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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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Story of a new beryllium worker “Keigo”
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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Story of a new beryllium worker “Keigo”
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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Story of a new beryllium worker “Keigo”
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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Story of a new beryllium worker “Keigo”
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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Story of a new beryllium worker “Keigo”
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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Story of a new beryllium worker “Keigo”
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