training program for beryllium workers at ngk (ja experience) · training program for beryllium...

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Training Program for Beryllium Workers at NGK

(JA experience)

28-30 June 2017, ITER Site, France

Keigo NOJIRI

NGK Insulators, ltd

Aichi Japan

Workshop on Beryllium Applications and Health & Safety Aspects for ITER

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Before biginning my presentation,,,

Beryllium is one of hazardous materials.

Some knowledge and precaution are necessary

to work with beryllium.

ITER will need certain quantity of beryllium very

soon.

We need review and discussion for total safety

& health with beryllium,,,

Commented by NOJIRI in 11th IEA International

Workshop on Beryllium Technology, Barcelona, 2013

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ENVIRONMENTAL CONTROL OF BERYLLIUM IN NGK

Today’s presentation

– NGK Insulators, ltd

– NGK’s Beryllium business

– Training Program for Beryllium Workers

• Policy

• Story of a new beryllium worker “Keigo” – 1st day in NGK

– Assigned to the New Metal Division as Beryllium Worker

– 1st day in the New Metal Division

– OJT of operations, Basic operation/Authorised operation

– Periodical training

– Operation chief for specified chemical substance(national qualification)

• Beryllium Environmental Hygiene Management System

– Conclusion

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JapanPoland

Belgium

China

Thailand

Indonesia

South Africa

Australia

Canada

France USA

UK

Germany

South Korea

Production Bases

Sales Offices

Mexico

JapanPoland

Belgium

China

Thailand

Indonesia

South Africa

Australia

Canada

France USA

UK

Germany

South Korea

Production Bases

Sales Offices

Mexico

NGK Insulators, ltd

Consolidated Subsidiaries

17,517

Date of Establishment

May 5, 1919

Sales

435.8 Billion Yen

Number of Employees

As of March 31, 2017

Company Name

NGK INSULATORS, LTD.

58 companies

Main Products CeramicCeramic

ProductsProducts

BusinessBusiness

ElectronicsElectronics

BusinessBusiness

PowerPower

BusinessBusiness

World Network

History of product development

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1919 1958

1976

1998 1996

2002 2002

Insulators Beryllium copper

Haneyceram

Fine filter

AlN heater

Micro actuator

NAS battery

Electricity

network Mobil phone

PC, etc. Automotive

Semi conductor

production Printer City water

Sustainable energy

At the beginning of 20th century,,,

A engineer visited the United States and impressed so much by higher

developed society. He had brought back a small broken piece of Insulator,,,

Beryllium contained products

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NGK’s Beryllium business

New Metal Division Beryllium Copper

Beryllium Metal

Non-beryllium copper alloys

Precision Mold

BeCu

Be-M

Production Volume

(Be base weight)

Beryllium workers work here

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NGK’s Beryllium business

Calcining

Reduction

Melt & Cast

Hot working

Cold working

Machining

Heat treating

Cleaning

Finishing

Be-M Production

Training Program for Beryllium Workers

• Policy

• Story of a new beryllium worker “Keigo”

– 1st day in NGK

– Assigned to the New Metal Division as Beryllium Worker

– 1st day in the New Metal Division

– OJT of operations, Basic operation/Authorised operation

– Periodical training

– Operation chief for specified chemical substance(national

qualification)

• Documents

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“Policy”, “How to control”

No CBD any more !

Sensitisation Chronic Beryllium

Disease

Beryllium exposure

Minimise risk of

sensitisation

Minimise Be

airborne

concentration

Select operators

who aren’t

sensitive

- Maximum automation

(no access to dust/fume source)

- Exhaust Ventilation System

(maximum reducing dust/fume)

- Respiratory Protective Equipment

(direct protection)

- Selection by allergic tendency

- Minimum operation staff

- Exclusion immediate when

sensitisation detected

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Story of a new beryllium worker “Keigo”

1st day in NGK

Examination, Interview,,, Adopted !!!

• Start General education programme

• Medical test

• General test, height, weight, blood pressure, electrocardiography, etc.

• Chest radiography, pulmonary function test, medical examination by doctor

• Be-LTT(beryllium lymphocyte transformation test), Allergy test(typeⅠ)

For everyone

Legal

NGK Autonomous

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Assigned to the New Metal Division as Beryllium Worker because Keigo

passed the medical test

Access strictly

forbidden to Be zone

no

Allergic

tendency

yes

Be operator

candidates

OK

1st medical

check

NG

OK

Periodical

medical check

NG

Be operator

selection

Keigo is here

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1st day in the New Metal Division; in addition to general introductions,,,

Initial education

• What is CBD?

• About the Ordinance on Prevention of Hazards due to Specified

Chemical Substances

• Medical test

• NGK’s internal rule(documents)

• Beryllium Health Management Manual

• Beryllium Environmental Hygiene Manual

• Access permission into the plant

• Working regulation of beryllium workers

• Protection equipment and its using instruction

• How to react to abnormal cases

• How to prepare non-routine work

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OJT of operations, Basic operation/Authorised operation

Start with coach by basic things,,,

• How to entry into the Be Zone --- one way control

• Fit the Protection equipment

Respiratory protection equipment fitting test to be passed

• Support operation to senior workers

Several days later,,,

• Level authorisation test to be passed

Challenge to other authorised job

Increase the job range little by little,,,

Learn many things by QC circle activity

Entry

zone

Be

zone

Exit

zone

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Periodical training

• About the Beryllium Environmental Hygiene Management System

• Understand this year’s actions

• Follow up the initial education

• Respiratory protection equipment fitting test

• End of Year Meeting

• Seminar by Occupational Health Physician

with all member

of division

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Operation chief for specified chemical substance(national qualification)

Several years later,,,

Keigo decided to challenge to get the national qualification of operation

chief for specified chemical substance to become job team leader

foreman manager ,,,

He pays attention to other younger workers for the total security of the

operation and their health.

Training continue and continue,,,

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Operation chief for specified chemical substance(national qualification)

Several years later,,,

Keigo decided to challenge to get the national qualification of operation

chief for specified chemical substance to become job team leader

foreman manager ,,,

He pays attention to other younger workers for the total security of the

operation and their health.

Training continue and continue,,,

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Beryllium Environmental Hygiene Management System

Object

• Prevent health disorders of beryllium workers

• Prevent water & air pollution which cause health disorders of local residents

Policy

• First priority is to secure health of people concerned in the NGK’s Be operation

• Prevent any pollution and keep strictly related laws and agreements with the authorities

• Promote developments & improvements for reducing airborne concentration

• Push recycling & lifetime extension to reduce beryllium waste

• Raise awareness of employees by education & training

• Continue improving by revising periodically the management system

• Set objects & goals and execute actions and revise them

Evaluation of

airborne

environment

Set objects/goals

and actions Education & training

Communication

inside/outside

Be environmental hygiene manual

Documents

28 internal rules incl. Be Environmental Hygiene Education rule

Operation manuals with security and hygiene issue

To be audited by top

management once a year

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Conclusion

• Beryllium environmental hygiene issue is endless improvement

• Education & Training are one of the most important issue

• NGK is also leaning and changing for better management

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NGK Insulators and our Beryllium Activity

Thank you for your attention