily known and available to all affected workers and Toyota representatives.

3.16 Means of Egress

In every building or structure, exits shall be maintained to provide free and unobstructed egress from all parts of the building at all times when it is occupied. No containers, working materials, building materials, etc. shall impede egress. No lock or fastener to prevent free escape from the inside of any building shall be used. Readily visible signs shall mark access to all exits including where they are not immediately visible to the occupants. Where man doors are not available, workers shall proceed with caution only after confirming it is safe to do so.

3.17 Emergencies: Evacuation/Severe Weather/Spills/Fires (CSMS 3.10)

The Contractor shall use the host plant’s fire, spill, and evacuation/seek shelter plan which provides site-wide procedures to be followed in case of fire, explosion, spills, or severe weather. Where there is no host plant Emergency Plan, or it does not cover the location/scope of the Contractor’s project, the Contractor shall implement its own. This plan shall be in writing and provide a set of procedures to be followed throughout all phases of the project.

As the project progresses, emergency plans shall change to accommodate new conditions at the site that introduce a previously unidentified hazard, including procedures which cover incidents occurring both before and after building enclosure timing. Contact List (CSF D-08) shall be submitted to Toyota Safety and posted on the Contractor’s Site Control Board.

3.18 Incident Reporting Procedures (CSMS 9.2)

All injuries and injury-free incidents (First Aid, Recordable, Near Hit/Miss, Property Damage etc.) shall be reported immediately to Contractor Supervision and Toyota Safety. Host NAMC management reserves the right to review all incidents. The Toyota Initial Report (CSF D-12) shall be completed for all incidents and submitted to Toyota Safety within 24 hours of the incident. The Toyota Final Incident Report (CSF D-12) shall be completed for all incidents and submitted to Toyota Safety within 5 days. The incident shall be communicated to all workers at the project site to prevent re-occurrence.

3.19 Housekeeping/5S

Good housekeeping shall be maintained in all work areas at all times. During construction, debris shall be kept cleared from work areas, emergency equipment, passageways, and stairs. Debris shall be removed at regular intervals as often as necessary, but no less than once each work day. Containers shall be provided by the contractor for collection of debris and personal trash. Contractors shall provide a housekeeping plan in their SSSP and shall cover policies, procedures and labor requirements for effective implementation.

All materials and tools shall be placed on racks, cribbing, dunnage, skids, pallets, or tables and shall be secured to prevent movement to help eliminate trip hazards. No items shall be left on floor.

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Cords shall be elevated at least 7 feet off the ground or walking/ working surface. If elevation of cords is not feasible or creates a greater hazard, they shall be covered with a hard barrier to prevent damage (if in areas where mobile equipment is in use) and taped or covered with high visibility tape to prevent slip, trip hazards.

The supplier, contractor, or other responsible party is responsible for proper storage (including time limitations), handling, and disposal of hazardous waste generated on site according to applicable Federal, State and Local laws and regulations. Notify Toyota Environmental for disposal requirements, where applicable.

Refer to the Roll-Off Container Work Rule for staging of dumpsters. (See Appendix)

3.20 Commissioning

Commissioning is the process to verify and validate the performance of equipment (e.g. initial power-up, debugging, confirming safety function, etc). All commissioning members shall review the work area with the Toyota Project Leader or designee responsible for the equipment, prior to commissioning activities commencing and identifying potential risks/hazards to all persons participating in the commissioning:

• All authorized personnel shall be identified by a badging or other identification system. • Each specific commissioning zone shall have a sign-in sheet. • A notice shall be sent out by the commissioning contractor to Toyota Engineering, Toyota

Safety (host NAMC Safety Dept. where requested), and other affected contractors, 72 hours prior to initial equipment activation.

• Commissioning Tape (Red and White Candy Stripe tape) dimension shall create clear barrier to prevent access into the hazard area.

• Signage shall be posted in adequate locations stating “DANGER, Do Not Enter, Commissioning in Progress, Authorized Personnel Only” or similar (CSF D-25). Prior to ‘start up’, the line shall be inspected to ensure it is ready for commissioning and to ensure that no unauthorized personnel are in the hazard area.

• Commissioning training is required to become an authorized person. • Only authorized personnel shall be in/over/under the hazard area during testing. Authorized

personnel shall be visually identified as Commissioning Team Members (e.g. badge, sticker). • All commissioning activities shall have a JSA, which shall be signed by all involved workers in

the commissioning zone. • If the line of visibility is obstructed, spotters shall be stationed, complete with a communication

system to ensure a safe start up. • When commissioning tests are completed the red and white candy-striped tape and

commissioning signs shall be removed.

3.21 Handover to NAMC (CSMS 10.1)

A plan must be in place to ensure the construction work zone is safe before handover to the NAMC for startup of production activity.

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• All tools must be removed from the area. • All anchor bolts must be hammered down, cut or otherwise removed from the walking/working

surfaces. • All open pits must be protected by guardrails. • NO items that could interfere with or impact production operations shall be left in the work zone,

e.g. wires, pipes, etc. that could be struck by moving machinery or equipment. • When work is performed in the trusses, a visual overhead 5S truss sweep must be completed.

3.22 Safety/Security Violations (CSMS 9.1)

Where Toyota or its authorized representatives observe or are formally made aware of a violation of Toyota Construction Safety Requirements or applicable law by the Contractor, its workers, Subcontractors or Suppliers, the contractor shall be immediately notified. Each contractor shall immediately notify Toyota Project Management and Toyota Safety regarding violations of any applicable legal requirements by its own workers, Subcontractors or Suppliers. (CSF D-13) If contractor is found to be in violation of a plant specific safety or security requirement, Toyota shall investigate the incident with the host plant to determine access privileges of the party involved.

Every contractor shall have a clearly defined progressive corrective action policy that shall address any collective agreement and shall meet the requirements for this project (where applicable.) Contractors shall inform Toyota Security of any actions taken regarding corrective action that includes removal or barring any worker from a Toyota site(s). In addition, Toyota reserves the right, based on the severity of the incident(s), to request that the contractor remove or bar worker(s) from the site for rule(s) violations.

Violations subject to immediate barring from all Toyota sites:

• Fall Protection • Lockout • Hot work • Confined Space • Crane operation • Disabling or bypassing a safety guard or device • Reckless driving • Failure to report safety incident • Molten metal procedures • Operating equipment when not qualified to do so • Entering dumpsters

Behavior

• The willful and/or reckless failure to comply with a standard and/or abate a recognized hazard and the consistent failure to observe safety rules

• Falsification of a qualification or certification to operate specialized machinery • Possession, sale, or use of alcoholic beverages or controlled substances • Supervisors or foremen intentionally instructing workers to work in an unsafe manner or

intentionally not enforcing the Toyota site safety policies with workers.

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Violence

• Sexual misconduct/ Sexual harassment/ Public indecency • Arson/Intentional property damage • Robbery/ Burglary/Criminal trespass • Disorderly conduct/ Fighting on Toyota property • Possession of a firearm or other deadly weapon on Toyota property

Security

• Insubordination • Failure to surrender official Toyota identification when asked to by Toyota, Security or

Contractor supervision • Piggy Backing Badges or Badge Pass Back

Any other acts that may result in injury to the worker, other workers or cause damage to Contractor or Toyota property could result in removal and barring from site.

3.23 Smoking and Tobacco Products Policy

Smoking and the use of any tobacco or herbal products including, but not limited to, chewing tobacco, electric cigarettes, clove cigarettes, and tobacco pouches shall follow local NAMC’s policies and procedures. Violation of the tobacco policy may result in removal and barring from site. Smoking and tobacco product infractions not directly related to the safety of workers shall be referred to NAMC Security.

3.24 Recording Devices

Use of recording devices (e.g., cameras, video recorders, photo capable cell phones, digital recorders etc.) is prohibited without prior written authorization from Toyota Security. Violations will be referred to NAMC Security.

3.25 General Security Rules/Site Access

Please contact the local Toyota or NAMC representative for a comprehensive list of security requirements. A badge request form and Safety Orientation verification shall be required from security prior to entering any NAMC.

3.26 Work Hour Restrictions

The maximum number of hours a worker is allowed to consecutively work is 16. After 16 hours on the job, a break of at least 8 hours must be allowed. No worker may work more than 4 consecutive 16 hour days. Maximum weekly work hours will be capped at 70 hours. The Toyota job leader must be informed if work hours exceed 70 hours for the week (Saturday-Friday) or 16 hours in one day.

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Section D

4.0 Environment/Site Conditions

4.1 First Aid

Provisions shall be made prior to the beginning of the project by the contractor to ensure the availability of prompt medical attention in case of injury. First aid supplies are required to be easily accessible (within two (2) minutes). The contents of the first aid kit shall be placed in a weatherproof container with individually sealed packages for each type of item. The first aid kit shall be checked by the employer before being sent out and weekly. The contractor shall provide suitable facilities for quick drenching or flushing of the eyes and body within the work area for immediate emergency use.

4.2 Sanitation

An adequate supply of potable water shall be provided for drinking. Portable containers used to dispense drinking water shall be capable of being tightly closed and equipped with a tap. Portable containers shall also be sealed, dated, and cleaned on a regular basis. Water shall not be dipped from the container. A shared drinking cup is prohibited. Only single use cups shall be provided. A sanitary dispenser and trash receptacle shall also be provided.

General Contractors or Prime Contractors shall provide or make arrangements for toilets for workers according to applicable law for the jurisdiction.

When toilets are provided by General Contractors or Prime Contractors, they shall maintain an adequate cleaning schedule as to not affect the health and safety of their workers or other contractor workers on the site. The facilities must be inspected for cleanliness daily and cleaned once a week or more, if needed. Toilet facilities shall comply with local, state, province, and federal laws.

Hand washing/ hand cleansing stations must also be provided and maintained.

4.3 Noise Exposure

Protection against the effects of noise exposure shall be provided by the Contractor. The proper protection shall meet or exceed OSHA/ANSI/OHSA requirements (See Section E, 5.0).

4.4 Illumination

The contractor shall provide general and task lighting suitable for the work activities being performed. Construction areas shall be lit with either natural or artificial illumination and shall be lit to not less than the minimum illumination intensities required by 29CFR 1926.56(a), Table D-3.

4.5 Ventilation

The contractor shall provide adequate controls of fumes, vapors, mists, or gases that meet or exceed OSHA requirements listed in 29 CFR 1926.55, Appendix A. Air monitoring shall be utilized in the presence of a potentially hazardous atmosphere.

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4.6 Dust Control

Contractors shall develop and implement a dust control program that contains a description of the methods to be used for controlling dust. Water shall be the preferred method. Any variance shall be approved by Toyota Safety. Contractors shall have this program on file and submit it to Toyota Safety when requested.

4.7 Radiation

In construction and related activities involving the use of sources of ionizing radiation, the pertinent provisions of the Nuclear Regulatory Commission’s Standards for Protection against Radiation, relating to protection against occupational radiation exposure, shall apply. Any activity which involves the use of radioactive materials or X-rays shall be performed by a Competent Person trained in the proper and safe operation of such equipment.

4.8 Heat Illness Prevention

Contractors shall develop and implement a program to prevent heat illness. Facilities must be provided for outside workers to take rest breaks in shaded areas. See Appendix for signs and symptoms of heat related illnesses.

Section E

5.0 Personal Protective Equipment

5.1 Requirement

It is important to note that each NAMC may have specific PPE requirements within its production areas that all workers must comply with.

Contractors shall ensure their workers, Subcontractors, suppliers, and visitors are familiar with all personal protective equipment required on the project, and have been instructed how to use and maintain the equipment according to good safety and hygiene practices. Toyota will not provide any PPE to contractor employees. Where employees provide their own protective equipment, the Contractor shall be responsible to ensure the required protection is adequate. Failure to wear required PPE may subject the worker to dismissal from Toyota property. Other personal protective equipment may be required in specific areas of the local NAMC. Verify the additional PPE requirements with the local NAMC prior to arrival at the plant.

5.2 Foot Protection

Safety-toed work boots, covering the ankle, appropriate for the work activity, and approved by applicable law, shall be worn at all times in construction zones. In Canada, footwear meeting the provisions of CSA Z195 M92, labeled with “green triangle” signifying additional sole puncture protection of “Class 1”, are required. Metatarsal foot covers are required when using Jack Hammers or hand-controlled tamping equipment. Contractors shall verify with the local NAMC as to any additional foot protection requirements outside of the construction areas (ANSI Z41.1).

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5.3 Hand Protection

Employers shall make available to their employees the appropriate hand protection when employees hands are exposed to hazards, such as those from skin absorption of harmful substances, cuts or laceration, abrasions, punctures, chemical burns, thermal burns or harmful temperature extremes. Verify the minimum level of hand-cut protection requirements with each NAMC prior to arrival at the plant.

The selection and use of hand protection shall be based on an evaluation of hand position and task as it is relative to the exposure or tool. This can be accomplished by reviewing the task, conditions present, duration of use and hazards/potential hazards that have been identified through the JSA (Job Safety Analysis) (CSF D-16). Kevlar or cut resistant gloves with a minimum cut level of ANSI A6 are required when handling or cutting sheet metal.

5.4 Head Protection

Approved hard hats, meeting the requirements of “Type I, Type II Class E or G”, shall be worn at all times by workers in construction areas. Class G hard hats are not allowed on Canadian projects. Hard hats shall be worn with the brim facing forward. It may only be worn in reverse if, the job, task, or work environment necessitates wearing it backward (e.g. face shield or welding helmet), and the hard hat has a reverse orientation mark with a reversible ratchet liner. No “cowboy” hardhats or “bump” cap style hats allowed in construction areas. Hard hats shall be replaced periodically based on manufacturers’ specifications. Toyota Safety reserves the right to ask that PPE be replaced if it is damaged or outdated.

5.5 Hearing Protection

When noise levels exceed 85dba, the proper hearing protection shall be worn and provided by the Contractor.

5.6 Eye and Face protection- Reference OSHA 29 CFR 1926.102

Approved eye protection (ANSI Z87/CSA Z94.3) with fixed side shields or safety rated goggles shall be worn properly at all times. Prescription safety glasses shall be fitted with secured side shields and have a minimum ANSI rating of Z87.1. The use of thin plastic slip-on side shields shall not be permitted. Tinted safety glasses shall not be worn inside of buildings.

Refer to OSHA 29CFR 1926.102 Table E-1 for recommended protectors.

5.7 Respiratory Protection- Reference OSHA 29 CFR 1910.134

The Contractor shall take all actions necessary to ensure air quality standards are met on the project and in its work areas. Contractors shall evaluate emissions caused by their work processes (e.g., welding, running vehicles, etc.) and/or by the materials used. The contractor shall have a respiratory protection program and provide NIOSH/MSHA approved respirators and dust masks. Where respirators are necessary to protect the health of the worker, the Contractor shall include the following provisions in the program as part of the Site-Specific Safety Plan.

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• Procedures for selecting respirators for use. • Medical evaluations of employees required to use respirators. (Must be provided by a PLHCP.) • Fit testing procedures for tight fitting respirators. • Procedures for the proper use of respirators. • Procedures and schedules for cleaning, storage, and maintenance. • Procedures to ensure air quality, quantity, and flow of breathing air for atmosphere-supplying

respirators. • Training of employees in the proper use of respirators. • Training of employees in the respiratory hazards to which they are potentially exposed.

5.8 Protective Clothing

Proper protective clothing shall be worn at all times, including full length pants and shirts with a minimum of 4” sleeves. Approved high visibility shirts, vests, or jackets shall be worn while on the site. It shall be permissible to remove high visibility vests/jackets that are not arc rated (AR) while performing work activities where danger of sparks, arc, or fire exists. High visibility vests with reflective stripes shall be worn in heavy traffic areas, when spotting or directing traffic, and for work in low light conditions.

Section F

6.0 Fire Protection/Prevention

6.1 Requirement

The Contractor shall at no time impede or impact any life safety system (e.g., fire suppression, fire alarms, etc.) without written authorization from Toyota Safety or designee and local NAMC’s Security according to local requirements. The Contractors shall verify with local NAMC any documentation requirements. The Contractor shall be responsible for the development of a fire protection program to be followed throughout all phases of the construction and demolition work. Contractors shall train their workers in the potential fire hazards of their jobs. A record of this training shall be kept on file by the Contractor and submitted to Toyota Safety upon request.

6.2 Fire Extinguishers

In case of fire, Contractors may try to extinguish incipient (beginning) fires with a portable fire extinguisher of the proper size and rating, only if they have been properly trained and it is safe to do so. Fire extinguishers that have been listed or approved by a nationally recognized testing laboratory shall be used to meet the requirements of this guideline. Contractors shall not be permitted to claim a local NAMC's fire extinguisher to satisfy its requirements as part of construction activities. Any discharge of a local (NAMC) fire extinguisher, whether by accident or in the event of extinguishing a fire, shall reported to the NAMC's Security Department. All extinguishers shall have a documented annual and monthly inspection. Refer to local NAMC Hot Work requirements for size of appropriate fire extinguisher.

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6.3 Flammable and Combustible Liquids

Only approved containers and portable tanks shall be used for storage and handling of flammable and combustible liquids. Flammable and combustible liquids shall be handled and stored consistent with the requirements of the SDS (formerly MSDS). No plastic portable fuel cans are allowed on site. Portable fuel cans shall be constructed of metal and contain spark arrest features.

6.4 Fuel Storage

Propane, fuel, oxygen, etc., shall be stored away from work or working areas, from buildings and in appropriate lockable storage “cages” in accordance with all federal, state and local laws. See Section 10.4 for more information.

Section G

7.0 Signs/Barricades

7.1 Requirement

Construction work areas shall be posted with appropriate signs and shall be positioned conspicuously around the perimeter of the protected area (CSF D-38). In addition to the warning information, signs shall contain the Company name, Contact name, contact number(s), list of the hazards within, and a clear indication of the PPE required for entry. Safety warning signs may be attached directly to barrier fences or signage tape and shall be posted at all access/egress points. Barricaded areas shall have designated entry and exit points and these shall be maintained and functioning at all times to prevent the need to go under or step over signage tape.

7.2 Barricades

Barricades or guardrails are required around excavations, openings in floors or roof areas, edges of platforms, roof and overhead work areas. Means of access or egress shall be available where it does not pose a hazard. Barricades and guardrails used for the prevention of falls shall comply with applicable federal, state and local laws.

7.3 Signage Tape

7.3.1 Yellow Caution Signage Tape

Yellow Caution signage tape is used to designate a controlled area that poses no specific, immediate hazard such as laydown/storage areas, break areas, general construction or work area boundaries where no overhead hazards exists, etc. Workers may enter this area only if it is necessary and only after first determining it is safe to do so by confirming the general hazard(s) within and any PPE requirements as indicated on the warning signage. Yellow Caution signage tape shall be maintained in working condition and shall be supported to hang such that it is between 42 inches (1.1 m) plus or minus 3 inches (8 cm) above the walking/working level.

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7.3.2 Red Danger Signage Tape

Red Danger signage tape is used to designate a Danger Area that poses a specific and immediate danger to workers within due to the high-risk activity. Workers not directly involved with the work in progress inside this area shall not enter unless given permission by the controlling contractor. Additionally, the entering worker shall fully understand the hazards in the area (review of the JSA is recommended) and Red Danger signage tape shall have signage indicating specific hazards (ex: overhead work). Areas barricaded with Red Danger signage tape shall be maintained in working condition and for only as long as necessary to perform the work.

The area designated by Red Danger signage tape shall not completely block access to other areas of the work site. Pathways are to be created to allow access around the designated areas. Red Danger signage tape shall be maintained in working condition and shall be supported to hang such that it is between 42 inches (1.1 m) plus or minus 3 inches (8 cm) above the walking/working level.

7.3.3 Red and White Candy Stripe Tape (Used Solely for Commissioning)

Red and White Candy Stripe tape, or Commissioning tape, is used to designate a controlled area that is under the commissioning process to indicate the unique hazards experienced during the commissioning procedure. The designated area shall completely encompass the area under commissioning including any adjacent areas that are being used for commissioning purposes (e.g. drive path of a vehicle, extents of a robot in teach mode, etc.). Workers entering the commissioning zone shall be properly trained and identified as part of the commissioning team for that specific process or work zone. A sign shall be posted at the entrance of the commissioning zone, (CSF D-25) warning of restricted access. The sign shall be in English, Japanese, and Spanish. (Please see TMNA PE Commissioning Training for additional specifications and requirements.) Commissioning tape shall be maintained in working condition and shall be supported to hang such that it is between 42 inches (1.1 m) plus or minus 3 inches (8 cm) above the walking/working level.

Section H

8.0 Materials/Handling and Storage

8.1 Requirement

The contractor shall only store material in the “lay-down” area(s) approved by Toyota. The perimeter of the designated areas shall be barricaded, roped-off, or otherwise identified.

The area must have proper signage, which includes:

• Contractor Name • Purpose of the lay-down area • Date Contractor will relinquish area • Contact Person and Phone number

Contractors shall relocate their material lay-down and fabrication areas upon the request of Toyota. All contractor material shall be removed from the site at the completion of the job.

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Materials stored inside buildings under construction shall not be placed within 6 feet of any hoist way or inside floor openings (i.e. pits, holes, etc.) Maximum safe load limits of floors and rooftops shall not be exceeded. Materials shall not be stored on scaffolds or runways in excess of supplies needed for immediate operations. All material shall be stacked, racked, blocked, interlocked, or otherwise secured to prevent sliding, falling or collapse. All materials stored outside of building(s) shall be secured in the event of severe weather. Used lumber shall have all nails removed or hammered down before stacking.

All refuse material shall be disposed of daily in proper containers such as dumpsters designated for specific materials. Dumpsters shall be staged per the Roll Off Container Work Rule (See Appendix).

8.2 Trip Hazards

Aisles and passageways shall be kept clear to provide for the free and safe movement of material, handling equipment, and people.

8.3 Liquid Spills

Report all spills to the appropriate Toyota member immediately. Spill Kits shall be provided by the Contractor, readily available, and fully stocked while working with or around oils, liquids, and chemicals.

8.4 Rigging Equipment for Material Handling

Each day before being used, the rigging equipment, all fastenings, and attachments shall be inspected for damage or defects by a competent person designated by the employer. Additional inspections shall be performed during rigging equipment use where service conditions warrant. Damaged or defective rigging equipment shall be immediately removed from service. The equipment shall have permanently affixed and legible identification markings as prescribed by the manufacturer that indicate the recommended safe working load. The rigging shall be stored in such a manner as to prevent a hazard to workers, or damage to the rigging or rigging equipment.

Section I

9.0 Tools/Hand and Power

9.1 Requirement

Contractors shall be responsible for ensuring hand tools, power tools, and equipment are maintained in safe working order.

9.2 Condition

Electrical tools shall be maintained per the manufacturers’ requirements and inspected before each use. Power supplied to electrical tools shall be provided with ground fault circuit interrupter (GFCI) protection. Double insulated tools must also be powered by a GFCI-protected receptacle.

If any hand or power tools are found defective, they shall be tagged and removed from the jobsite immediately until repairs have been made or tools replaced.

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9.2.1 Cut Off Wheels

Multipurpose wheels shall be used only with Toyota Construction Safety and Toyota Management approval and used as a last resort if alternative methods are not feasible. Contractors Supervisor shall review and issue the appropriate media for the task after receiving Toyota approval. Approved multipurpose cutting / grinding discs that can both cut and remove excess material shall be made of 3 layers of bonded reinforcement and manufactured to EN12413 standards. The minimum thickness shall be 0.078” (5/64”) or 1.9mm. Before an abrasive wheel is mounted, it shall be inspected closely for damage and should be sound or ring-tested to ensure that it is free from cracks or defects.

9.3 Guarding

Proper guards shall be installed on all power tools before being issued. Modified tools (i.e., missing handles, or homemade handles or extensions) are not permitted.

9.4 Powered Tools

All mechanically powered equipment, tools, machines, and devices rated at greater than 10 horsepower shall be inspected by a competent person on a regular planned basis and documented monthly.

9.4.1 Operating Controls and Switches

The following hand-held power tools shall be equipped with a constant-pressure switch or control that shuts off the power when pressure is released: drills; tappers; fastener drivers; horizontal, vertical, and angle grinders with wheels more than 2 inches (5.08 centimeters) in diameter; disk sanders with disks greater than 2 inches (5.08 centimeters); belt sanders; reciprocating saws; saber saws, scroll saws, and jig saws with blade shanks greater than ¼ inch (0.63 centimeters) wide; and other similar tools. It is recommended that the constant-pressure control switch be regarded as the preferred device on all power tools.

9.5 Identification

Contractors shall have company name, signs/labels on all job boxes, toolboxes and equipment, to include: lifts, site carts, job trucks, etc.

9.6 Powder Actuated Tools

Powder actuated hand tools used on the construction site shall comply with the following:

• Operator shall be certified by the tool manufacturer or their representative, with a copy on file with the contractor, available upon Toyota Safety request.

• All powder actuated hand tools used on site shall utilize low velocity shot, comply with all applicable safety requirements, and be maintained in a safe working condition.

• The powder actuated tool shall be tested in accordance with the manufacturer’s recommended procedure before loading, to verify all safety devices are in proper working condition.

• All shot casings (spent or misfired) shall be placed in an approved metal receptacle used only for this purpose and disposed of daily.

• Powder actuated tool use is considered a hot work activity at some NAMCs. Check with local NAMC for hot work requirements.

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9.7 Securing Material

All materials used at elevations shall be secured to prevent a falling object hazard. This includes materials being used in the screen-guard, next to guardrails or in lifts. Also, standing materials shall be secured so to prevent a falling object hazard. At completion of job, a 5S truss sweep must be performed to ensure all tools and material are removed.

Section J

10.0 Welding and Cutting

10.1 Requirement

A “Hot Work Permit” shall be issued by the local NAMC for any work that produces an arc, spark, flame and/or could ignite flammable or combustible materials. All contractors shall follow the local NAMC’s “Hot Work” requirements. Hot Work Training may be required at some NAMC’s before a permit will be issued.

Hot work is not permitted within 35 feet of flammable or combustible materials.

If flammable or combustible materials are not able to be moved 35 feet from the hot work area, a positive means shall be implemented to protect the material from the heat, sparks, and/or slag.

When hot work is performed on walls, floors, and ceilings where direct penetration of sparks or heat transfer may introduce a fire hazard the same precautions shall be taken.

10.2 Clothing/PPE

Welders and other employees who are exposed to radiation from welding and sparks from grinding operations shall be suitably protected (welding hood, eye protection, gloves, leathers, leather shoes etc.) so the skin is covered completely to prevent burns and other damage from the work process. Special care shall be taken to protect fall protection equipment during welding, grinding and burning operations while still allowing for the fall protection devices to operate properly.

10.3 Protection

Flashback or flame arrestors at gauges shall be provided on all gas welding/cutting equipment. The contractor shall provide proper protection for the surrounding area(s) of “Hot Work” including protection for equipment, product, and workers. Whenever practicable, all arc welding and plasma cutting operations shall be shielded by noncombustible or flameproof screens which shall protect employees and other persons in the vicinity from the direct rays of the process.

The contractor shall provide an employee to serve as Fire Watch during hot work operations. The Fire Watch shall be equipped and trained by the Contractor, with an appropriate fire extinguisher per local NAMC hot work requirements. The Fire Watch shall be maintained for 30 minutes after the welding or cutting has been completed, unless site conditions warrant further time. While serving as Fire Watch, the employee shall maintain visual contact with the hot work activity and shall not perform any other duties. The fire watch shall monitor areas adjacent to partitions, walls, ceilings, or roofs where materials may be ignited.

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The Fire Watch shall know the following information;

• Locations of the nearest manual fire alarm box and/or phone. • Local NAMC Emergency Number. • How to use a portable fire extinguisher. • The Fire Watch may cover more than one hot work job if he/she is near the work zones and

approved per local hot work permit procedures.

The Fire Watch shall be easily identifiable by wearing a red bonnet over their hard hat during Fire Watch activities. At the end of the Fire Watch activity, the bonnet must be removed. A red band is also acceptable. See Visualization of Construction Contractors Work Rule.

10.4 Storage and Transport/ Compressed Gas Cylinders

Temporary storage of gas cylinders shall be allowed on approved carts with gauges removed and protective caps installed. Long term storage of compressed gas cylinders, such as propane, oxygen, etc., shall be stored away from work or working areas, outside at least 50 feet from buildings and in appropriate lockable storage “cages” in accordance with all federal, state and local laws.

All racks or “cages” must be protected from vehicular traffic. All storage "cages" shall be identified with the Contractor’s name and contact number and have gas type and associated hazards listed. Oxygen cylinders in storage must be separated from fuel-gas cylinders or combustible materials by a minimum distance of 20 feet or by a noncombustible barrier at least 5 feet high with a fire resistive rating of at least one-half hour. Cylinders must never be stored next to a heat source of any type. Verify with local NAMC or Toyota Safety for the proper “storage area.”

Compressed gas cylinders and storage containers shall be moved on an adequate crib or cart. For short distances, they may be moved by tilting and rolling on their bottom edges. When transported by vehicles, cylinders shall be secured in a vertical position with valve caps in place. When cylinders are hoisted, they shall be secured on an adequate hoisting crib. Cylinders shall never be taken inside tanks, vessels or confined spaces. Gas cylinder wrenches shall be kept available for emergency purposes. Regulators must be removed and the protective caps placed back on a cylinder when not in use. Caps must be on cylinders when being stored and during transport.

10.5 Restricted Hot Work:

Certain areas of the NAMCs have been designated as “RESTRICTED or HIGH HAZARD HOT WORK AREAS” due to extremely high fire and/or explosion risks. Local NAMC verification of document requirements for any Hot Work occurring in a Restricted or High Hazard Hot Work Area shall be completed prior to the pre-job review. All applicable risks shall be identified on the JSA. The JSA shall then be sent the Shop Manager, Project Leader, Toyota Safety Representative, and Fire Prevention member at the site for review and approval.

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Section K

11.0 Electrical

11.1 Requirement

All electrical equipment/systems, which have been connected to an electrical source of power, shall be considered energized until de-energized, locked out, and verified as zero energy using appropriate procedures. All contractors who are required to work near or on exposed energized conductors or circuit parts shall use the guidelines identified in NFPA 70E, CSA Z462, NOM 029-STPS or TMNAS SEI 2001-001 as applicable, to determine appropriate PPE requirements and establishment of Shock and Arc Flash Boundaries. All workers subject to being exposed to energized electrical conductors or circuit parts must have received adequate training on electrical safe work practices. In addition, all workers trained in electrical safety/electrical safe work practices must have proof of proper training. If work is required on an energized conductor or circuit, an Electrical Energized Work Permit (EEWP) shall be utilized as prescribed in the most current version of NFPA 70E, CSA Z462, NOM 029-STPS or the Toyota Electrical Safety Standard (50-1000V) TMNAS SEI 2001-001.

11.2 Cord Sets (i.e., Extension Cords)

Extension cord sets used shall be of the three-wire type and shall be designed for hard or extra-hard usage per National Electric Code (NEC) Table 400.4, Canadian Electrical Code (CEC) Table 11 or the Mexican Electrical Code (MEX) Table (table) 400.4. Cord sets of “flat” construction are strictly prohibited. Cord sets having ground prongs which are damaged or removed shall not be used at any time. Cord sets that have damage to the outer insulation or strain relief shall not be used at any time. Cord sets shall be visually inspected for damage prior to each shift that they are used and removed from service if defective. Cord sets in use shall be marked/tagged with electrical tape per the Monthly Inspection Tape Color Chart located in the Appendix of this document.

Extension cords shall not be connected end-to-end (daisy chained) unless specified by the cord manufacturer with the manufacturers’ tag fastened on the cord.

Cord sets shall only be repaired by qualified individuals using “Listed” components (e.g., Underwriters Laboratory (UL). Cord sets and power cords on portable electrical tools may be repaired only by qualified individuals using "Listed" components intended for the purpose and to an equivalent level of performance. Temporary lighting shall be protected from accidental contact or breakage and shall not be suspended by cords, unless cord and lights are designed for this means of suspension.

11.3 GFCI

Contractors shall use ground fault circuit interrupters (GFCI) on all 125-volt single phase, 15 and 20 ampere receptacles, cord sets, devices, and portable electric tools used on the site. GFCI protection shall be provided at the supply end (plug) of the cord set or power cord for a portable electric tool. Portable GFCI’s shall be tested prior to each use and permanently installed GFCIs shall be tested monthly to ensure proper operation. A written log of all GFCI tests shall be maintained by the contractor and made available to Toyota Safety or their designee upon request.

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All 125-volt, single-phase, 15-and 20-ampere receptacle outlets that are a part of a 15-kW or smaller portable generator shall have ground-fault circuit-interrupter protection for personnel integral to the generator or receptacle. If the generator was manufactured or remanufactured prior to January 1, 2015, listed GFCI adapters or cord sets incorporating GFCI protection at the supply end shall be permitted when plugged directly into the generator.

11.4 Cable/Wire Stripping Safety

Reference Cutting Tool Standard Chart in Appendix for cable/wire stripping safety guidelines.

Section L

12.0 Scaffolding

12.1 Requirement

All scaffolding equipment and installations shall comply with applicable laws and regulations. Contractors shall train all workers using, dismantling, or erecting scaffold in accordance with applicable laws and manufacturers guidelines. A training record for this activity shall be available for review or submitted to Toyota Safety, as requested.

All elevated work performed in crane bays shall require lockout of the overhead cranes that could come into contact with any elevated work platform such as scissor lifts, aerial lifts, scaffolds, ladders, etc.

12.2 Erection/Dismantling/Access

A Competent Person Declaration Form (CSF D-01) shall be completed by the contractor for the worker(s) who shall be supervising the assembling and disassembling of scaffolding.

The use of personal fall protection equipment shall be required during scaffolding erection and dismantling. It must be attached to an approved anchorage point.

Contractors shall not permit their workers to climb on (unless a ladder is part of the hand rail system) or work from, any scaffold handrail, mid-rail, or brace member. Slippery conditions on scaffolds shall be eliminated as soon as possible after they occur and prior to work.

12.3 Scaffold Tags

Scaffolding shall have a Scaffold Status Tag attached to it at all times. A competent person shall complete and apply this tag. The tags shall be supplied by the Contractor. (Sample in Appendix). The Competent Person shall inspect the scaffold, all components and surroundings prior to first use, prior to each shift, and the tag must be initialed or signed by Competent Person.

12.4 Falling Object Protection

The area below a scaffold shall be cordoned off and have appropriate warning signs while work is performed from the scaffold. Where workers are required to work or pass under the scaffold, scaffolds shall be provided with falling object protection.

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12.5 Rolling Scaffolds

Contractors shall not permit their workers to ride a rolling scaffold at any time. All tools and material on the deck shall be removed or secured before moving. The wheels shall be locked prior to using rolling scaffolding.

12.6 Scissor Lifts

Only certified operators, trained in the manufacturer’s recommended methods, shall operate an elevated work platform or scissor-type lift. Documentation of such training shall be available for review by Toyota Safety upon request. Personal fall restraint shall be worn while in a scissor lift. Where scissor-type lifts are equipped with a designated or pre-engineered tie-off point, that point shall be used as the fall restraint tie-off point. If no pre-engineered point is provided, the Contractor shall be responsible for determining the location of the manufacturer’s approved tie-off point(s). Hand rails on scissor lifts shall be of sound structural integrity with no visible signs of damage. Workers are not allowed to stand on the work platform toe-boards, mid-rail or top-rail. Workers shall not use the railings for lifting or placement of work. Engineered stands may be used for lifting and placement of work material if allowed by manufacturer or a PE stamp is obtained. See Spotter Work Rule in Appendix in regards to when a walking spotter shall be used.

Section M

13.0 Fall Protection

13.1 Requirement

The contractor shall develop a detailed Fall Protection Plan to cover all work conducted where the workers’ feet are at or higher than 6 feet (2 meters) (10 feet or 3.0 meters in Canada) above a lower level or where there is a potential to fall into equipment or other hazard (e.g., vertical rebar, etc.).

In Canada, guardrails shall be the first line of defense and must be constructed to meet the requirements set out in the OHSA Regulations for Construction Projects 213/91.

13.2 Fall Protection Plan

The Fall Protection Plan shall address the prevention of falls through training, guardrails, and travel restraint. The fall protection plan shall identify the type of equipment that shall be used including anchor points, lifelines, connectors, shock absorbing and retractable lanyards, and harnesses. It shall include procedures to train personnel, inspect equipment, and a plan to rescue a fallen worker. The plan must list the competent person who performed the training. The plan shall be submitted to Toyota Safety at least four (4) working days in advance of work beginning.

13.3 Fall Protection Equipment

Full body harnesses, shock absorbing lanyards, locking snap hooks and proper anchorage points are the minimum requirements for a personal fall arrest system. Body belts are not acceptable. All components shall be inspected prior to and after each use. A monthly documented inspection procedure shall be put in place and verified by a competent person. Any component of a fall protection system that is subjected to in-service loading shall be immediately removed from service and removed from the jobsite.

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For work requiring free climbing (e.g., climbing on top of machines), leaving the basket or scaffold, a double lanyard system shall be used to maintain 100% tie-off. This work shall be identified in a JSA.

13.4 Walking Working Surfaces

Adequately secured and identified covers and/or guardrails shall be provided to protect personnel from the hazards of open pits, tanks, vats, ditches, or any other such hazards. Open-sided floors or platforms 4 feet (1.2 meters) or more above adjacent floor or ground level shall be guarded with a standard railing and toe board wherever persons can pass underneath, where there is moving machinery, or where falling materials could create a hazard. All floor surfaces should be kept free from protruding objects (nails, splinters, or other projections) and loose boards, holes, etc. Contractors shall determine the floor load ratings or load capacities of all temporary and permanent structures prior to commencing work on or loading materials onto the floors or structures. Sufficient safe clearances should be allowed between machinery and adjacent aisles or passageways. Snow, ice, and other hazardous walking surface contaminants shall be removed or treated as soon as possible.

13.5 Leading Edges

Each worker who is constructing a leading edge which is 6 feet (2 meters) or more above lower levels shall be protected from falling by guardrail systems, safety net systems, or personal fall arrest systems. Exception: When the Contractor can demonstrate that it is infeasible or creates a greater hazard to use these systems, the Contractor shall develop and implement a fall protection plan which meets the requirements.

13.6 Warning Lines

For roof work, warning lines shall be erected around all sides of a roof work area or unprotected edge if personal fall restraint/arrest systems are not in use. Warning lines shall not be located closer than six (6) feet (2 meters) from a roof edge. PFAS or a fall restraint system shall be provided and be used by any workers who are required to work on the roof edge side of a warning line. For workers engaged in work other than roofing activity, a warning line may be used if it is 15 feet or more from the nearest unprotected leading edge or nearest hole. No work or work-related activity is to take place between the warning line and the hole or unprotected edge.

In Canada, a warning line must not be installed closer than 3 meters from a roof edge or 2 meters from a platform edge where a worker is exposed to a fall.

The Contractor must effectively implement a work rule prohibiting workers from going past the warning line. If work must take place past the warning line, then PFAS or a fall restraint system shall be provided and used by any workers on the roof/unprotected leading edge side of a warning line. The warning line shall consist of rope, wire, or chain and supporting stanchions. DANGER TAPE is not sufficient material to use for installation of a warning line.

13.7 Horizontal Lifelines

Horizontal lifelines shall be designed by a licensed professional engineer or be pre-engineered and have the accompanying manufacturer’s specifications. Lifelines shall be secured above the point of operation to an anchorage point or structural members capable of supporting a minimum static load of 5,000 lbs.

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13.8 Floor Openings

No floor hole covers, grating, or access hatches shall be opened or removed without first contacting Toyota Safety or its designee and completing a Floor Opening Checklist (CSF D-40). Prior to removal and start of work, Toyota Safety (or designee) shall review the checked procedures and protective measures on the permit. Only then shall the contractor be allowed to remove the covering. After completion of work or the end of shift, the floor covering shall be replaced and clearly marked and easily identifiable. No floor opening shall remain open beyond shift end.

13.9 Covers

During construction, if an opening is made in a walking/working surface, then it shall be covered. All covers located in roadways and vehicular aisles shall be capable of supporting, without failure, at least twice the maximum axle load of the largest vehicle expected to cross over the cover. All other covers shall be capable of supporting, without failure, at least twice the weight of employees, equipment, and materials that may be imposed on the cover at any one time. All covers shall be secured when installed. All covers shall be marked with the word “HOLE” or “COVER” to provide warning of the hazard.

OSHA defines a hole as “a gap or void 2 or more inches in its least dimension in a floor, roof or other walking/working surface.” Covers are required to protect employees from tripping in, stepping into or through holes, including skylights.

13.10 Roof Work/Access

It is the responsibility of all contractors or other party(s) requiring roof access to prepare a fall protection plan that includes the precautions and emergency/rescue plan for work on the roof (e.g. skylight protection/roof openings). The contractor shall identify why, when, where, and how its work is to be performed. Procedures should also address such issues as work during inclement weather (wind, ice, snow, etc.). When required by the local NAMC, the contractor shall obtain a Roof Access Permit or similar before allowing workers on the roof. Some NAMCs require Roof Access Training. See Appendix – (Recommended Wind Speeds for Roofing Operations)

13.11 Controlled Access Zone (CAZ)

Before any non-conventional fall protection systems are used as part of the work plan, a Controlled Access Zone (CAZ) shall be clearly defined by a competent person as an area where a recognized hazard exists. The demarcation of the CAZ shall be communicated by the competent person in a recognized manner, either through signs, wires, tapes, or ropes. The contractor shall take the following steps to ensure that the CAZ is clearly marked or controlled by a competent person:

• All access to the CAZ shall be restricted to authorized entrants. • All workers who are permitted in the CAZ shall be listed in the appropriate sections of the

Fall Protection Plan, prior to implementation. • The Competent Person shall ensure all protective elements of the CAZ are implemented

prior to the beginning of work.

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13.12 Working over Water

Contractors working over or near water, liquids, or other materials where the danger of drowning exists shall require the workers to wear life jackets or buoyant work vests that meet the requirements of the United States Coast Guard Type III Personal Flotation Device. Prior to each use, the buoyant work vest/life preserver shall be inspected for defects. Ring buoys shall be available with at least 90ft of line for emergency rescue. Distance between available ring buoys shall not exceed 200 ft.

13.13 General Equipment Use

Lifelines, safety harnesses, and lanyards shall be used only for worker safeguarding. (For example, fall protection equipment shall not be used for rigging purposes.)

Section N

14.0 Helicopter lifts

14.1 Requirement

When the need for a helicopter service has been established, a pre-lift meeting shall be held a minimum of one (1) month prior to the actual lift date.

The Pre-Lift meeting shall confirm the following:

• Establishment of a JSA, plan, and responsible parties. • Approvals required by applicable law or Governing Authorities. • The date(s) of the lift(s), with an alternate date in case of bad weather. • The assigned lay-down yard area. • Sequencing and numbering of all lifts with specified load rating clearly identified. • The assigned/approved flight path to be used. • Physical barricading of the assigned flight path to assure no admittance into the area by

unauthorized persons. • Radio-equipped observers shall be assigned to assure no one enters the areas of the lift,

set point or flight path at all levels. • Who the assigned signal persons will be and how they will be identified. • Notification by the Contractor of the closest medical facility, fire department and emergency

response team that a helicopter lift will be taking place on a given day and given time.

14.2 Notification

Notification shall be given to Toyota and Contractor(s) that a helicopter lift shall be taking place on a given date and time. A written plan shall be submitted and a follow-up meeting held with Toyota Safety or their designee two (2) weeks prior to the lift taking place with appropriate confirmations and notices by Governing Authorities.

14.3 Governing Authorities, Laws

Helicopter cranes shall be expected to comply with applicable law and requirements of any Governing Authorities, including requirements of the F.A.A. while operating in the US, or the Canadian Aviation Regulation Advisory Council (CARAC), in Canada.

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14.4 Day of Pre-Lift Meeting

Within 1 hour prior to the start of the lifts, a briefing shall be held by the General Contractor to set forth the plan of operation for the pilot and ground personnel both at the lifting and setting points.

• Mono-goggles and hard hats equipped with chinstraps shall be provided for all workers rigging and receiving the load and anyone subject to being struck by the rotor downwash.

• Any remaining loose materials within 200 feet of the staging and departure areas and flight path shall be secured or removed.

• Warning barricades and signage for the assigned flight path plus 200 feet on each side of the flight path shall be placed.

• All controlled areas shall be inspected to ensure they are clear of unauthorized persons and observers with radios shall be posted to assure no one enters the area of the lift, set point or flight path at all levels.

• The medical facility shall be notified of the start time and finish time of the operations. • Before the lifts begin, the helicopter crane maintenance records shall be provided to Toyota

Safety. • For wind restrictions, refer to Sec CC.

14.5 Operator Responsibility

Proof of valid helicopter operator qualifications shall be provided to Toyota Safety before the lifts begin. The helicopter operator shall be responsible for size, weight, and manner in which loads are connected to the helicopter. If, for any reason, the operator believes the lift cannot be made safely, the lift shall not be made.

14.6 Static Charge

Static charge on the suspended load shall be dissipated with a grounding device before ground personnel touch the suspended load, or protective rubber gloves shall be worn by all ground personnel touching the suspended load.

Section O

15.0 Motor Vehicles/Mechanized Equipment

15.1 Speed Limits

All posted Speed limits on Toyota property(s), shall be followed. The on-site construction zone speed limit (near active construction) is 7mph, inside buildings speed limit is 4mph. Toyota production equipment has the right of way.

15.2 Equipment

All vehicles and mechanized equipment shall prominently display the Contractor’s name and on-site contact number. For rental equipment temporary signs may be used. All equipment not designed for “over the road” use shall be equipped with an operable horn, headlights (if equipped), back-up alarm, and a fire extinguisher rated at 5ABC minimum. Some NAMCs may have Site Specific Guidelines regarding equipment and vehicles on site. Check with the Host NAMC.

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15.3 Operation

Vehicle/equipment operators shall not talk, text, or use a “hands free” device on cell phones while operating a vehicle or mechanized equipment. Vehicles shall operate with lights on at all times, if equipped, unless otherwise reviewed by Toyota Safety. Personnel may not ride in the bed of a pickup truck. All mechanized equipment shall maintain a three (3) foot (1 meter) clearance from pits, trenches or other floor openings. If required to perform work within three (3) feet (1 meter) of the opening, the equipment shall be positioned parallel to the opening and have its wheels chocked. The contractor shall ensure that the vehicle and equipment exhaust is adequately controlled to maintain safe concentrations of carbon monoxide and other exhaust components inside any building.

All vehicle/equipment operators must be fit for duty and for operating mobile equipment daily.

15.4 Inspections

All rental equipment shall be inspected and documented prior to delivery to the project site. Any repairs shall be completed before being delivered. All equipment shall be inspected prior to use at the beginning of each shift and a record of mechanical fitness shall be documented. This record shall be available for review by Toyota Safety when requested. If the equipment is propane fueled, the valve of the tank shall be closed during overnight storage.

15.5 Forklifts

The Contractor shall ensure that each forklift operator is competent to operate a forklift safely, as demonstrated by the successful completion of training, and hold a valid and current operating certification (less than 3 years old) in his/her possession. This operating certification shall be provided to any Toyota project member or Safety member upon request. Lift trucks shall have the rated capacity clearly posted on the equipment to be clearly visible to the operator. At no time, shall any person be allowed to ride on forklifts. All attachments shall be manufacturer approved and certified for capacities. Trucks equipped with attachments shall be operated as partially loaded trucks when not handling a load. Operators shall follow all local NAMC, and/or federal/state policies when operating outside of a designated construction area. Minimum 2 points of rigging contact from the fork lift truck to the machine/crate/equipment/load is required. Approved rigging must be of sufficient size and strength to secure the load. Only loads within the rated capacity of the truck shall be handled. Any forklift found in need of repair, defective, or in any way unsafe, shall be taken out of service until it has been restored to a safe operating condition. See Spotter Work Rule Decision Matrix for rules regarding spotters and forklifts.

15.6 Aerial Lifts

All Aerial Lifts shall also follow the standards in “Section O” in this document pertaining to Equipment, Operation and Inspections in addition to the following:

• Use of Fall Restraint system shall be required in Aerial Lifts unless otherwise specified in equipment manual.

• A fall restraint device shall be worn properly at all times while operating and/or working in any aerial lift.

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• Where Aerial Lifts are equipped with a designated or pre-engineered tie-off point, that point shall be used as the fall restraint connection point. If no pre-engineered point is provided, the contractor shall be responsible for determining the location of the manufacturer’s approved attachment point(s).

15.7 Aerial Lift Operation

Only authorized operators, trained in the manufacturer’s recommended methods, shall operate an aerial lift. Aerial lifts controls shall be tested each day prior to use to determine that such controls are in safe working condition. Employees shall always stand firmly on the floor of the basket. Employees shall not sit or climb on the edge of the basket. Employees shall not use planks, ladders, or other devices for a work position. Boom and basket load limits specified by the manufacturer shall not be exceeded. Aerial lifts shall not be modified for uses other than those intended by the manufacturer unless the modification has been certified in writing. This certification must be by the manufacturer or by any other equivalent entity, such as a nationally recognized testing laboratory. The modification must be in conformity with all applicable provisions of ANSI A92.2-1969 and be at least as safe as the equipment was before modification.

Red danger signage tape shall be used to identify the hazard area below the elevated work platform and a spotter shall be used during overhead work operations. If red danger signage tape is not practical, contact Toyota Safety to discuss other options such as cones and signs.

See Spotter Work Rule Decision Matrix for rules regarding spotters and aerial lifts.

15.8 Duties of a Spotter

Spotters shall be used whenever mobile equipment is being moved on Toyota property. All spotters and operators shall receive spotter training from their respective employers. Examples include forklifts, cranes, aerial lifts, scissor lifts, dump trucks, etc. Tuggers are exempt from the spotter requirement. The Dedicated Spotter Work Rule supersedes the text of this manual. If there is any question regarding the duties of a spotter, refer to the work rule. The duties of a spotter are as follows:

• Watch out for other people, property and him/herself. • Communicate with Operators, making sure that the Operator understands the hand signals

that will be used during the activity. • Pay attention to the travel path and obstacles therein. • Allow for sufficient stopping distance and clearance. • Use the same hand signals for the same moves. • Concentrate on the task at hand. • Maintain eye contact with the Operator. • Be sure that he/she is clearly seen by the Operator. • If spotter does not have full view of entire work zone, then additional spotters are required.

Refer to Form CSF D-30 Spotter Work Rule Decision Matrix.

15.9 Safe Work Practices for Fueling Equipment

When fueling equipment, the following precautions must be taken:

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Spill kit on fuel truck. Spill kit on mobile equipment. No over-filling of tanks allowed. Maintain three points of contact when climbing on and off equipment. NO SMOKING during fueling process. NO HOT WORK in the fueling zones. DO NOT leave fuel pump unattended. Keep metal fill nozzle in contact with lip of tank so static does not build up. Be sure static chain is attached. Wear face shield and safety glasses when fueling equipment.

Section P

16.0 Excavation/Trenching - See Appendix for Sloping, Benching Requirements

16.1 Requirement

As-built drawings shall be reviewed and the work areas shall be surveyed by the contractor prior to work beginning to determine the locations of underground lines (pipe, electrical, or otherwise). Ground Penetrating Radar shall be used to inspect all excavation work zones. Hand digging only does not require Ground Penetrating Radar. If a known utility exists, then hand digging shall be performed within a three-foot radius of the buried utility. Should a buried obstruction be encountered, all excavation shall stop until the Toyota Project Leader or representative investigates and clears the situation.

An Excavation Permit and Pre-Excavation Form for GPR Scanning shall be required prior to starting the excavation work. (CSF D-02, CSF D-02A). Soil classification shall be determined by a competent person.

16.2 Protection

While the excavation is open, underground installations shall be protected, supported, or removed as necessary to safeguard workers. All excavations over 5 feet deep (4 feet deep in Canada, per OHSA Reg. 213/91) shall be sloped, benched, or shored, depending on soil conditions, in accordance with applicable standards. No worker shall be permitted under loads handled by lifting or digging equipment. Workers shall be required to stand far enough away from any vehicle being loaded or unloaded to avoid being struck by any spillage or falling materials. Employees shall be protected from excavated or other materials or equipment that could pose a hazard by falling or rolling into excavations: a) by placing and keeping such materials or equipment at least 3 feet (1 meter) from the edge of excavations, or b) using retaining devices that are sufficient to prevent materials or equipment from falling or rolling into excavations, or c) by a combination of both if necessary. Under no conditions shall personnel enter an excavation while equipment is operating near the edge. Equipment shall remain away from occupied trenches. Workers shall not work in excavations in which there is accumulated/accumulating water, unless adequate precautions have been taken. Protection for excavations greater than 20 feet (6.5 meters) deep shall be designed by a registered professional engineer.

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16.3 Inspections

Daily inspections of excavations, their adjacent areas, and protective systems shall be made by a competent person for evidence of hazardous conditions, prior to the start of work and as needed throughout the shift. Inspections shall also be made after every rain event or other event that has the potential to increase the hazards of the excavation.

16.4 Access/Egress

A means of egress from trench excavations shall be provided by the contractor. A stairway, ladder, ramp or other safe means of egress shall be in trench excavations that are 4 feet (1.2 meters) or more in depth to require no more than 25 feet (7.6 meters) of lateral travel for employees.

Section Q

17.0 Concrete and Masonry

17.1 Personal Protection/Sanitation Requirements

The contractor shall provide adequate means of washing/flushing of exposed areas when workers contact wet concrete. Workers shall wear the proper PPE for protection of concrete materials.

No contractor employee shall be permitted to apply a cement, sand, water mixture through a pneumatic hose unless the employee is wearing a hard hat and face-shield.

17.2 Concrete Buckets / Working Under Loads

No contractor employees shall be permitted to work under concrete buckets while buckets are being elevated or lowered into position. Elevated concrete buckets shall be routed so that no employees are exposed to the hazards associated with falling concrete buckets. Concrete buckets equipped with hydraulic or pneumatic gates shall have positive safety latches or similar safety devices. Concrete buckets equipped with hydraulic or pneumatic gates shall be designed to prevent concrete from hanging up on top and the sides.

17.3 Other Equipment/Tools

Powered and rotating type concrete troweling machines that are manually guided shall be equipped with a control switch that will automatically shut off the power whenever the hands of the operator are removed from the equipment handles. Bull float handles shall be constructed of nonconductive material or insulated with a nonconductive sheath.

17.4 Masonry Construction

Workers shall be guarded from exposed reinforcing steel where scratching, lacerations or impalement is a hazard. A “limited access zone” shall be established whenever a masonry wall is being constructed.

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Requirements of the limited access zone are as follows:

It shall be established prior to the start of construction of the wall. It shall be equal to the height of the wall to be constructed plus four feet, and shall run the

entire length of the wall. It shall be established on the side of the wall which will be un-scaffolded. The limited access zone shall be restricted to entry by employees actively engaged in

constructing the wall. It shall remain in place until the wall is adequately supported to prevent overturning and to

prevent collapse.

All masonry walls over eight feet in height shall be adequately braced to prevent overturning and/or to prevent collapse. This bracing shall remain in place until permanent supporting elements of the structure are in place.

17.5 Concrete Formwork / Column Erection

The contractor must ensure form components and/ or hardware are kept clean, and, if appropriate, lubricated to ensure proper performance and to allow for inspection. The formwork must also be inspected regularly for damage or excessive wear. Formwork layout shall be prepared or approved by a person qualified to analyze the loading and stresses which are induced during the construction processes. Forming installation and pouring procedures must comply with safe practices and with the requirements of local governmental regulations, laws, codes, etc. Adequate temporary bracing must be in place while initially setting formwork. Braces used to withstand concrete pressure must be designed by a qualified formwork designer. Do not exceed rated load of the braces. Before removing braces, assure the concrete has attained sufficient strength to safely support the imposed load at support locations. Inspect completed formwork prior to placing concrete to assure proper placement and secure connections of ties and associated hardware. The contractor must verify prior to and during concrete placing that the method of placement and the rate of pour is consistent with formwork design. Never overload formwork.

Prior to removing formwork, be certain that concrete has sufficiently set to carry its own weight and any imposed loads prior to stripping. The contractor must ensure that no construction loads are placed on a concrete structure unless it is can support the loads.

17.6 Respirable Crystalline Silica

Contractors must limit worker exposure to respirable crystalline silica and take steps to protect workers. Respirable crystalline silica can cause lung cancer and other respiratory diseases. Exposure to respirable crystalline silica can occur during common construction tasks. Examples include, but are not limited to:

Using masonry saws, grinders, drills, jackhammers. Using handheld powered chipping tools. Using operating vehicle-mounted drilling rigs. Using heavy equipment for demolition.

Contractors can refer to Table 1 of the OSHA Standard 29 CFR 1926.1153 for control methods when working with materials that contain crystalline silica. In some operations, respirators may also be needed.

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Section R

18.0 Steel Erection

Requirements of this section apply to steel structural systems. Steel structural systems shall be defined as a steel structure consisting of beams and floor supported columns or posts over 8 feet tall designed to resist vertical and lateral loads. Structural systems include, but are not limited to new buildings, building additions, demolition, mezzanines and platforms, conveyor support steel, etc. Although not floor supported, roof truss hung conveyor support systems shall conform to the requirements of this section with the exception of the erection stability plan.

Utilize toyotasupplier.com for latest checklists and forms.

18.1 Project Management Responsibility

The following table SS-1 should be utilized to determine project management responsibility of structural steel projects as defined in section 18.0. Regardless of project management responsibility, all requirements of section R herein are applicable.

Table SS-1

If a meeting is required per Table SS-1 to determine management responsibility, the meeting should occur at the project planning/Ringi phase. Project details will be evaluated to determine management responsibility with agreement from TMNA Executive Management.

18.2 Requirement

The CSF D-29 forms must be completed for all steel erection activities before the start of the work.

“Double” or “Shared” connections in structural steel systems shall not be permitted without approval of engineer of record and Toyota. Use single plate/angle shear connection where possible. If a “double” or “shared” connection is required, the connection shall be detailed such that it can be erected in any sequential order (having extra bolts or having seats on both sides of column/beam web). Sequence dependent double connection safety measures are prohibited.

During all phases of steel erection, the contractor shall provide all safety devices, (e.g., guardrails, handrails, hole covers, etc.) required to keep the work area safe. These devices shall not be removed from the project until their use is no longer required. The contractor shall implement a written fall protection plan that requires their worker to use fall protection 100% of the time for any work over 6 feet (2 meters) in elevation during all steel erection. (CSF D-29)

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Connectors and other personnel involved in the erection of structural steel must not climb out of the basket of the aerial/scissor lift unless it is a last resort. If the need to climb out of the basket arises, then STOP-CALL-WAIT, and contact Toyota Safety.

18.3 SSEP: Site Specific Erection Plan Requirement (SSEP)

A site-specific erection plan shall be required for erection of all structural systems as defined above. See D-29 for SSEP requirements.

18.4 Erection Stability Plan Requirement

An erection stability plan shall be submitted for all structural systems as defined above.

For interior structural systems not subject to wind loads during erection, an erection plan shall be provided by a qualified person.

For structural systems subject to wind loading or in seismic zones with seismic design category D or greater, an erection plan and stability calculations shall be provided and stamped by a professional engineer.

No changes shall be made to the erection stability plan without written approval from the stability plan originator and reviewed by Toyota.

Erection stability plans shall include the following:

Overall plan labeling members, sequence numbers, and the initial starting bay. Analysis of loads to be resisted throughout the erection period. (Environmental, construction,

etc.) Submit stamped calculations for structural systems subject to wind loading. Description of the order of placement of structural elements, by sequence, to maintain structural

stability including placement of joists, beams, decking bundles, plating, mechanical/electrical loads (Utilities, equipment, etc.)

Identify members that require actions such as “hold on crane” until subsequent activities are completed.

Minimum bolts, welds, or special erection connection requirements. Requirements for bridging (erection, construction, permanent) Temporary bracing, shoring, guying requirements, and details (anchorage points, cables,

turnbuckles, etc.) Removal of temporary bracing, shoring, and guying. Step by step erection plan for building showing one sequence at a time. Each plan shall have a

description of the erection sequence for each sequence. The erection stability plan shall be in accordance with OSHA 1926 Subpart R and referenced on

erection stability plans. Reference ASCE 37 – Design Loads on Structures During Construction.

18.5 Protection from Falling Objects

The controlling contractor shall bar other construction processes below steel erection unless overhead protection for the employees below is provided. Routes for a suspended load shall be pre-planned to ensure that no contractor employee is required to work directly below a suspended load.

18.6 Multiple Lift Rigging Procedure (Also known as Christmas Treeing)

A multiple lift shall only be performed if the following criteria are met. A detailed plan for this procedure must be in JSA.

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A multiple lift rigging assembly must be used. A maximum of three members are hoisted per lift. Only beams and similar structural members are lifted. All employees engaged in the multiple lift have been trained. No crane is permitted to be used for a multiple lift where such use is contrary to the

manufacturer's specifications and limitations.

Components of the multiple lift rigging assembly shall be specifically designed and assembled with a maximum capacity for total assembly and for each individual attachment point. This capacity, certified by the manufacturer or a qualified rigger, shall be based on the manufacturer's specifications with a 5 to 1 safety factor for all components. The total load shall not exceed the rated capacity of the hoisting equipment specified in the hoisting equipment load charts or the rigging capacity specified in the rigging rating chart.

18.7 Steel Erection Kanban

Structural steel shall be erected in accordance with the design drawings/steel erection sequence plan and erection stability plan as defined above. The steel erection sequence plan must not be deviated from. All structural steel meeting the criteria of section 18.0 shall follow the steel erection Kanban process. See www.ToyotaSupplier.com for example of latest Steel Erection Kanban document.

18.8 Inclement Weather

No steel erection work shall be performed during bad weather (rain, snow, lightning, severe weather) where workers are expected to walk on or straddle steel. Work can continue if employer is using aerial lifts to reduce slip/fall hazards (If no lightning or high winds). Work shall cease if crane operator cannot maintain adequate visual contact with connectors fastening steel due to weather conditions.

Section T

19.0 Demolition

19.1 Building or Structure

Prior to permitting workers to start demolition operations, an engineering survey shall be made by a competent person (CSF D-42). The survey is used to determine the condition of the framing, floors, and walls, and possibility of unplanned collapse of any portion of the structure. Any adjacent structure where workers may be exposed shall also be equally checked. The contractor shall have evidence, in writing, that such a survey has been performed. The survey shall be presented to Toyota Safety or its designee at least 48 (working) hours in advance of the commencement of work.

Where workers are required to work within a structure to be demolished or repaired which has been damaged, the walls, floor and ceiling/roof shall be shored and/or braced.

A written plan detailing how exposure and the possible spread of contaminants shall be controlled is to be submitted and approved by Toyota Safety & Environmental department designated persons 2 days before demolition begins. All electric, gas, water, steam, sewer, compressed air, and other service lines shall be shut off, capped, or otherwise controlled outside the building or in the specified area(s) of demolition before demolition work is started. Review NAMC Site Specific Environmental Guidelines.

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During demolition, only authorized personnel are allowed in the area. Nothing shall be dropped to the floor unless prior authorization is received. All demolished items must be placed on floor in a controlled method to prevent injury of personnel and property damage. It is permissible to drop items into dumpsters.

19.2 Machines and/or Equipment

Follow the manufacturers’ or Toyota PE recommendations for isolating/shutting down any machines, process, or support equipment prior to demolition. It shall be verified that all energy sources are disconnected or terminated prior to removal.

19.3 Handover to NAMC

A plan must be in place to ensure that the demolition work zone is safe before handover to the NAMC. All energy sources must be demolished to the “fed from” source. No leftover wires, pipes, conduit, hangers, etc. shall be left in the work zone unless specific instructions from the Project Leader are given. All tools must be removed from the area. All anchor bolts must be hammered down, cut or otherwise removed. All open pits must be protected by guardrails. No items shall be left that could interfere with or impact production operations. A visual 5S truss inspection must be performed.

Section V

20.0 Energy Control Policy and Program

20.1 Lockout

Lockout is required where the unexpected energizing, startup, or release of stored energy could occur and cause injury, the contractor shall implement a Control of Hazardous Energy program. It shall consist of energy control procedures, employee training, and periodic inspections to ensure workers are trained before they perform any servicing or maintenance of any machinery, supply lines, or equipment.

For each job/task requiring energy control, a JSA (CSF D-16) shall be completed and submitted to Toyota Project Leader (or designee) preferably 2 weeks, or no later than 48 hours, prior to beginning the work.

The contractor shall identify all sources of energy, which may affect their work such as hydraulic, pneumatic, thermal, electrical, gravitational, residual, chemical, radioactive, etc, with host NAMC and Toyota Project Leader (or designee) prior to locking out.

Electric equipment and lines, pressurized lines (hydraulic, pneumatic), stored energy (electrical, mechanical), pressurized tanks/vats, etc., shall be considered energized/pressurized until determined de-energized/de-pressurized by tests or other appropriate methods or means.

After all designated switches and disconnections have been opened, rendered inoperable, drained, blocked and/or locked out, the appropriate inspection and/or test(s) shall be conducted to ensure that all equipment or energy sources are de-energized.

While locking out, workers shall apply their personal lockout lock and identification. This identification can be in the form of:

a) A durable tag securely affixed to the lock, and have a visible means of identification (i.e. the Company name, employee’s name, and telephone contact information), or;

b) Label affixed to the lock with the required information.

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Prior to locking out any existing equipment, the contractor shall contact a Toyota Project Management Representative to coordinate lockout activities with existing Toyota NAMC facility.

Contractors shall submit copies of their general Lockout Program to Toyota Safety or their designee, when requested. The Lockout Program shall meet or exceed Toyota’s Lockout Policy and all applicable regulations/standards/legal requirements.

20.2 Lockout Training

The employer shall provide training to ensure that the purpose and function of the energy control program is understood by employees and that the knowledge and skills required for the safe application, usage, and removal of the energy controls are obtained by employees at a level of proficiency. Only trained, qualified, and authorized personnel shall work on equipment requiring lockout. Toyota reserves the right to review training records for any Contractor’s employee.

20.3 Group Lockout

Group lockout shall be applied when the following conditions exist (not all inclusive):

Multiple crews Multiple crafts Multiple Contractors NAMC members working with contractors Work involving multiple shifts

Multi-lock hasps or group-lock boxes shall be used to ensure others can apply additional locks. When there are two (2) or more isolation points that shall be locked out and when more than one (1) worker is required to work on the equipment, a group lockout method shall be used.

When a group lock box is used, there shall be a designated Job Leader for each shift that shall be performing work. The group lock box shall be placed at the site visual control board for major projects or an area conducive to visual management of the group lockout (line of sight of the lockout area). The Job Leader shall use a “Job Control Lock” and be responsible for maintaining an accurate log of locks installed and removed. The Job Control Lock shall remain in place until the lockout is complete. Each Job Leader may have a key to the Job Control lock OR there may be one key that is under his/her exclusive control in a designated location. It shall be made clear that only a Job Control Leader may remove the Job Control Lock unless in case of emergency or lock abandonment.

For group lockout, a lockout sign in sheet or roster is required to be used. Refer to the Host NAMC for the appropriate form to be used for group lockout.

Lock Colors for Group Lockout:

Lock for Machine/Equipment/Energy Isolating Devices- Yellow Individual Worker Safety Locks- Red Shift to Shift Handover Project Control Locks- Green

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20.4 Lock Abandonment

Where a lock is abandoned, immediately notify the Toyota Project Leader or designee and Toyota Safety or designee. Where it has been determined that the removal of the lock is essential, the appropriate TMNA and NAMC Management members shall ensure with 100% certainty the owner of the lock is not available, and the owner is aware of the lock being removed prior to its removal. The CSF D-14 form or NAMC form shall be completed and signed prior to lock removal. Check with local NAMC Security to determine if their assistance in the removal of the lock is required.

Section X

21.0 Stairways and Ladders

21.1 Requirement

A stairway or ladder shall be provided at all personnel points of access where there is a break in elevation of 19 inches or more, unless a ramp, runway, or sloped embankment is provided.

Stairways having four or more risers or rising more than 30 inches, whichever is less, shall be equipped with at least one handrail and one stair rail system along each unprotected side or edge. Handrails and top rails of stair rail systems shall be capable of withstanding, without failure, a force of at least 200 pounds applied within 2 inches of the top edge, in any downward or outward direction, at any point along the top edge.

Extension or step ladders constructed of fiberglass, wood, or other approved non-conductive materials with anti-slip footings are allowed on Toyota sites. Wooden ladders are not allowed on jobsites in Canada and Mexico. Ladders shall be visually inspected for structural integrity and damage before each use. Ladders in use (except for job made wooden ladders) shall be inspected daily and have an inspection sticker attached to the right siderail. See Appendix for Daily Ladder Inspection Sticker Template. Ladders that are faulty or defective shall be removed from the project/jobsite immediately.

21.2 Mobile Ladder Stands

Where practicable, mobile ladder stands are the preferred device for use instead of step ladders. Mobile ladder stands shall not be used for or near energized electrical work.

21.3 Ladder use

When portable ladders are used for access to an upper landing surface, the ladder side rails shall extend at least 3 feet (.9 m) above the upper landing surface to which the ladder is used to gain access; or, when such an extension is not possible because of the ladder's length, then the ladder shall be secured at its top to a rigid support that will not deflect, and a grasping device, such as a grab rail, shall be provided to assist employees in mounting and dismounting the ladder. In no case shall the extension be such that ladder deflection under a load would, by itself, cause the ladder to slip off its support.

Ladders shall not be loaded beyond the maximum intended load for which they were built, or beyond the manufacturers’ capacity. Ladders shall only be used for the purpose for which they were designed.

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The use of a personal fall arrest system shall be required when performing work on a ladder that is 6ft (2m) or greater above a secondary walking working surface (e.g. work being performed from a ladder on mezzanine where working height from ladder exceeds the height of guardrail).

Personal fall arrest systems are REQUIRED when ascending/descending a ladder which has a continuous climbing distance of 10 feet or more, unless the ladder is a fixed ladder equipped with a cage. In Mexico, a personal fall arrest system is REQUIRED when ascending/descending a ladder which has a total climbing distance of 11.5 feet or more. Workers shall maintain three (3) point contact while ascending/descending the ladder and shall never carry an object that could cause the employee to lose balance and fall. Workers shall always face toward the ladder.

Ladders shall not be moved, shifted, or extended while occupied. The top or top step of a stepladder shall not be used as a step. If working from a portable ladder, PFAS must be worn above six feet or whenever 3 points of contact cannot be maintained. In Canada, PFAs must be worn above ten feet or whenever 3 points of contact cannot be maintained.

Ladders placed in any location where they can be displaced by workplace activities or traffic, such as in passageways, doorways, or driveways, shall be secured to prevent accidental displacement, or a barricade shall be used to keep the activities or traffic away from the ladder. The areas around the top and bottom of ladders shall be kept clear.

21.4 Job Made Wooden Ladders – Reference CFR 1926 Subpart X

Job made ladders are allowed on the construction project for short term use only (30 days or less). Wooden ladders are not allowed on jobsites in Canada or Mexico. When permanent ladders and stairs are installed, the job made wooden ladders shall be removed. Secure the ladder’s base so that it does not move. Smooth the wood surface of the ladder to reduce injuries to workers from punctures or lacerations and to prevent snagging of clothing.

Section Z

22.0 Toxic and Hazardous Substances

22.1 Requirement

Contractors shall obtain approval before bringing any chemical on any Toyota property. The contractor shall also maintain and provide SDS sheets (formerly known as MSDS) information on the chemicals they are using or handling at Toyota. Contractors shall be familiar with the information and train their workers regarding the Global Harmonization System if they will be working in areas where chemicals are used. This information includes descriptions, handling precautions, protective equipment, symptoms of exposure and first aid for each chemical.

22.2 Material Usage Request

Toyota Safety and the local NAMC Environmental Department shall review and approve all chemicals prior to their arrival on site.

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22.3 SDS Sheets

The SDS files shall be current, per applicable law, and readily available for inspection. The location of the SDS file shall be posted on the job control board or equivalent.

22.4 Storage/Labeling/Use

All hazardous materials shall be properly labeled as per the GHS and stored in accordance with applicable law. Contractors shall provide all necessary PPE, and train all workers in the use and limitations of the PPE, required for safe handling of chemicals used by their workers.

22.5 Emergency Response

Contact the local NAMC Security/Fire for procedures and requirements regarding Emergency Response to release of toxic or harmful chemicals at the project site.

22.6 Disposal

Contractors shall be responsible for proper disposal of hazardous waste in accordance with the Toyota Environmental Requirements for construction and applicable law. When the contractor has plans or has reason to believe that hazardous waste shall be generated, the contractor shall contact the local Toyota Environmental Department for assistance in dealing with the waste. After drumming, the hazardous material shall be delivered to the containment area as designated by the local NAMC Environmental department.

22.7 Exposure

Contractors shall monitor work zones for exposure to toxic and hazardous substances that their workers may be exposed to. Some examples include the following:

Asbestos Lead Chromium VI Beryllium Silica

It is the Contractor’s responsibility to monitor for these substances and to communicate and protect its workers if exposure is possible. Contractors shall provide all required training, control methods, personal protective equipment, changing rooms, and medical surveillance as required by OSHA 1926 Subpart Z.

Section AA

23.0 Confined Spaces

23.1 Requirement

All Confined spaces shall be considered “Permit Required,” unless otherwise identified as a Non-Permit Required Space. Testing and verification is the Contractor’s responsibility.

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(US)

Space is large enough and so configured that a worker can enter and perform assigned work. Space has limited or restricted means for entry or exit (example, tanks, vessels, storage bins,

hoppers, vaults, and pits) Space is not designed for continuous human occupancy. (Sample CSF D-19)

(CAN) Confined space means a fully or partially enclosed space:

Space that is not both designed and constructed for continuous human occupancy, and In which atmospheric hazards may occur because of its construction, location or contents or

because of work that is being performed inside.

Permit-Required Confined Space definition:

Contains or has a potential to contain a hazardous atmosphere. Contains a material that has the potential for engulfing an entrant. Has an internal configuration such that an entrant could be trapped or asphyxiated by

inwardly converging walls or by a floor which slopes downward and tapers to a smaller cross-section.

Contains any other recognized serious safety or health hazard.

(Mexico)

The Mexican Standard NOM-033-STPS-2015, defines a confined space as “The place without natural ventilation, or with poor natural ventilation, in which one or more persons can perform a certain task inside, with limited or restricted means for their access or exit, which is not designed to be occupied continuously.”

In Mexico, confined spaces should be classified into the following types:

NOTE: BOTH TYPES REQUIRE A PERMIT.

Confined Space Type I: One in which there is no risk due to deficiency or enrichment of oxygen, or explosive or flammable atmospheres, and in which the concentrations of dangerous chemical substances are lower than the action level.

Confined Space Type II: One that has the potential to cause work injuries and / or illnesses, and may even be immediately dangerous to life and health. These can present a dangerous atmosphere.

23.2 Confined Space Procedures

Prior to any confined space entry (permitted or non-permitted), the Contractor shall submit a copy of its written confined space entry procedures to Toyota Safety and contact appropriate Toyota member for confined space permit review. All contractor confined space programs shall meet or exceed the Toyota confined space program requirements. Refer to the Host NAMC for specific requirements regarding confined space procedures.

60

Contractors shall provide appropriate safety equipment (including communications), attendant, and where necessary, ventilation equipment, 12-volt lighting or the equivalent, and appropriate rescue equipment and rescue plan. This equipment shall be in place prior to entering the confined space.

The confined space shall be tested for hazardous atmospheres/atmospheric hazards. The sampling shall be conducted WITHOUT ENTERING THE CONFINED SPACE. The person responsible for sampling shall be knowledgeable of the gas meter and proper calibration requirements of the equipment.

Contractors shall document the testing results and have them available for Toyota Safety review. (Sample CSF D-19). If the space meets the criteria for a non-permit required confined space, the contractor may proceed with the entry. If the space fails the criteria for a Non-Permit Required Confined Space, an entry permit shall be completed prior to entering the space. In a Permit Required Confined Space, continuous atmospheric monitoring must be performed. Some NAMCs require additional confined space entry instruction. Please consult your Toyota Safety contact for possible requirements. The checklist/permit (Sample CSF D-19) shall be posted in the work area where confined space entry work is done. They are valid for one shift only and are not valid for more than 12 hours. Evaluation and Permitting is the responsibility of the Contractor.

23.3 Responsibilities

It is the responsibility of the Contractor/entry employer to understand the duties and responsibilities of the entrant, attendant, and entry supervisor.

Section CC

24.0 Lifting Requirements

24.1 General Requirement

All lifts performed with the use of chain falls, come-a-longs, hoists, cranes, and/or forklifts/versa lifts must follow Toyota lifting and rigging requirements as defined in this section.

24.1.1 Lifts of objects less than 220 pounds or palletized equipment / objects

• Sequential job steps documented in daily JSA • Qualified Rigger when rigging equipment used

24.1.2 Lifts of objects over 220 pounds

• Completed D26 submitted with JSA • Qualified Rigger when rigging equipment used

24.1.3 Lifts meeting definition of critical lift

• Completed D26 submitted with JSA • Certified, Qualified Rigger or PE Stamp with Qualified Rigger

24.1.4 Critical Lifts

A lift that meets any of the following criteria shall be considered a critical lift at Toyota:

61

• Load greater than 1 ton that is being upended or down-ended AND center of gravity is moving or unknown.

• Unbalanced load of 5 tons or greater AND does not have engineered lift points. • Lift exceeds 70% of the rated capacity of the crane. • Lift being made in poor soil or unknown ground condition. • Lift requires the use of more than 1 crane or the use of a crane and an additional hoisting device.

24.1.5 D26

The D26 shall be submitted with the JSA to the Toyota Project Leader and Toyota Safety for review 2 weeks prior to lift, no later than 48 hours prior to the scheduled lift. Any lift outside these guidelines require Toyota Project GM signoff.

It is permitted to perform a single D26 for lifts of same/similar equipment or objects when a single D26 can cover the hazards of each lift.

Examples of lifts that can be performed using single D26:

• Lifting same/similar robots utilizing the same lifting points, rigging methods, and lifting equipment and no unique hazard is present between lifts. (example of unique hazard: different end effectors that change center of gravity)

• Lifting same/similar structural steel members utilizing the same rigging methods and lifting equipment where no unique hazard is present between lifts. (example D26 Beams, D26 Columns, D26 Joist, D26 Decking)

The D26 shall accompany the JSA at the work location and shall be reviewed with all involved personnel performing the lift.

Any deviation from the lift plan must require STOP, CALL, WAIT, the D26 revised and resubmitted communicated to all personnel involved in the lift.

24.1.1.6 Fall Zone

No worker is permitted to be in the fall zone at any point during any lift. Area must be properly barricaded with danger tape

24.2 Riggers

A qualified rigger is defined as:

• possesses a recognized degree, certificate, or professional standing, or

• has extensive knowledge, training, and experience, and

• can successfully demonstrate the ability to solve problems related to rigging loads.

A certified rigger is defined as:

• A person who has passed stringent written and practical exams related to rigging from an accredited organization.

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• This requirement is not applicable in Mexico due to lack of certified rigger equivalency. In Mexico, Contractors shall ensure riggers are qualified.

24.3 Rigging Equipment

All rigging hardware and slings shall be properly rated, labeled or tagged and have the accompanying manufacturer’s specifications present at the workplace. All rigging hardware and slings shall be visually inspected prior to each use. A periodic inspection must be conducted dependent on the use of the rigging equipment. Rigging equipment shall be stored in locations that shall not allow any type damage or deterioration to occur.

24.4 Cranes and Derricks

Prior to any crane, derrick, hoist, elevator, or temporary conveyor being placed into service at the Toyota site, a copy of the current annual third-party inspection shall be provided to Toyota Safety. Records of required frequent and periodic inspections shall be readily available while equipment is on site. All mobile cranes shall be inspected before its first use and comply with the most current version of ANSI or the equivalent and with applicable law. The inspection report shall be provided to Toyota Safety prior to the equipment being allowed on site.

General Requirements Cranes and Derricks

• Prior to moving a crane into an area, the contractor must evaluate the underground conditions for crane stability and the possibility of damage to the underground facilities or injury to personnel.

• Access to areas where lifting operations are carried out shall be restricted by barriers and signs must be posted.

• The swing radius of the load must be known and unauthorized personnel shall be restricted from accessing the area.

• Where hand signals are used, they shall be those prescribed in the relevant standard. • A copy of the manufacturer’s manual for each make and model, log book, and load chart must

be in the cabin of the crane. The load chart must be accessible and legible. • Loads shall not be lifted over persons. • Lifting operations shall be carried during daylight hours only. • Under no circumstances shall cranes be moved with the boom extended or with a load

attached. • If a malfunction occurs, operations shall cease until the crane has been evaluated and repaired,

if necessary, by a licensed mechanic. • Operators shall follow the manufacturer’s instructions for entering and exiting the cab. • Operators shall not exit the cab of the crane if a load is suspended. • Lifts shall not be made in winds that exceed the manufacturer’s recommendations or in winds

greater than 20 mph. • Booms shall be lowered if lightning is present within 10 miles. • No one shall work, stand, or walk under a suspended crane load. • No one shall be on the crane when it is in use. • Outrigger pads shall be used during all lifts.

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24.5 Conditions

Contractors shall verify and document that equipment placement areas shall support the weight of the equipment and loads prior to any hoisting. The documentation shall be submitted to Toyota Safety. The contractor shall mark boundaries for the minimum approach distance (MAD) with items such as flags or range limit/range control warning devices. The operator shall not operate the crane beyond those boundaries. All overhead power lines and obstructions shall be located and marked prior to placement of the crane and incorporated in the minimum approach distance planning.

Contractors shall comply with the manufacturer’s specifications and limitations applicable to the operation of all cranes, especially as it relates to high wind speeds. All NAMC local rules shall apply as to weather and lightning conditions.

24.6 Operations

. The operator shall maintain a 20-foot (6.5 meters) clearance from any power line (up to 350 Kilovolt). A qualified rigger and a qualified signal person shall be used on all lifts. For all critical lifts, a certified rigger must be used.

Where swinging hazards to workers exist, tag lines or other suitable devices shall be used to control loads being handled by hoisting equipment. A safe working zone shall be established and barricades erected to prevent inadvertent entry by unauthorized personnel. Operators shall be required to utilize a spotter per the Spotter Work Rule Decision Matrix (CSF D 30) located in the Appendix of this document.

24.7 Qualifications

24.7.1 Hoist operator

Certified Crane Operator (CCO) certificate or other third party recognized crane certification organization is required to operate any crane. The record of training and qualification required by applicable law shall be submitted to Toyota Safety. If a contractor feels a certification meets or exceeds the CCO requirement, the contractor shall submit organization credentials to Toyota Safety for evaluation and disposition.

24.7.2 Signal person

The signals used (hand, voice, or audible) and means of transmitting the signals to the operator (direct, line of site, radio, etc.) shall be appropriate for the site conditions. The types and means of signaling shall be determined prior to hoisting by all involved. The signal person shall be qualified.

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Lift requires the use of more than one (1) crane or the use of a crane and an add'l hoisting device

Lift exceeds 70% of the rated capacity of the crane

Lift being made in poor soil or unknown ground condition.

NOTE: Previous excavation, noticeable standing or ponding water, underground pits, tanks, vaults

Critical LiftWhen clear instructions from manufacturer to safely lift the load are NOT provided, a RANK A lift is defined by one (1) of the following conditions being present:

Load greater than 1 Ton is being upended AND center of gravity is moving or unknown

Load greater than 1 Ton is being down-ended AND center of gravity is moving or unknown

Unbalanced load of 5 tons or greater AND does not have engineered l ift points

65

25.0 Safety Qualifications for Contractor Safety Representation

25.1 Supervisors/Project Managers

Contractors shall ensure that all supervisors are adequately trained. The minimum required training is the OSHA 30-hour Outreach Course for the Construction Industry or equivalent. Some projects may require additional training specific to the location or to the work being performed. All supervisors shall have the authority to make decisions and corrections regarding safety issues that may arise on the project.

25.2 Dedicated Construction Safety Coordinator/ Dedicated Subcontractor Safety Representative (CSMS 3.8)

A resume shall be submitted to Toyota Safety prior to work beginning on the project for the approval of the Dedicated Construction Safety Coordinator / Dedicated Subcontractor Safety Representatives.

Education & Certification

Required – National Construction Safety Officer (NCSO) Designation (Canada)

Required – OSHA 30 Construction Industry Outreach Program (U.S.)

Required – OSHA 510 Construction Industry Standards (U.S.)

Required – Knowledge of applicable consensus standards i.e. NFPA 70E/CSA Z462, if electrical work will fall under his/her scope, knowledge of OSHA Subpart R and ANSI/AISC 360 if steel erection of structural steel buildings will fall under his/her scope.

Preferred – A recognized, independent third-party safety certification. Examples: CSP/ASP, SMS, CHST, STSC, CSHO, CSHT, etc.

Preferred – OSHA 500 Construction Industry Train the Trainer (indicates the ability to communicate safety information to others) (U.S.)

Preferred – Degree in Occupational Safety, or related field.

Experience

Required – Minimum of 5 years direct experience with the specific type of hazards that can reasonably be expected in the contractor’s daily work.

Example - If the contractor will perform site prep, the contractor’s Safety Coordinator should be knowledgeable in trenching and shoring, earth moving equipment, dust control measures, etc. If performing crane work, the Safety Representative should have extensive knowledge of crane safety, rigging requirements, signaling requirements, etc.

Expected – Minimum 3 years’ experience conducting safety related activities including, not limited to:

Construction Safety Orientation Construction Safety Audits Implementing countermeasures for systemic problems that did not minimize risk or that

lead to illness/injuries Formally tracking and reporting illness/injury data to project leadership

66

Leading construction safety meetings with trade workers, project engineers/management, construction safety professionals, etc.

Preferred – Experience developing or improving a construction safety management system or process:

Writing a contractor safety manual, Site Specific Safety Plan, etc. Developing a process for JSA review and approval Developing a construction safety orientation program Developing a site audit program Implementing a line-side management review process for safety

Preferred – Experience leading successful interactions with any Federal/Provincial/State inspections, e.g. OSHA, Ministry of Labor, Fire Marshall, etc.

Dedicated Construction Safety Coordinator resumes and Dedicated Subcontractor Safety Representative resumes should be sent to the Project Leader and should be considered approved on a per project basis. Dedicated Construction Safety Coordinator badges and Dedicated Subcontractor Safety Representative badges will be deactivated when their current assignment is complete.

25.3 Workers

All construction workers shall possess proof of training in an OSHA 10 hour Outreach Course for the Construction Industry (U.S.).

25.4 Designated Construction Safety Representative – See Table in Section 1.7

Required – OSHA 30 Construction Industry Outreach Program (U.S.)

Required - Minimum of 5 years direct experience with the specific type of hazards that can reasonably be expected in the contractor’s daily work.

Required – Knowledge of applicable consensus standards.

Full time Dedicated Construction Safety Coordinator / Dedicated Subcontractor Safety Representative requirement may be waived by Toyota Safety in limited circumstances.

To determine if the requirement shall be waived, the Contractor shall complete a JSA for the task and submit it to Toyota Safety for review. A Supervisor who is qualified and knowledgeable in safety may be designated to serve as the Designated Construction Safety Representative, as a collateral duty. This person shall have the authority to address all safety concerns, provide all the safety support documentation, and dedicate time to support safety issues that apply to that company.

67

Toyota Safety Requirements for Construction, Equipment Installation, & Equipment Decommissioning Version 2020

Appendix

07/01/2020 Toyota Motor North America TMNA Construction Safety Department

68

Index Construction Support Forms The forms in the Appendix are to be used as needed to provide information from the contractor to Toyota Construction Safety. A contractor must receive permission from Toyota Construction Safety for substitution of documentation. These forms are available electronically. Each NAMC may have their own forms for specific activities. Check with Toyota Construction Safety before beginning work to determine which form should be used.

CSF D-01 Declaration of Competent Person Form 70 CSF D-02 Excavation Review Form 72 CSF D-02 A Pre-Excavation Form for GPR Scanning 73

CSF D-02B Example Pre-Excavation Form 74 CSF D-03 Utility Request Form 75 CSF D-03A Utility Tie-In Request Form 76 CSF D-04 Safety Committee Meeting Minutes 77 CSF D-05 Contractor’s Daily Safety Coordination Meeting 78 CSF D-06 Weekly Toolbox Talk Record 79 CSF D-07 Contractors Weekly Man Power Report 80 CSF D-08 Emergency Contact List 81 CSF D-09 Safety Cross Calendar 82 CSF D-12 Incident Reporting – Process and Form 83 CSF D-13 Safety Violation Form 86

CSF D-14 Lock Surrender / Abandonment Form 87 CSF D-15 Toyota Notice of Work Form 88 CSF D-16 JSA Form (sample) 89 CSF D-17 Toyota JSA Review Checklist 90 CSF D-18 Toyota Construction Daily JSA 91

CSF D-19 Confined Space Entry Form (sample) 96 CSF D-20 Contractor Equipment Inspection Form (sample) 97

CSF D-25 Commissioning Warning Sign 98 CSF D-26 Critical Lift Checklist 99-100 CSF D-27 Contractor’s Crane Review 101

69

CSF D-29 Steel Erection Plan / Checklist (A-C) 102 CSF D-30 Spotter Work Rule Decision Matrix 109

CSF D-35 Toyota Safety Construction Audit Form 110 Escalation Matrix 114

CSF D-38 Construction Area Sign 116 CSF D-40 Floor Opening Checklist 117 CSF D-42 Demolition Checklist 118

Site Control Board 119

Construction vs. Maintenance Definition 120 Heat Illness Symptoms Diagram 121 Sloping and Benching Examples 122 Job Made Wooden Ladder 129 Scaffold Tags 130 Quarterly/Monthly Inspection Tape Colors 131 Steel Erection Kanban 132 Cutting Tool Standard 134 Recommended Wind Speeds for Roofing Operations 135 Daily Ladder Inspection Sticker Template 136 Revisions 137

JSA Guidelines 138 Work Rule Process Flow Chart 145 Work Rules 146

70

CSF D-01 Declaration of Competent Person Form

CSF D-01 Declaration of Competent Person

Contractor:

Confined Space

Energy Control/Lock-out

Excavation

Fall Protection

First Aid / CPR

Scaffolding

Other

Competent Person:

Supervisor:

Toyota Safety Review:

DATE

DATE

DATE

PRINT NAME SIGNATURE

PRINT NAME SIGNATURE

PRINT NAME SIGNATURE

Toyota Construction Procedure

Procedure Section: Production Engineering

Environmental & Safety Eng. Approvals

IGN. Date

GM

AGM

MGR.Revision Number: TCSR 3.0 Revision Date: 4/1/19

Procedure Name: CSF D-01 Declaration of Competent Person

Procedure Number: Effective Date:

(Check only the box that applies)

THIS IS TO ATTEST THAT THE UNDERSIGNED HAS RECEIVED THE ADEQUATE TRAINING AND EXPERIENCE AND HAS BEEN APPOINTED TO ACT AS THE COMPETENT PERSON, AS DEFINED BY APPLICABLE LAW, FOR

THE FOLLOWING REQUIREMENTS;

THE UNDERSIGNED WILL PERSONALLY ENSURE COMPLIANCE IN ACCORDANCE WITH APPLICABLE LAW, THE CONTRACTOR'S PROGRAM AND HAZARD SPECIFIC WORK PROCEDURES.

Attach proof of training for boxes checked above

71

COMPETENT PERSONS 29 CFR 1926.32(f) "Competent person" means one who is capable of identifying existing and predictable hazards in the surroundings or working conditions which are unsanitary, hazardous, or dangerous to employees, and who has authorization to take prompt corrective measures to eliminate them. The Competent Person procedure establishes the requirements for the designation of Competent Persons who will be responsible for complying with specialized activities such as testing, repairs, machinery/equipment maintenance, operations inspections, and maintenance of an incident prevention program. Each Contractor is responsible for designating the Competent Person for each required specialized activity as required by OSHA. The Contractor will ensure that the required qualifications are met, performance is evaluated, and a Competent Person is available for each required activity. The Contractor will ensure that the designation of the Competent Person is documented on a Competent Person Designation Form and is available for review by the Toyota Safety and the state or federal entity having jurisdiction over the Project. The Contractor shall ensure that all requirements of the designation of Competent Persons on the project are implemented, documented, monitored, evaluated, and modified as needed. The designated Competent Person is responsible for complying with the required testing, repairs, machinery/equipment maintenance, and the maintenance of an incident prevention process that includes, but is not limited to the following equipment and activities covered by OSHA:

• 29 CFR 1926.20/01A.17 Safety Coordinator/General Safety • 29 CFR 1926.53 Ionizing Radiation • 29 CFR 1926.62 Lead • 29 CFR 1926.0101 Hearing Protection • 29 CFR 1926.103 Respiratory Protection • 29 CFR 1926.251 Material Handling • 29 CFR 1926.404 Electrical (Assured Grounding) • 29 CFR 1926.450-454 Scaffolds • 29 CFR 1926.500-503 Fall Protection • 29 CFR 1926.550 Cranes and Derricks • 29 CFR 1926.552 Material Hoists, Personnel Hoists, and Elevators • 29 CFR 1926.650-652 Excavations • 29 CFR 1926.705 Concrete and Masonry-Lift Slab Operations • 29 CFR 1926.751-756 Steel Erection • 29 CFR 1926.800-803 Underground Construction • 29 CFR 1926.850, 859 Demolition • 29 CFR 1926.900 Blasting • 29 CFR 1926.1053, 1060 Ladders and Stairways • 29 CFR 1926.1101 Asbestos • 29 CFR 1926.1127 Cadmium

72

CSF D-02 Excavation Review Form

CSF D-02 Excavation Review Form

Contractor performing work:

Work Description:

Work Location:

Excavation Dimensions:

Penetrometer Test Results: (Check One)

Protective System Used: Soil Type: Conditions:

Hydraulic Shoring System Stiff Clay Dry

Timber Shoring System Firm Clay Wet

Trench Shield/Box Dry Granular Saturated

Sloped Angle of Repose (Width & Height) Wet Granular

Benched (Measurement Required) Saturated Granular

Unsupported Wall - (Height) Running

Yes No N/A

Employee protection from cave-ins and loose rock/soil planned for

Spoils, material, and equipment, 3 feet set back required and planned for

Engineering designs reviewed for excavations over 20 feet deep

Manufacturer's data for trench box or hydraulic shoring on file if used

Adequate sign posting and barricades planned for

Will utility company be contacted 72 hrs. prior to starting work

Any overhead lines located, and noted for review with the operator

Any underground utility locations located and marked for review with the operator

Any underground utility support or protection that crosses the excavation planned for

Any underground structure protection, supported, or removed planned for

Are plans in place to protect employees from water accumulation if necessary

Will the excavation be exposed to surface water or runoff

Will inspections be made after every rainstorm or other hazard-increasing occurrence

Will excavation meet Confined Space requirements (attach Confined Space Permit)

Will special permitting be required for the equipment used to excavate

Are plans in place for entrance and egress of the excavation

Are plans for severe weather in place

Arrangements in place for access to the excavation for workers and equipment

Competent Person:

Toyota Construction Safety Review:

Toyota Project Leader Review:

NAMC Facilities Review:

SOIL EVALUATION

SITE EVALUATION

>2.5 2.5 2.0 1.5 1.0 <1.0

Date

DateName

Signature

Signature

Name

Name Signature Date

Name Signature Date

73

CSF D-02A Pre-Excavation Plan for GPR Scanning

Pre-E

xcav

ation

Plan

Area

of W

ork:

Utilit

y Plan

and E

xcav

ation

Area

Date:

Utilit

y Ide

ntific

ation Lo

cated

Impa

ct1G

as2 E

lectri

cal

3Wate

r4C

ommu

nicati

ons

5Sew

er6S

torm

7Othe

r

Utilit

y Ide

ntific

ation

Meth

od:

EM Sc

anGP

R - no

t use

d due

to cl

ay so

il and

distu

rbed s

urfac

e co

nditio

n

74

CSF D-02B Example Pre-Excavation Plan for GPR Scanning

Pre-Ex

cavati

on Pla

n

Area o

f Work

: CHDY

10 Pit

Utility

Plan a

nd Ex

cavati

on Ar

eaDa

te: W

eek of

10/24

Utility

Iden

tificat

ion Locate

dImp

act1G

asO

Impac

ted2E

lectric

alO

No im

pact

3Wate

rO

No im

pact

4Com

munic

ation

sO

No im

pact

5Sew

erO

No im

pact

6Stor

mO

No im

pact

7Othe

rN/A

N/A

Utility

Iden

tificat

ion M

ethod

:EM

Scan

GPR -

not u

sed du

e to c

lay so

il and

distur

bed su

rface

condit

ion

75

CSF D-03 Utility Request Form (Verify with local NAMC for current form)

76

CSF D-03A Utility Tie In Request Form (Verify with local NAMC for current form)

77

CSF D-04 Safety Committee Meeting Minutes

CSF D-04 Safety Committee Meeting

MEETING # Facility / Site

Date: Start Time: End Time:

Toyota Construction Safety Rep:

The next Safety Committee Meeting will be held on @

Toyota Construction Procedure Environmental & Safety Eng. Approvals

Procedure Section: Production Engineering IGN. Date

Item Speakers Documents Requested

Procedure Name: CSF D-04 Safety Committee Meeting Minutes GM

Procedure Number: Effective Date: AGM

Revision Number: TCSR 3.0 Revision Date: 4/1/19 MGR.

Toyota Safety Announcements

Please inform of any omissions or errors.

Security/NAMC Announcements

78

CSF D-05 Contractor’s Daily Coordination Meeting

CSF D-05 Contractor's Daily Coordination Meeting

Toyota Construction Procedure Environmental & Safety Eng. Approvals

Procedure Section: Production Engineering IGN. Date

Procedure Name: CSF D-05 Contractor's Daily Coordination Meeting GM

Procedure Number: Effective Date: AGM

Revision Number: TCSR 3.0 Revision Date: 4/1/19 MGR.

Contractor Superintendent/General Foreman:

Signatures:

Area/Location of Work for the Day:Number of total Safety Representatives on site for both:

Work activities for the day:

Date:Number of workers on site for your company:

Number of workers on site for your subcontractors:

Number of Supervision on site for your company:

Number of Supervision on site for your subcontractors:

Company Name:

Key safety concerns and controls:

Area/Location of Work for the Day:

Key safety concerns and controls:

Work activities for the day:

Contractor Safety Rep:

79

CSF D-06 Weekly Toolbox Talk Record

CSF D-06 Weekly Toolbox Talk Record

___________________________________________ __________________________________________

Supervisor Signature: Safety Rep Signature:

10 20

Recommendations from Workers:

5 15

6 16

7 17

2 12

3 13

4 14

Saturday:

Sunday:

Special Topic:

Special Topic:

Attendance: Print Name and Initial Attendance: Print Name and Initial

Contractor: Project ID#:Date: Time:Supervisor: Work:

Site Specific Topics

Supervisor Comments:

8 18

9 19

1 11

Tuesday:

Wednesday:

Thursday:

Friday:

Monday:

80

CSF D-07 (Sample) Verify with Toyota Construction Safety for correct form used at current NAMC

81

CSF D-08 Emergency Contact List

CSF

D-0

8 Em

erge

ncy

Cont

act N

umbe

rs

Com

pany

Nam

e

Nam

e (p

leas

e pr

int)

Toyo

ta C

onst

ruct

ion

Pro

cedu

reE

nviro

nmen

tal &

Saf

ety

Eng

. App

rova

ls

Pro

cedu

re S

ectio

n:P

rodu

ctio

n E

ngin

eerin

gIG

N.

Dat

e

Pro

cedu

re N

ame:

CS

F D

-08

Em

erge

ncy

Con

tact

Num

bers

GM

Pro

cedu

re N

umbe

r:E

ffect

ive

Dat

e:A

GM

Rev

isio

n N

umbe

r:TC

SR

3.0

Rev

isio

n D

ate:

041/

01/1

9M

GR

Cont

act N

umbe

re-

mai

lLa

stFi

rst

Posi

tion

/ Ti

tle

82

CSF D-09 Safety Cross Calendar

Safety Calendar

Safety SloganAccident Free Day Green

OSHA Case Red

23

12

13 14 15 16 17 18

24

11

19 20 21 22

3029 31

7 8 9 10

25

27

26

28

1 2

3 4

5 6

83

CSF D-12 Toyota Construction Incident Report-Initial Report Contractors are required to report and document all incidents (regardless of severity) and near miss events while on Toyota property. Below is a diagram to detail the flow of information from the Contractor to Toyota. Any question shall be submitted to the designated Toyota representative at the start of the work. The first page of the D-12 (below) shall be submitted within 24 hours as the initial report. Contractor shall obtain the latest electronic form prior to report submission.

84

CSF D-12 Toyota Construction Incident Report- Initial

85

CSF D-12 Toyota Construction Incident Report- Final

86

CSF D-13 Safety Violation Investigation Report

PHONE:

YES (attach to form CSF D12) No

Length:

PICTURES, SKETCH, COMMENTS:

SUPERVISORS NAME:

WORKERS STATEMENT:

WAS AN INJURY A RESULT OF THIS VIOLATION:

SUPERVISOR/FOREMAN BRIEF SUMMARY:

ACTION BY CONTRACTOR:

ACTION BY TOYOTA:

PERSON OBSERVING VIOLATIONCOMPANY NAME

VIOLATION TIME (24hr Clock):PLANT:

TOYOTA D13 Safety Violation Investigation Report

D13:

Thi

s re

port

to b

e co

mpl

eted

by

the

Supe

rinte

nden

t/For

eman

and

sub

mitt

ed w

ithin

24h

rs M

AX.

VIOLATION DATE:VIOLATION TYPE:

DEPARTMENT:

WORKERS NAME:

VIOLATION DESCRIPTION

87

CSF-D14 Lock Surrender/Abandonment Form

CSF D-14 Lock surrender / Abandonment Form

Date: Time: LOCATION:

EQUIPMENT:

CONTRACTOR: SUPERVISOR:

Lock removal due to:

Missing or lost key Worker went home without removing his/her lockAbandon Lock without Tag Mechanical failure of lockLock obstructed from removal Other

If other, please give details:

Lock Surrender: All attempts must be made to contact the worker. (please complete this section)

Yes NoWas the worker contacted?Did the worker give permission to remove the lock?

Workers signature to remove lock:Yes No

Worker contacted off site and gave permission to remove the lock.

Competent Supervisor Signature :

Witness Signature:

Abandoned Lock (complete this section if the worker did not give permission to remove the lock)

If the worker did not give permission to remove the lock please state the reason.

Yes NoWere all attempts made to contact the owner of the lock

If the owner of the lock cannot be located, then the system or equipment must be inspected by a competent person to ensure if is safety to remove the lock.

Signature of competent person that it is safe to remove the lock.

Authorization to remove the lock. (all parts of the surrender and abandon lock out form must be completed and reviewed)

Contractor Supervisor Signature Date & Time

Contractor Safety Signature Date & Time

Toyota Security Signature Date & Time(if required)

88

CSF D-15 Notice of Work Form

CSF D-15 Notice of Work Form

Date: General Contractor:

P.O. #: Supervisor Name:

Location: Contact Phone #:Plant

Dept.: Project Leader TEMA

Column# Contact Number:

# Workers Per Day: Work Dates From: To:

Time Period From: To:Check all that apply

Weekday Saturday Sunday Day Night

Description of Work:

Special Work Items Yes No InitialsHot Work Follow local NAMC's Hot Work ProcedureCO2 System Requires special training and approvalConfined Space Follow OSHA Confined Space Entry ProcedureOverhead or roof Work Overhead / roof work risks included in JSAGas, Diesel, Propane, etc. Local NAMC prior written approval requiredEquipment Commissioning Follow TEMA Commissioning ProcedureFloor Penetrations/Excavations Location identified prior to beginning workWork on or within 4 ft. of energizedcircuits > 50V? Confirm following NFPA 70E requirementsEquipment Lockout Confirm lockout plan completedLocal NAMC Restricted Substances Prior local NAMC written approval requiredChemical Substances Attach MSDS from local NAMCFire Alarm/Suppress System Work Local NAMC Security and Facilities approvalTie into Existing Equip/Sply lines Attach Tie in Request FormSpecial Protective Equipment List equipment to be used in JSA

Contractor SupervisorName Signature

Dept. / Area Rep( Mgr/AM/Maint/etc) Name Signature

Engineering plant/TEMA

Name Signature

Toyota Construction Safety

Name Signature

Date

Date

If Contractor requires use of utilities during non-production hours, please complete and attach local NAMC utility request form.

Work cannot commence until this form has been signed by a Plant Representative (when appropriate).

Special Instructions:

I have read and understand the Construction Safety Requirements, and agree to comply with all requirements and procedures as outlined within, and in addition, any special instructions on this form.

Contractors must submit a JSA with this form for review & approval.

Date

Date

89

CSF D-16 (Sample) Job Safety Analysis (JSA)

CSF

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90

CSF D-17 Toyota JSA Review Checklist

Toyota JSA Review Checklist Toyota’s three (3) key elements that need to be checked for a quality JSA.

1. Identify each individual step or sub task of the job. 2. Identify workplace hazards associated with each step or sub task of the work being done. 3. Determine suitable and sufficient control measures which address identified hazards.

Detail of each key element (Check each box as you complete the steps listed below):

1a- Identify each individual step or sub task of the job.

Every job can be broken down into sub tasks or steps. Starting from the project plan, break down each job into sequential steps required to complete the work.

If needed, gather input from other workers who have performed the same job before and have experience with the detailed steps and job sequence. KEYWORDS to trigger consultation: Steel Work, Roof Work, Helicopter Lift, Crane Lift, Confined Space, Greater than 480 V, penthouse, tag line, etc.

1b- Are the job steps sequential?

2a- Identify workplace hazards associated with each step or sub task of the work being done.

Using the breakdown of sequential tasks or steps, the job safety analysis is now an exercise in detective work.

• What could go wrong? • How could a potential hazard arise? • What contributing factors exist (not immediately related to the task at hand?)

The best way to identify workplace hazards is to walk the worksite in advance. Look for hazards that are directly associated with the tasks that will be conducted as well as hazards that are not related to the target task. All potential hazards must be identified. For long term plans, consider the impact of the evolving environment.

2b- Have you walked the jobsite?

3- Determine suitable and sufficient control measures which address identified hazards.

After reviewing this list of hazards, consider what control methods will eliminate or reduce them to an acceptable level. When developing any JSA, the Hierarchy of Risk Control (from most to least effective) should be referenced regularly.

1. Can the hazard be eliminated? Ask if the step is truly necessary to accomplish the task. If #1 is not practical; 2. Can a substitution be put in place? For example, replace a manual task with equipment that eliminates the exposure.

If #2 is not practical; 3. Can worker be isolated for hazards? For example; moving work to an off shift if excessive noise or atmospheric

hazards may be introduced by a process. If #3 is not practical; 4. Can engineering controls be put in place? For example; can ventilation be provided to decrease heat, remove

atmospheric hazards, If #4 is not practical; 5. Can administrative controls be put in place? For example; Move work to off shift if 2 contractors need to work in the

same space. If #5 is not practical; 6. Provide appropriate PPE until better controls are available.

JSA Review Signatures

Toyota PE Project Leader_______________________________________________________________

Toyota Safety Rep _____________________________________________________________________

91

CSF D-18 Toyota Construction Daily JSA

TOYOTA CONSTRUCTION DAILY JSA

Project: ______________________________ Date: __________________________ Company Name: ______________________ Shop/Col Number: _______________ Primary Daily Tasks

Area Emergency Procedures: Evacuation/Take Shelter Locations _______________________________________________________________________________________________________________________________________________________________________________________________________________________________________

1. Toyota Project Leader __________________________

2. Company Supervisor __________________________

3. Safety Representative Name __________________________

4. Competent Person Required YES/NO If yes, list name of Competent Person below.

Excavation: Scaffolding: Fall Protection: Rigging:

_________________ ____________________ ____________________ _________________

5. Prior To Beginning Work: Is This a Construction Activity Yes ___ No ___ Check all that are applicable: ____ Utilities Review *(PE Group)* ____ Facility Review *(PE Group)* ____ SDSs Reviewed by Environmental ____ PE Stamp Required

1. 2. 3. 4. 5. 6. 7. 8. 9.

92

Atmospheric Conditions- Countermeasures Yes No Atmospheric Conditions Poor Ventilation Windy*(Wind Factor)* Other

Environmental Hazards- Countermeasures Yes No Environmental Hazards Waste Disposal, Storm Water,

Chemicals, Drain Protection Industrial Hygiene- Countermeasures Yes No Noise: *(Continuous 85dbl.)*

Dust, Lead, Silica, Heat/Cold Stress Job Description/Location-

Countermeasures Yes No Job Description/Location

Heavy Equipment: On/Off Loading Close clearance/congestion/traffic Pinch points/caught between Overhead hazards: power lines,

falling objects, etc. Other

Electrical Hazard- Countermeasures Yes No Electrical Hazards High Voltage Overhead Power Lines Exposed Bus Exposed Conductors Exposed Terminals Capacitors (Stored Residual Energy) Static Potential Temporary Power (Protected and

Barricaded) Possible Arc Flash High Voltage - Clearance Required Near Proximity (OSHA 1926.1408

(h)) Testing: Exposed Electric with Meter High Voltage Training Required Arc Flash Training Required Arc Flash PPE Required Other: Yes No Grounding Use of Ground Sticks, Insulation

Blankets Other:

Task Induced Exposures- Countermeasures Yes No Task Induced Exposures Carbon Monoxide (CO2) (Burning/Welding, Exhaust) Welding / Burning Fumes (metals) Painting / Fiberglass Exposure Corrosives / Cleaning Agents Lead (Paint removal)

Weather/ Heat or Cold:

HAZARD CONTROL / ELIMINATION HAZARD INDENTIFICATION

93

Task Specific Hazards- Countermeasures Yes No Task Specific Hazards Grinding, Chipping, Proper Wheel,

PPE/Barricade, Screens, Blankets Protruding Objects/ impalement

hazards Fall Hazard- Countermeasures Yes No Falls- Different Levels

Unprotected Leading Edges Working over 6 feet, open holes

Scaffolding- Countermeasures

Yes No Working in Lifts Scaffolding

Scaffold erection, dismantling

Hot Work/ High Hazard Hot Work- Countermeasures Yes No Hot Work/ High Hazard Hot Work Overhead Fire Hazards: Burning or

Welding, Fire Blanket, Screens Fire Hazards: Between walls/above High Hazard Area Hot Work- Paint

Shop, etc. Excavations- Countermeasures Yes No Excavations

Excavation over 4 feet- access/egress

Excavation over 5 feet- sloping, shoring, benching, etc.

Type C Soil Present Power Transmission/Distribution- Countermeasures Yes No Power Transmission/Distribution

Simple/Group Lockout Energy Sources Identified/Locked

Out Energy Sources Verified/Tested

Before Task Begins Special Equipment/Operator Needed- Countermeasures Yes No Special Equipment/operator needed

Mobile Crane / Hoist/lifting device in use

Critical Lift – tandem, over 70% capacity, awkward loads

CSF D26 Complete/Pre-Lift Meeting Man basket, man lift device in use Forklift, JLG, Scaffold, Scissor lift,

Aerial Lifts, Genies in Use Fixed Rail Crane / Hoist in use Heavy Equipment (Construction)

Ergonomics- Countermeasures Yes No Ergonomics Reaching, bend, twisting, push, pull Frequent heavy lifting >40lb. 2

Hr./day Force exertion / lifting >50lb. Lifting above shoulders Repetitive motion / vibration of tools

Confined Space-Countermeasures Yes No Confined Space Oxygen deficient/enriched

Carbon Monoxide (CO) Flammable, combustibles, Corrosives List Other Toxins:

94

Necessary PPE: [Mandatory Hard Hat, Safety Glasses, Steel Toe Boots, Reflective Vest] *Steel Toe Boots for Construction*

Respirator ½ Face, Full Face Face Shield Ear Plugs/Muffs Gloves Chemical Work Gloves Welding Sleeves, Welding Hood Goggles Kevlar Sleeves, Cape Leather Gloves Side Shields F/Pre-Scrip Paint Suits Leather Apron Kevlar Gloves Knee Pads Arc Flash PPE List tools & equipment: Current Inspection /Calibration Fall Protection Electrical Tools & Cords Retrievable Tripod & Equipment Equipment/Tool Guarding Fire Extinguishers Excavation Tools & Equipment Intrinsic Tools Fire Blankets/Screens Powder Actuated Tools Ladders—Extension/

A-Frame *(Set-Up & Secure Point) *

Rigging-Slings, Straps, Chain Falls, etc.

Meta-Bo, Sawzaw---Blades, Grinder Wheels

Barricades Scaffolds Air Monitor Instruments

Engulfment, Slips, Trips, Falls Other Hazards:

Ladders- Countermeasures Yes No Ladders Ladders Set Up Properly Ladders- Nonconductive

95

I acknowledge that I have inspected the work site and am familiar with the conditions, including hazards on the site. I hereby certify that I will fully comply with all of Toyota safety policies, while on Toyota property. I will comply with all rules, regulations and laws regarding construction activity while on Toyota property that are intended to protect health, safety and the environment. This document is not all encompassing and is to be used a second- tier hazard assessment along with the overall JSA.

______________________________ ________________________________________ Contractor Supervisor Signature Contractor Safety Representative Signature Employee: Print Name: Signature: __________________________ ________________________________ __________________________ ________________________________ ____________________________ __________________________________ __________________________ ________________________________ __________________________ ________________________________ __________________________ ________________________________ __________________________ ________________________________ __________________________ ________________________________ __________________________ ________________________________ _____________________________ __________________________________ __________________________ ________________________________

96

CSF D-19 (Sample) Confined Space Entry Checklist/Permit

CSF D-19 Confined Space Entry checklist / Permit sample

Company/Contractor

Date

Area of Entry

Purpose of entry: Inspection Repairs Cleaning Installation Other (specify)

YES NO YES NO

Test

%

%

ppm

ppm

F

Additional notes

Date Time

- All entrants and attendants covered by this permit shall sign and date the back of this form prior to entering the confined space - Record air monitoring results at least every 2 hours or whoever conditions change. - Results of the atmospheric tests shall be logged on the back of this form with the names or initials of the testers and time of the tests. - This permit must be posted at or near the entrance to the space. - This permit shall be valid for one shift or a maximum of 12 hours.

Signature of Entry Supervisor Date

Signature of Entry Supervisor Date

If ANY of the following questions answer YES , the space is a permit required confined space

Estimated Completion Time

Entry Supervisor

Estimated Start Time

Description of Space to be Entered

If ALL of the following questions answer NO , the space is a non-permit required confined space.

Will you be introducing a hazard into the space?

Does the space contain materials which could cause entrapment, engulfment, and/or suffocation?

Does the space have an internal configuration such that an entrant could be trapped or asphyxiated by inwardly converging walls or by a floor which slopes downward and tapers to a small cross-section?

Atmospheric Conditions must be analyzed by a competent person prior to entering the confined space.

Does the space contain any other recognized serious safety or health hazard?

Oxygen (O2)

Has the space been identified by Toyota as a Permit Required Confined Space?

Does the space contain a hazardous atmosphere?

Results

19.5% to 23.5%

Date Time

Entry Closed Out (hh:mn)

Temperature (for oven entry)

Entry Authorized (hh:mn)

The following questions/procedures must be documented prior to entering the confined space.

Measures used to isolate the permit space and to eliminate or control permit space hazards before entry

Equipment which will be provided (PPE, testing equipment, communications, rescue equipment)

Emergency & Entrant communication procedures Rescue procedures (include name and numbers of rescuer service)

Additional permits needed or issued (if any)

Other:

Tester InitialsPermissible Entry Level

Signature of authorized Person Completing Checklist

Flammable (LFL)

Carbon monoxide (CO)

Hydrogen Sulfide (H2S)

Under 10%

Under 35 ppm

Under 10 ppm

SAMPLE

97

CSF D-20 (Sample) Contractor Equipment Inspection form

D-20 Contractor Equipment Inspection Form sample

(Required for equipment greater than 10 HP in size)

Contractor: Supervisor:

Project: Date Submitted:

required documents are provided with the equipment.

Inspector's Name: Signature:

Qualifications:

Equipment Inspected Make/Serial # Date on Site Last Inspection

This report will attest that prior to its first use on this project, all of the mechanically powered equipment, tools,machines, and devices rated at greater than 10 horsepower listed above, have been inspected by a competentperson and are considered to be in competent operating condition in accordance with the manufacturer'sdesign, maintenance and testing criteria. All known defects and deficiencies have been corrected prior to useon the project. A list of inspected items, operator's manual, logbook (if applicable) , engineers reports (ifapplicable) , non-destructive test report (if applicable) , manufacturer's approvals (if applicable) and other

SAMPLE

98

CSF D-25 Commissioning Warning Sign

99

CSF D-26 Critical Lift Checklist

MOBILE CRANE FORKLIFT/ VERSA LIFT COME-A-LONG HELICOPTERSPECIFIC PLAN

FIXED CRANE CHAINFALL OTHER- REQUIRED

NEARESTDEPT:________________COLUMN #:_______________ LIFT ROOF PLANT GROUNDS PIT

LOCATIONPLANT:_______________AREA:________________ MEZZANINE GROUND FLOOR PENTHOUSE

BRIEF LIFT DESCRIPTION:

OK NG NA Countermeasure if NG OK NG NA

CSF D-26 Lift ChecklistCompany Name: Date of Lift Day: Month: Year:

Contact Name: Phone Number

EQUIPMENT USED:Check all that apply

LOCATION OF LIFT:

Confirmation of Load Lifting Equipment

Item Weight Item Weight Model Capacity

Main Block Jib Bridge Crane

Load Lifting Beam Mobile Crane

Load Support- Engineered Device

Rigging Forklift / Versa Lift

Auxiliary Block Hoist Rope Gantry

Site Conditions Site Control

Solid Level Surface Safety Perimeter Established (min 2 m from swing path)

Other Other Chain Fall

Wind Speed Pick Point, Set Point and Swing Path area controlled

Proximity to Electrical Energy Sources Crane Assembly Area Clearly Identified

Soil Type Known & Adequate High Visibility Vest Worn in Lift Area

Floor Structure Capacity Areas Inside Building Secured/Controlled

LIFT PLAN CHECKLIST

Does Lift plan identify and mitigate the following: OK NG N/A Countermeasure if NG

Weather (Ice, Lightning, etc.) Other

Overhead Hazards Other

Engineered Lift Points

Specified Rigging Points

How to Upended or / Down-ended load

Center of Gravity- known or moving

Crane Capacity Based on Angle of Lift, Extension of Boom and Load Chart

Type of Softeners used

D-26 Review Verification

Number of Taglines used and location

Number of Spotters required and location

Toyota Safety

Certified/Qualified Rigger Name: Rigger Certification #: Operator Name: Operator License #:

All riggining equipment inspected prior to use

Sling tension within capacity (including angle factor)

Hitch type correct for object lifted

Hardware within working load limit

GC/Subcontractor Safety Signal Person Toyota Project Leader

PE Stamp for lift plan (If Rigger does not possess certification)

100

Provide sketch and detailed lift plan

CSF D-26 Lift Checklist

Day: Month: Year:Date of LiftCompany Name:

Contact Name: Phone Number

101

CSF D-27 (Sample) Contractor’s Crane Review

CSF D-27 (Sample) Contractor's Crane Review

CRANE OPERATOR SIGNATURE: APPROVED:

REJECTED:

15. Are all windows safety plate or equivalent and free of defects?16. Is the machine capable of running on propane for indoor use?17. Does the operator have the appropriate license of the type of crane to be used?

YES

9. Does the anit-two block device(s) function properly?10. Do all lights work properly?11. Does the horn work?12. Does the backup alarm work?13. Are safety latches or their equivalent in place and functioning?14. Is there a functional fire extinguisher available?

4. Do the outriggers function properly without leaks?5. Are appropriate pads available to prevent outriggers from damaging floor or road surfaces?6. If used indoors, is there a diaper in place to catch accidental fluid drips?7. Is the wire rope(s) in good condition and free of damage?8. Is the wire rope(s) terminated properly?

YEARLY INSPECTION PERFORMED BY:

1. Is there an operator's manual provided with the machine?2. Is there a load chart available for the machine as it is equipped?3. Is there an external placard displayng standard hand signals?

NO

Contractor's Crane ReviewCrane reviews are required when equipment arrives on site, if the crane changes possession, or is reconfigured.

DATE:REQUESTED BY:CONTRACTOR:CRANE OWNER:

CRANE MANUFACTURER:MODEL:SERIAL NUMBER:DATE OF LAST INSPECTION:

102

CSF D-29A Pre-Detail Meeting See www.ToyotaSupplier.com for latest Structural Steel Erection Forms.

Date

Structural Steel Pre-Detail Meeting AgendaMeeting Date:

Project Name: PJ Location Desc.

General Contractor: Toyota PJ Rep:

SS Contractor: Engineer of Record:

SS Fabricator:

SS Detailer(s) and/or Design Engineer(s)

Steel Joist & Deck Manufacturer

The topics listed below shall be discussed during the meeting at a minimum.

General

Roles and Responsibilities

Key Contacts

Communication Protocol

RFI ProcessDistribution

Shop Drawings

What to Submit

Format Requirements

Shop Drawing Submitted by Sequence

How Many Copies

Sealed Calculations (if applicable)

Shop Drawing Approval Timing

The Structural Steel Pre-Detail Meeting shall include the above listed participants, as applicable, as well as any others involved in the design, detailing, fabrication, erection of structural steel, joists and decking associated with the Project.

Revision Number: Revision Date: MGR

Procedure Name: Structural Steel Pre-Detailing Meeting GM

Procedure Number: Effective Date: AGM

TOYOTA Construction Procedure PLEE & Safety Approvals

Procedure Department: Production Engineering PLEE PLEE SAF

Anchor Bolts

SS Contractor to Fabricate and Supply Anchor Bolts and Setting DiagramsFoundation Contractor to Install Anchor Bolts (as applicable)

SS Fabricator and Erector Shall be Responsible to Field Survey Existing Construction Where New Construction Joins Existing

Cutting Openings

Fire Watch Required

Weathertight Enclosures Required

Coordination of Openings with Owner

Joist and Structural Steel InterfaceThe SS Detailer and Joist Detailer are Responsible to Coordinate Seats, Connections, Bearing Lengths/Widths/Depths, etc.

OSHA Required DetailsBolted Joists, Erection Seats, Projections Above Deck for Floor Openings, Temporary Protection of Openings, etc.Detailing shall Meet OSHA "Safety Standards for Steel Erection; Final Rule, "29 CFR, Part 1926.

103

Connections

Use Single Plate Shear Connections or Similar Wherever Possible

"Shared" or "Double" Connections Through Column Webs or to Beams Over Columns shall NOT be permitted WithoutApproval of EOR and Toyota.

If a "Shared" or "Double" Connection is Required, the Connection Must be Detailed so That it can be Erected in AnySequential Order (Having Extra Bolts or Seats on Both Sides of the Column/Beam Web).

Painting & Cleaning of SteelSP-6 for Structural Steel, as applicable, SP-2 or SP-3 for Joists and Joist Girders

Site-Specific Erection Plan

The SSEP must be developed by a Qualified Person.

Deck Fastening

Field, Edges, Corners, and Attachment at Eves

Deck Support Angles at Columns

Erection Tolerances of Structural Steel

Erection Sequencing

Fabrication QC/QAReports3rd Party Inspections

Other Topics

Engineer Of RecordRepresentative Name Signature Date

Controlling ContractorRepresentative Name Signature Date

SS ContractorRepresentative Name Signature Date

SS DetailerRepresentative Name Signature Date

SS FabricatorRepresentative Name Signature Date

Joist/Decking Mfg.Representative Name Signature Date

Toyota Prj. LeadRepresentative Name Signature Date

Toyota SafetyRepresentative Name Signature Date

104

CSF-D29B Pre-Erection Meeting

Date

Structural Steel Pre-Erection Meeting AgendaMeeting Date:

Project Name: PJ Location Desc.

General Contractor: Toyota PJ Rep:

SS Contractor: Engineer of Record:

TMNA Safety Rep.

The below items are to be discussed at a minimum and confirmed in place/completeprior to structural steel erection.

Foundation Approval

The concrete in footings, piers, and walls must have cured to Adequate Strength for steel erection.

75% of concrete strength verified by Engineer or testing prior to starting the erecting.

Project Engineer must approved anchor bolt repairs, replacements, and modifications.

The controlling Contractor must provide Written Notification to the steel erector for the above.

Site Layout Requirements

The Controlling Contractor must provided adequate Access and means to maintain Access to the site.

The area must be firm, properly graded, well drained and accessible.

The areas of crane placement must be able to support the weight of the crane and loads.

There must be adequate room for the erection tasks and required support equipment.

The Controlling Contractor must provide means and methods for Pedestrian and Vehicular Control.

Pre-planning

Discuss Sequence of Erection.

Erection shall conform to the Erection Stability Plan. Deviations are PROHIBITED without priorreview and approval in writing of the Erection Stability Plan Engineer of Record or qualified person as appropriate for the project type.Coordination of activities with other trades or Plant activities expected during erection.

Path for overhead loads and how effected workers are notified been discussed.

Are there special procedures required for Hazardous non-routine Tasks?

Certifications for each employee that has received training for steel erection operations on file?

A list of Qualified and Competent persons on file?

Procedures in the event of Rescue or Emergency Response provided and reviewed?

Has all utilities in the area of work, been identified and protection provided if necessary?Safety Representative Requirements:

TOYOTA Construction Procedure PLEE & Safety Approvals

Procedure Department: Production Engineering PLEE PLEE SAF

Procedure Name: Structural Steel Pre-Erection Meeting GM

Procedure Number: Effective Date: AGM

Revision Number: Revision Date: MGR

105

Cranes

The Crane Operator must be trained and certified for the size of the crane.

Qualified Riggers must be utilized.

Will a signal person be required?

The operator and signal person must agree on type and means of signals they will use.

Is there enough room to assemble / disassemble the crane?

Will the assembly / disassembly of the crane be directed by a person that meets the criteria forboth a competent and qualified person?

Are there any Critical Lifts?

Has the CSF D-26 been completed?Site-Specific Erection Plan

The SSEP must be developed by a Qualified Person.

The plan be posted at the job site, available to all involved in the erection activities.

If applicable, the plan must provide Alternate Means of providing Employee Protection.

The plan must include the description of the crane selection and placement procedures.

The plan must include a description of Steel Erection Activities and Procedures.

Employees are not working directly below suspended loads

Employees engaged in the Initial Connection are identified and trained

Employees necessary for the hooking and unhooking of the loads are identified

Temporary column / beam connections

The plan must list Emergency Rescue Procedures.

Self-Rescue Stair Tower Aerial / Scissor lifts Man Basket

Emergency Response Team First Aid Trained Personnel Local Emergency Response

Erection Stability Plan

Outdoor Building systems as defined in TCSR section XXX

Must have Erection Stability Plan developed and sealed by a Professional Engineer including but notlimited to the following elements:

Analysis of loads to be resisted throughout the erection period (environmental, construction, etc.).Description of the order of placement of structural elements, by sequence, to maintain structural stabilityincluding placement of joists, beams, decking bundles, plating, mechanical/electrical loads (utilities, equipment, etc.).

Identify members that require actions such as "hold on crane" until subsequent activities are completed.

Minimum bolts, welds or special erection connection requirements.Requirements for bridging (erection, construction, permanent).

Temporary bracing, shoring, guying requirements and details (anchorage points, cables, turnbuckles, etc.)

Removal of temporary bracing, shoring and guying.The Erection Stability Plan must be at the erection site, reviewed daily, by sequence by the raising gang and allaffected persons to ensure understanding of the elements, procedures and timing required by the plan.

Indoor Structural SystemsMust have Erection Stability Plan developed and signed by a Qualified Person including but notlimited to the following elements:

Description of the order of placement of structural elements, by sequence, to maintain structural stabilityincluding placement of joists, beams, decking bundles, plating, mechanical/electrical loads (utilities, equipment, etc.).Identify members that require actions such as "hold on crane" until subsequent activities are completed.Minimum bolts, welds or special erection connection requirements.Requirements for bridging (erection, construction, permanent).Temporary bracing, shoring, guying requirements and details (anchorage points, cables, turnbuckles, etc.) Removal of temporary bracing, shoring and guying.

106

Safety RepresentationMust have at minimum: OSHA 30 Hour, CPR, First Aid, OSHA Subpart R - Steel Erection, OSHA Subpart M - Fall Protection, OSHA Subpart N - Cranes & DerricksMinimum 2 years field experience

Fall Protection

Will a competent person in fall protection be on site at all times?

Were fall protection systems designed by a Qualified Person?

Will the erection areas be properly signed and barricaded?

Are methods in place for securing loose items aloft?

Fall Protection Procedures (check all that apply)

Erection of Vertical Structural MembersLadders Aerial / Scissor lifts Horizontal Lifeline Guardrails Free Climbing

Erection of Horizontal Structural MembersLadders Aerial / Scissor lifts Horizontal Lifeline Guardrails Free Climbing

Installation of Roofing and Associated insolationLadders Aerial / Scissor lifts Horizontal Lifeline Guardrails Free Climbing

Installation of DeckingLadders Aerial / Scissor lifts Horizontal Lifeline Guardrails Free Climbing

Installation of Wall OpeningsLadders Aerial / Scissor lifts Horizontal Lifeline Guardrails Free Climbing

Controlling ContractorName Signature Date

Structural Steel Cont.Name Signature Date

Toyota Project Leader Review Name Signature Date

Toyota Construction Safety Review Name Signature Date

107

CSF D-29C Daily Start Up Meeting

Date

Meeting Date:

Project Name: PJ Location Desc.

General Contractor:

SS Contractor:

The below items are to be discussed at a minimum and confirmed in place/completeprior to structural steel erection.

Foundation Approval

The concrete in footings, piers, and walls must have cured to Adequate Strength for steel erection.

75% of concrete strength verified by Engineer or testing prior to starting the erecting?

Project Engineer has approved anchor bolt repairs, replacements, and modifications?

Has the Controlling Contractor provided Written Notification to the steel erector for the above?

Site Layout

Has the Controlling Contractor provided adequate Access and means to maintain Access to the site?

Is the area firm, properly graded, well drained and accessible?

Will the areas of crane placement support the weight of the crane and loads?

Is there adequate room for the erection tasks and required support equipment?

Has the Controlling Contractor means and methods for Pedestrian and Vehicular Control?

Pre-planning

Has the Sequence of Erection Activities for the day been discussed?

Has the Erection Stability Plan been reviewed with raising gang?

Do all affected persons understand no variance to the Erection Stability Plan without

written approval for the EOR or Qualified person?

Has the path for overhead loads and how effected workers are notified been discussed?

Are there special procedures required for Hazardous non-routine Tasks?

Procedures in the event of Rescue or Emergency Response provided and reviewed?

Has all utilities in the area of work, been identified and protection provided if necessary?

Cranes

Has the Crane Operator been trained and certified for the size of the crane?

Will a Qualified Rigger be used?

Will a signal person be required?

Has the operator and signal person agreed on type and means of signals they will use?

Is there enough room to assemble / disassemble the crane?

Will the assembly / disassembly of the crane be directed by a person that meets the criteria for Y Nboth a competent and qualified person?

TOYOTA Construction Procedure PLEE & Safety Approvals

Procedure Section: SAF PLEE

Procedure Name: Structural Steel Daily Pre-Start-up Meeting GM

Procedure Number: Effective Date: AGM

Daily Structural Steel Erection Pre-Start Meeting Agenda

Revision Number: Revision Date: MGR

108

Site-Specific Erection Plan

Plan is posted at erection site and available to all who are affected?

Does the plan provide, Alternate Means of providing Employee Protection?

Does the plan include the Sequence of Erection Activity?

Does the plan include the description of the crane selection and placement procedures?

Does the plan include a description of Steel Erection Activities and Procedures?

Does the plan list Emergency Rescue Procedures?

Self-Rescue Stair Tower Aerial / Scissor lifts Man Basket

Emergency Response Team First Aid Trained Personnel Local Emergency Response

Fall Protection

Were fall protection systems designed by a Qualified Person?

Will the erection areas be properly signed and barricaded?

Are methods in place for securing loose items aloft?All affected employees understand no leaving lift basket without special approval for eachinstance?

Controlling ContractorName Signature Date

Struc. Steel ContractorName Signature Date

Toyota Project Leader Review Name Signature Date

Toyota Construction Safety Review Name Signature Date

109

CSF D-30 Spotter Work Rule Decision Matrix

Revision Number: TCSR 3.0 Revision Date: 4/1/19 MGR

Procedure Name: CSF D-30 Spotter Work Rule Decision Matrix GM

Procedure Number: Effective Date: AGM

TOYOTA Construction Procedure Environmental & Safety Eng. Approvals

Procedure Section: Production Engineering IGN. Date

110

CSF D-35 Toyota Construction Safety Audit Sheet

Contractor Name Audit Date

Location NAMC Department100.00%

No. Question Response Points Received

Point Value Possible Comments

1 Reviewed by workers, signed (JSA) Yes2 Follows Work: Applicable Yes3 Updated: being followed Yes4 Hot Work Requirements Met: issued5 100% tie off in use6 Leading Edges: Identified, protected7 Floor openings: permit issued, followed8 Excavation over 5ft; sloped, benched, shored9 Energy Sources: Identified, isolated, locked out10 Crane Operator Certified: Card checked11 Confined space air quality tested13 Additional Comments for this section:

Section Points 30 30

1 Posted, easy access Yes 1 12 Required documents on control board Yes 1 13 Additional Comments for this section:

Section Points 2 2.0

1 First Aid Kit: Stocked, Eye Wash, Accessible Yes 0.5 0.52 Sanitation: Toilets clean, stocked (portables) 0 03 Noise: Below 85dba, protection used 0 04 Lighting: General, Task Yes 0.3 0.35 Ventilation: Heat, Odors 0 06 Dust Control 0 07 Additional Comments for this section:

Section Points 0.8 0.8

Audit Score

1. Section C - Major

3. Section D - Environment / Site Conditions

2. Section C1 - JSA

TCSR - CSF D-35 Toyota Construction Safety Audit Sheet

MM/DD/YYYY

Shop

30 30

1 Stand: Hard hat, glasses, high vis clothing, boots 0 02 Other: Correct for area, task, department 0 03 Additional Comments for this section:

Section Points 0 0

1 Extinguishers: Sized for task, inspected Yes 1.5 1.52 Flammable Liquids: Controlled, stored properly 0 03 Additional Comments for this section:

Section Points 1.5 1.5

4. Section E - Personal Protective Equipment

5. Section F - Fire Protection

111

1 Proper Barricades: Placement 0 02 Signs: Correct, posted, phone number, red, yellow 0 03 Additional Comments for this section:

Section Points 0 0

1 Mat, Tools, Equipment: Stored properly, neatly stacked Yes 0.5 0.5

2 Trip Hazards: Cords neatly run, areas clean Yes 0.5 0.5

3 Liquids on floor: spill kit available Yes 0.5 0.5

4 Rigging for mat handling correct, stored properly N/A 0 0

5 Additional Comments for this section:

Section Points 1.5 1.5

1 Condition: Handles on, cord not cut 0 02 Guarding: Used, adjusted correctly 0 03 Proper Usage: Correct tool for the job 0 04 Identification on gang boxes, tools, equipment 0 05 Additional Comments for this section:

Section Points 0 0

1 Proper PPE: Non-flammable clothing 0 02 Shields, Barriers: Equipment, area protected 0 03 Gas Equipment: Proper storage, flash arrestors used 0 04 Additional Comments for this section:

Section Points 0 0

1 GFCI Protection: tested Yes 1.5 1.52 Extension Cords: Condition, Protected, Inspected 0 03 Additional Comments for this section:

Section Points 1.5 1.5

1 No missing planking, bracing, guardrails 0 02 Inspected: Tagged, hazards noted 0 03 Falling Object Protection: Toe boards 0 04 Rolling Scaffolds: Wheels locked 0 05 Basket: Floor cleaned, materials loaded properly 0 06 Additional Comments for this section:

Section Points 0 0

7. Section H - Materials / Handling / Storage / SS

6. Section G - Signs, Barricades

9. Section J - Welding, Cutting, and Grinding

10. Section K - Electrical

8. Section I - Tools: Hand and Power

11. Section L - Scaffolds

1 PFAS/PFRS: Inspected, good condition, worn properly 0 02 Proper Anchorage: Clamps, Straps, Lines 0 03 Workers tied off in scissor lifts 0 04 Warning Lines: Used, proper distance 0 05 Roof work: Permitted, weather conditions 0 06 Additional Comments for this section:

Section Points 0 0

12. Section M - Fall Protection

112

1 Daily inspections, equipment identified Yes 0.5 0.52 Safety Devices: Seat belts, lights, alarm 0 03 Operators: Certified, authorized, licensed 0 04 Forklift operated correctly 0 05 Additional Comments for this section:

Section Points 0.5 0.5

1 Over 4 ft: Ladder access, every 25 ft. 0 02 Spoils: Back 3 ft. 0 03 Water Intrusion: Rain, seepage 0 04 Excavation Protected: Equipment, workers 0 05 Additional Comments for this section:

Section Points 0 0

1 Rebar / rods capped, protected Yes 1.5 1.52 Masonry walls supported, limited access zone 0 03 Additional Comments for this section:

Section Points 1.5 1.5

1 Area protected from overhead lifts 0 02 Site specific erection plan in place 0 03 Area will support equipment and load 0 04 Additional Comments for this section:

Section Points 0 0

1 Engineer survey by Competent Person made Yes 1.5 1.52 All Serv: Shut off, capped, disc, removed 0 03 Additional Comments for this section:

Section Points 1.5 1.5

1 Sign In/Out Sheet: Used and correct 0 02 Group LO: Key box used / key inside 0 03 Locks: Labeled, contain required information 0 04 Arc Flash: Proper PPE, workers trained 0 05 Additional Comments for this section:

Section Points 0 0

1 Secured: Used properly, right type for work 0 02 Non-Conductive: No metal side rails 0 03 Good Condition: rungs, rails, bracing 0 04 Additional Comments for this section:

Section Points 0 0

1 Chemicals: Identified, labeled Yes 1 12 Stored Properly: Correct containment Yes 1 13 SDS Sheets: Available, correct Yes 0.5 0.54 Proper PPE being used 0 05 Additional Comments for this section:

Section Points 2.5 2.5

14. Section P - Excavations

13. Section O - Motor Vehicles / Mechanized Equipment

15. Section Q - Concrete and Masonry Construction

16. Section R - Steel Erection, Equipment Placement

17. Section T - Demolition

18. Section V - Power Transmission / Distribution / LO

20. Section Z - Toxic / Hazardous Substances

19. Section X - Ladders

113

1 Crane Inspection: Certifications current 0 02 Rigging: Condition, inspected, rating tag 0 03 Rigger Qualified: Checked 0 04 Signal Person: Qualified, checked 0 05 Additional Comments for this section:

Section Points 0 0

1 Permit / Checklist Posted 0 02 Workers Trained / Rescue notified Yes 3 33 Additional Comments for this section:

Section Points 3 3

Total Score: 100.00% 46 46

21. Section CC - Cranes and Derricks

22. Section A1 - Confined Space

114

D-35 Escalation Matrix

115

116

CSF D-38 Construction Area Sign

117

CSF D-40 Floor Opening Checklist

CSF D-40 Floor Opening Checklist

Date: General Contractor:

Supervisor Name:

Location: Contact Phone #:

Dept.: Plant / TMNA Contact

Column# Contact Number:

Description of Work:

Hazards and Precautions:Fall Protection: Lockout Required: Follow TMNA Lockout ProceduresRespiratory protection Confined Space: Attach Confined Space Entry FormAdditional protective PPE

Y NWill signs and notices be posted at the area of the grating removal?

Will ridged covers be used where the grating was removed?

If no: why?

If using a "solid cover" the wording "Hole" or "Opening" must be stenciled or painted on it.

Will the cover need cleating or secured by tie wire or clips?

Will a barricade be erected prior to the removal of any grating in the area of work?

If no, why:

Type of barricade: rigid signage tape other

Will barricading be constructed of wood (2" X 4" nom) or a material of comparable strength?

Will it have a complete top rail? (no voids), with exception to the designed access point.

Will the access point be protected to prevent accidental entering?

Be of proper height? ( no less than 3', nor more than 3'6" in height)

Be self supporting and capable of withstanding a side load of 200 lbs.?

Have a toe board, with exception to the designed access point?

Removed grating must be:

Set in an area not to cause a tripping hazard or interfere with other work.

Stacked away from the opening , flat, and in a manner to prevent falling into the opening.

Handled wearing the proper hand protection

The area of the removed grating must have enough light, so opening can easily be seen.

P/L, Mgr, Spec, Reviewed: Date:

Construction Safety Reviewed: Date:

The following items must be reviewed prior to removing ANY covering protecting a "below grade" void

No Grating is to be removed from any area (painting, inspection, drainage pit, etc.) without contacting Safety for review.

If the area is left open past the working hours, the area must be secured to prevent any unauthorized entry.

Toyota Safety Reviewed:

118

CSF D-42 Demolition Checklist

CSF D-42 Demolition Checklist

Date: General Contractor:

Work Scheduled: Supervisor Name:

Location: Contact Phone #:

Dept.: P/L Name:

Area Contact Number:

Description of Work:

Utilities: Check the utilities that require removing/termination

Location (panel #, bus #, column #, etc.)1 Natural Gas2 Propane3 Oxygen4 Compressed Air5 Water6 Coolant7 Electrical (high V)8 Electrical (low V)9 Ventilation

10 Hydraulic11 Data Lines12 Communication13 Fire (sprinkler)14 Fire (data)15 Chemical16 Gas (other)17 Other18 Other

Equipment/fixtures:Y N

19 Will equipment be removed or re-located? (robots, conveyors, crane, etc.)20 Will the equipment require dis-assembly prior to removal/moving?21 Will fixtures/ walls be removed or re-located? (stairways, modular office, mezzanine, etc.)22 Will removal of utilities require removal of #19 or #21 above first?23 Will removal of #19 or #21 above require large equipment?24 Will work be performed during production hours?

Structure:

25 Has the demolition of any structure been reviewed by an engineer?26 Will the demolition of any structure require special permitting? (state, local, environmental)27 Will any demolition of the structure require shoring/bracing?28 Will any temporary support(s) require engineering design?

Documentation: Check any documentation/permitting required for this work

29 Hot Work (provided by host facility)30 Confined Space (contractor supplied)31 Excavation (attach CSF D-02)32 Critical lifting (attach CSF D-26) 33 Environmental (check with host location)34 Facility required What:35 State/local required What:

Toyota Construction Safety Review: Signature: Date:

The following items must be reviewed prior to demolition starting

P/LContractor

119

Site Control Board

1. Emergency Planning 2. Project Site Layout 3. Project Schedule 4. Site Accident Statistics 5. Contractor Org Chart 6. Safety Calendar 7. Weekend Work 8. Daily Audits 9. Safety Meeting Minutes

10. TMNA Org Chart 11. Housekeeping Plan 12. Job Safety Analysis 13. Toyota Safety/Security Contacts 14. Toyota Audit Results 15. Applicable Safety Data Sheets 16. Weekly Toolbox Talks/Safety Flashes 17. Miscellaneous Information 18. Miscellaneous Information

120

Construction versus Maintenance Construction Activities

• Erection of Scaffolds • Building Erection/Demolition/Decommissioning • Excavation/Earth Moving • Steel Erection/Demolition • Overhead Rail System Installation • Concrete/Masonry • Power Transmission/ Distribution • Power Cable Routing and Termination to Machine Disconnect • Equipment Relocation/ Installation/ Demolition/ Decommissioning • Piping up to the Equipment Main Valve • Overhead Work in Lifts • Heavy Equipment Operation – Cranes, Versa-Lifts • Duct/HVAC Ventilation Work

Maintenance Activities

• Removal/Attachment of Machine/Robot components. o Tooling Subassemblies o Air Cylinders o Slide Units o Light Curtains

• Internal machine wiring and hosing of newly added machine components • Logic Programming

o Debugging o I/O Confirmation o Automatic Running Confirmation

• Adjustment / Tuning of machine components • Robot End-of-Arm Tooling Modification

o Removal/Attachment o Wiring / Piping

• Robot Teaching / Programming

121

Section D- Environment/Site Conditions Heat Illness Symptoms

Follow Local NAMC Emergency Procedures

122

Section P Excavations- Sloping, Shoring Examples

Slope Configurations

(All slopes stated below are in the horizontal to vertical ratio) Excavations made in Type A soil.

1. All simple slope excavation 20 feet or less in depth shall have a maximum allowable slope of ¾:1.

SIMPLE SLOPE -- GENERAL

Exception: Simple slope excavations which are open 24 hours or less (short term) and which are 12 feet or less in depth shall have a maximum allowable slope of ½:1.

SIMPLE SLOPE -- SHORT TERM

2. All benched excavations 20 feet or less in depth shall have a maximum allowable slope of 3/4 to 1 and maximum bench dimensions as follows:

123

SIMPLE BENCH

MULTIPLE BENCH

3. All excavations 8 feet or less in depth which have unsupported vertically sided lower portions shall have a maximum vertical side of 3½ feet.

UNSUPPORTED VERTICALLY SIDED LOWER PORTION -- MAXIMUM 8 FEET IN DEPTH)

All excavations more than 8 feet but not more than 12 feet in depth with unsupported vertically sided lower portions shall have a maximum allowable slope of 1:1 and a maximum vertical side of 3½ feet.

124

UNSUPPORTED VERTICALLY SIDED LOWER PORTION -- MAXIMUM 12 FEET IN DEPTH)

All excavations 20 feet or less in depth which have vertically sided lower portions that are supported or shielded shall have a maximum allowable slope of ¾:1. The support or shield system must extend at least 18 inches above the top of the vertical side.

SUPPORTED OR SHIELDED VERTICALLY SIDED LOWER PORTION

4. All other simple slope, compound slope, and vertically sided lower portion excavations shall be in accordance with the other options permitted under § 1926.652(b). Excavations Made in Type B Soil

1. All simple slope excavations 20 feet or less in depth shall have a maximum allowable slope of 1:1.

SIMPLE SLOPE

2. All benched excavations 20 feet or less in depth shall have a maximum allowable slope of 1:1 and maximum bench dimensions as follows:

125

SINGLE BENCH

MULTIPLE BENCH

3. All excavations 20 feet or less in depth which have vertically sided lower portions shall be shielded or supported to a height at least 18 inches above the top of the vertical side. All such excavations shall have a maximum allowable slope of 1:1.

VERTICALLY SIDED LOWER PORTION

4. All other sloped excavations shall be in accordance with the other options permitted in § 1926.652(b).

126

Excavations Made in Type C Soil

1. All simple slope excavations 20 feet or less in depth shall have a maximum allowable slope of 1½:1.

SIMPLE SLOPE

2. All excavations 20 feet or less in depth which have vertically sided lower portions shall be shielded or supported to a height at least 18 inches above the top of the vertical side. All such excavations shall have a maximum allowable slope of 1½:1.

VERTICAL SIDED LOWER PORTION

3. All other sloped excavations shall be in accordance with the other options permitted in § 1926.652(b). Excavations Made in Layered Soils

1. All excavations 20 feet or less in depth made in layered soils shall have a maximum allowable slope for each layer as set forth below.

127

B OVER A

C OVER A

C OVER B

A OVER B

128

A OVER C

B OVER C

2. All other sloped excavations shall be in accordance with the other options permitted in § 1926.652(b).

129

Section X- Stairways and Ladders Job Made Wooden Ladder – Single Cleat

130

Scaffold Tags Scaffolding must have a Scaffold Status Tag attached to it at all times.

A competent person employed by the Contractor shall complete and apply this tag.

Red Tag –

No access allowed. Scaffold is being erected or dismantled, or a major safety defect has been found.

Yellow Tag – Scaffold does not meet all Federal, State/Provincial and Local requirements. Access requires Personal fall protection to be used at all times.

Green Tag –

Scaffold meets all Federal, State/Provincial and Local requirements, and is safe to use.

131

Section K- Electrical Monthly Inspection Tape Color Chart

Month Color

January White

February Yellow

March Red

April Blue

May Green

June Orange

July White

August Yellow

September Red

October Blue

November Green

December Orange

132

Section R-Steel Erection Steel Erection Kanban See www.ToyotaSupplier.com for latest structural steel erection forms.

133

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135

Section M- Fall Protection Recommended Wind Speeds for Roofing Operations Recommended Wind Speeds for Roofing Operations All speeds listed in mph. All tasks will be evaluated for crane operations, material

handling, and roof access to determine if/when work should be stopped.

136

Section X- Stairways and Ladders Daily Ladder Inspection Sticker Template

137

Revision History Revision Section Changes Date 2005-1 Original Mar, 2005 2006-1 All Change all TMMNA to TMNA, TMMC to NAMC May 2006

Modified the Commissioning Section 2007-2 Section 2 Added several required definitions and moved definitions Mar, 2007

(were previously in an Appendix – moved to integrate as part of document text)

2009-1 All Changed name from “TMNA Construction Safety Oct, 2009 Management Handbook” to “TMNA Construction Safety Requirements” Changed many “should” requirements to “must”

2009-1.3 Annex E TMNA PE JSA guideline document added July 2011 2013-1 All Re-organized, re-written, added and deleted text, information forwarded May 2013

to appendix, new appendix documentation 2015-2 All Re-organized, re-written, added and deleted text, information forwarded Sep 2015 to appendix, new appendix documentation 2016-2.01 Intro Clarification to required drug testing letter from Bill Horsford added Jan 2016 2019 All Re-organized, re-written, added and deleted text, information forwarded Aug 2019 to appendix, new appendix documentation 2020-3.1 CC Revised lifting requirements and D-26 Form July 2020

138

Toyota PE Safety Engineering

Job Safety Analysis (JSA)

Guidelines

(For Construction,

Equipment Installation,

& Decommissioning Projects) August 1st, 2018

139

Toyota believes the Job Safety Analysis (JSA) process is a critical component to a successful safety plan. We expect contractors, vendors, and suppliers who provide services to Toyota to embrace the JSA process. To enhance understanding and improve communication with our business partners, the following document was created as a tool for Toyota Production Engineering to reference when construction or machine installation work is conducted by TMNA at a NAMC or other location.

NOTE: This information is intended to provide guidance to Toyota PE regarding the Toyota JSA requirements as contained in the Toyota Construction Safety Requirements document. This document should be referenced when confirming contractors’ adherence to the Toyota PE JSA process and content requirements. In addition, the concepts and process discussed in this document should apply to construction and equipment installation projects performed by Toyota PE members.

Introduction

This document will provide answers and direction in the following areas as it relates to JSA’s:

• What is a JSA? • When is a JSA required? • What are the roles & responsibilities associated with the JSA process? • Who should create the JSA? • What are the three (3) key elements of a JSA? • What is the review process for a JSA? • How should a JSA be applied in the field?

What is a JSA?

A Job Safety Analysis (JSA) is a proactive technique that, at the job task level, identifies potential hazards and how they will be controlled. The process requires contractors to identify, document, and communicate potential hazards, and the steps to eliminate or reduce that risk to an acceptable level.

The JSA shall be formally documented in writing. The Toyota PE Construction Safety Requirements document provides a JSA template that may be used by contractors. Contractors may use their own form provided it contains, at a minimum the following fields:

1. Company Name. 2. Date JSA was completed. 3. Name of task/job/activity. 4. Steps to complete the task in sequential order. 5. Potential hazards associated with each step of the task. 6. The countermeasures or preventive action associated with each hazard.

140

The contents of the written document shall be reviewed with all affected workers prior to the initial start of the job and on each subsequent day work is performed on that job. It is important to remember affected workers may include workers on other jobs or from other companies who are working in the area. (The review process will be covered in more detail in a subsequent section).

The JSA process begins in the planning phase and is utilized by those responsible for determining how a job will be performed. The JSA should prompt strong planning of tasks and should begin to outline known hazards associated with the type of work to be performed. This outline is then refined once at the jobsite to include local hazards such as the proximity of other workers, site traffic, and other site specific conditions.

When is a JSA required?

The JSA process is a key risk mitigation tool that shall be implemented on all Toyota PE projects. The Toyota Construction Safety Requirements document requires contractors to complete a JSA for all construction and machine installation activities/tasks they are contracted to perform or that arise as a consequence of fulfilling those contractual obligations.

Every construction or machine installation task that is planned to be performed or that arises out of additional requests or unforeseen circumstances must have a JSA. The level of detail included in the JSA should be commensurate with the level of risk. Simple sub tasks may be included or added into a broader scoped JSA.

What are the roles and responsibilities associated with the JSA process?

The JSA process is primarily the responsibility of the contractor. The planning and execution of process steps rest solely with the contractor. Toyota Production Engineering’s role includes, but is not limited to:

1. Confirming the contractors understand the JSA process, and; 2. Reviewing JSA’s to confirm Toyota PE clearly understands the contractor’s tasks, potential

hazards, and countermeasures.

The job shall not commence until the applicable JSA has been reviewed by Toyota Project Management Group Designee(s) AND Toyota PE Safety Representative(s). All questions regarding the steps, potential hazards, and countermeasures must be addressed to the satisfaction of both these groups before the contractor shall allow work to begin on the job.

The roles and responsibilities of each respective area are provided in TABLE 1.

141

Table 1

Section Responsibility Toyota PE Project Department Leads

1 Understand the JSA process. 2 Ensure contractors understand the JSA requirements/expectations when bidding work. 2 Provide time for JSA training.

Toyota Project Management Group (PMG) Organization or Designee* (e.g., Project Engineers) (*These are Toyota PE resources that are dispatched, assigned, or located at the project location.)

1 Confirm contractor understanding of JSA requirements. 2 Review all JSAs prior to beginning of job to a) confirm understanding of job steps in the required work scope, and; b) risk countermeasures are commensurate with the potential hazards listed on each step. 3 Confirm execution of JSA as part of periodic site tours.

Toyota PE Safety Department 1 Serve as Subject Matter Expert for JSA process. 2 Set criteria for JSA completion and quality. 3 Train PE team members as needed. 4 Review JSA Audit findings 5 Resolve JSA questions/issues.

Toyota PE Site Construction Safety Team (or designee)

1 Serve as Subject Matter Experts for JSA process. 2 Train PE members as needed. 3 Review all JSAs prior to beginning of job to confirm risk countermeasures are commensurate with the potential hazards listed on each step. 4 Coach Toyota PE and Contractors if JSA quality is substandard.

General Contractor 1 Understand contractual obligations as they relate to the JSA process. 2 Create thorough JSAs for all tasks as identified in the Toyota Construction Safety Requirements document. 3 Ensure JSAs include all critical steps of the job process in sequential order. 4 Submit JSAs in a timely manner to allow proper review. 5 Confirms Toyota appropriate Toyota review conducted before beginning of work. 6 Effectively communicate to workers prior to start of work & obtain signatures on JSA. 7 Confirm execution of JSAs in the field as work progresses. 8 Modify JSAs in the field immediately if conditions/tasks/risks should change & communicate updates to affected workers.

142

Who should create the JSA?

It is very important to involve employees of all disciplines and levels in the JSA process; Supervisors, Foremen, Laborers, Technicians, Safety, etc. They all can contribute in providing a practical understanding of the job which is invaluable in identifying potential hazards. This practical knowledge will help minimize oversights, improve quality of the analysis, and get all workers to “buy in” to the process of identifying hazards and the countermeasures associated with their work.

What are the key elements of a JSA?

There are three (3) elements essential to creating a quality JSA:

1. Identify each individual step or sub-task of the job. 2. Identify workplace hazards associated with each step or sub-task. 3. Determine suitable and sufficient control measures which address identified

hazards.

Let’s examine each one in more detail.

1 - Identify each individual step or sub-task of the job.

Every job can be broken down into sub tasks or steps. Starting from the project plan, break down each job into the sequential steps required to complete it (components or sub tasks). It may be helpful to get input from workers who have performed the same job before in fully understanding the detailed steps and job sequence.

2 - Identify workplace hazards associated with each step or sub-task.

Using the breakdown of sequential tasks or steps, the job hazard analysis is now an exercise in detective work. The goal is to foresee;

• What could go wrong? • How could a potential hazard arise? • What contributing factors exist (not immediately related to the task at hand)?

The best way to identify workplace hazards is to walk the worksite in advance. Look for hazards that are directly associated with the task that will be conducted as well as hazards not directly related to the target task. From trip/fall hazards to overhead power lines, all potential hazards must be identified.

143

3 - Determine suitable and sufficient control measures which address identified hazards.

After reviewing this list of hazards, consider what control methods will eliminate or reduce them to an acceptable level. When developing any JSA, the Hierarchy of Risk Control (from most to least effective) should be referenced regularly. (See below)

1. Can the hazard be eliminated? Ask if the step is truly necessary to accomplish the task. If #1 is not practical,

2. Can a substitution be put in place? For example: replace a manual task with equipment that eliminates the exposure. If #2 is not practical,

3. Can workers be isolated from the hazard? For example: moving the work to an off shift if excessive noise or atmospheric hazards may be introduced by a process. If #3 is not practical,

4. Can engineering controls be put in place? For example: Can ventilation be provided to decrease heat, remove atmospheric hazards, etc. If #4 is not practical,

5. Can administrative controls be put in place? For example: Move work to off shift if 2 contractors need to work in the same space. Shift workers to off shift on extremely hot days. If #5 is not practical,

6. Provide appropriate PPE until better controls are available.

See appendix 1 for an example of a completed JSA.

What is the review process for a JSA before it is finalized and shared with the work crew?

All JSAs created by contractors must be reviewed by the Toyota PMG designee responsible for the work. The Toyota PMG designee is responsible to ensure the contractor has adequately considered the key steps associated with the contracted task, associated hazards, and controls. After the Toyota PMG review, Toyota Safety or their designee will also review the JSA for content and risk control measures. The work shall not commence prior to review of the JSA by Toyota PE Project Lead (or designee) and Toyota Site Construction Safety (or designee).

Periodically, Toyota will conduct field JSA audits to confirm correct application at the jobsite.

Key items covered during the field audit are:

• JSA document is present at the jobsite. • JSA is applicable to work being performed. • JSA has been reviewed by workers. • JSA is signed off by workers • JSA is being followed by the workers.

Figure 1 provides a flow chart for the JSA initiation, development and review process.

How should the JSA be applied in the field?

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The JSA process is only effective if, prior to work starting, it is reviewed on a daily basis with all affected workers and followed throughout the day’s activity. In addition, the JSA should always be considered a living document at the job site. If conditions change, or the task must be modified, it is required that the JSA is modified in the field to reflect the changes. Changes to the JSA should be documented in pen by the supervisor and communicated to the affected workers. The affected workers should write their initial and date on the modified JSA next to where they originally signed the JSA to document they are aware of the changes. It is expected that key items included in the audit will be exercised at all times during the course or the work.

If an injury occurs on a specific job, the JSA must be reviewed to determine the failure point in the process. If a hazard was not appropriately identified and/or a countermeasure listed on the JSA was insufficient, the JSA must be updated to address the failure point(s) prior to work restarts and all affected workers must initial and date the JSA. If an employee’s failure to follow proper job procedures results in a “close call” or “near miss”, discuss the situation with all employees who perform the job and remind them of proper procedures. Any time a JSA is revised, it is important to train all employees affected by the changes in the new job methods, procedures, or protective measures adopted and have them initial and date the updated JSA.

Appendix 2 identifies some key tasks and risks that should be considered when developing a JSA. It is by no means a complete list of all items that should be covered, but serves as a guide to reference when creating a JSA.

Summary

The JSA process outlined in this document is a PROACTIVE technique to protect workers on Toyota projects. It is a straightforward process designed to eliminate risk (where practicable) or reduce the risk to an acceptable level. The expectation is for Toyota PE to reinforce the use of the JSA process for Toyota-led construction, equipment installation, and decommissioning projects.

If you have any questions on the JSA process, please contact TMNA PE Safety Engineering.

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Work Rule Process Flow Chart

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146

147

Basic Concept:Provide safe method to maneuver construction equipment on work site.

Aerial Lifts / Elevated Work Platforms:

Forklifts:

Cranes:

Civil Equipment ( Loaders, Bulldozer, Skid Steer, etc. )

Flags and Signs:

Construction: Dedicated Spotter Requirements for Use of Dedicated Spotter

• Dedicated walking spotter is required any time an aerial lift is moving.• All overhead work requires use of dedicated spotter AND red danger tape to identify the hazard below. • Prior to movement, Spotter must give confirmation to the operator it is safe to move.

• Dedicated spotter is required anytime forklift has a load or is using attachments (Jib crane, fork extensions, etc).• Dedicated spotter is required anytime forklift operates outside of a designated construction area.• When 2 or more pieces of mobile equipment of any type are moving inside a designated construction area, a dedicated

spotter is required for each type of equipment. (Loaded or Unloaded).• Prior to movement, Spotter must give confirmation to the operator it is safe to move. • Only exception is if there is only one forklift with no load and no other mobile equipment present.

Dedicated Spotter:

• Dedicated spotter is required when crane is in operation within designated construction area. (All movement: swing, lift, lower, traveling).

• Escort vehicle with flashing lights is required when traveling to and from intended work areas on designated roadways.

• Prior to movement, Spotter must give confirmation to the operator it is safe to move.

• Areas with significant construction traffic require traffic control person (equipped with flags or signs) in addition to spotters when accessing established roadways or aisleways.

• A person assigned to observe and alert operator of mobile equipment (through verbal or visual communication).• The spotter must not perform any additional work tasks. • Spotters must remind the operator of safe operation rules ( seatbelt use, tie off in aerial lift, etc)• Spotters are to be designated by carrying a red or orange flag.

• Dedicated spotter is required for loaders, bulldozers, skid steer, and other civil equipment operating outside of designated construction area.

• No pedestrian access is permitted in designated construction areas where civil equipment is in operation UNLESS the person is completing a specific task documented on the JSA.

• A dedicated spotter is required for all commercial vehicles when inside interior areas of buildings.

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149

150

Work Rule

CONSTRUCTION SAFETY

Visualization of Construction Contractors

***IMPLEMENTATION DATE 7/14/18***

FIRE WATCH

BLACK HARD HATor 3" BLACK STRIPE (all around)

PURPOSE: Visualize Team Members assigned to observe and control safety of hot work

activity

CONSTRUCTION APPRENTICE, NEW HIRE, TRAINEE etc.

PURPOSE: Visualize New Team Members to ensure appropriate care for their safety and

well-being

Safety Representative -WHITE HARD HAT/GREEN SAFETY CROSS both sides

or 3' green stripe all around

Fire Watch - RED BONNET over their existing hard hat or 3" red stripe all around

PURPOSE: Visualize Safety Representatives to allow quick identification and access by

workers and other personnel on site

PURPOSE: Visualize key members on Construction Sites to ensure safe work on Toyota work sites

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In summary, remember the following:

Toyota Contractor Safety management is built around the principle of Find It, Fix It, No Repeats.

• Find It – TOYOTA expects our contractors to find safety hazards and behavioral issues by themselves before TOYOTA. This represents that the contractor management and safety representatives have a critical eye for safety. The ability to find and address problems proactively is essential for success at TOYOTA construction sites.

• Fix It – TOYOTA expects our contractors to show the importance of safety through rapid resolution of issues identified on audits or raised by their members. By stopping and addressing safety hazards quickly and communicating with the members, the contractor establishes the expectation that safety is the highest priority.

• No Repeats – Sustained success at TOYOTA requires contractors to demonstrate PLAN-DO-CHECK-ACT, reflect on lessons learned and prevent reoccurrence of safety issues. When safety hazards reoccur, it represents a failure of management to implement effective countermeasures.