contents environmental, industrial safety and … - 2005 corporate social responsibility report...

36 - 2005 Corporate Social Responsibility Report

Contents

Environmental, Industrial Safety and Health Management Environmental, Safety and Health Management System (ESH Management) 37 Equipment and Operation Safety 41 Fire Protection and Emergency Response 43 Occupational Accident Statistics and Analysis 45 Environmental Performance Indicators 46

Others Vocabulary Interpretation 51

2005 Corporate Social Responsibility Report - 37

Environmental, Industrial Safety and Health Management

Environmental, Safety and Health Management System(ESH Management)

ESH Management StructureUMC was verified for its integrated environmental and occupational safety and health management system in 2001. Since then, an annual audit is performed on UMC from the verifier to ensure the integrity of the system. To achieve the best performance in ESH management, GRM&ESH Division is responsible for planning the company’s policy and strategies for risk management. Moreover, GRM&ESH Division introduces effective systems and provides safety and health expertise to build a safe, healthy and nature-friendly environment. An ESH management committee is formed in each fab to discuss self-managed items. In addition, a company-wide industrial safety meeting is held quarterly and attended by high-level executives. This quarterly meeting is held to discuss issues that include ESH operation, international ESH trends and execution suggestions. This meeting also is held to periodically review the results and performance of the company’s ESH operations. With the participation and support of high-level executives, UMC builds a top-down, communication-effective environmental safety and health system.

ESH Initial ReviewTo reduce the impact on the environment and to lower safety and health risks, UMC has established a comprehensive initial review procedure to evaluate all environmental, safety and health risks on the company’s activities and to prioritize further improvement in high-risk areas.

To keep the information updated, UMC conducts an initial review prior to process alteration or new task implementation and periodical review every three years. The results of the initial and periodical review must then be signed-off by the employees in charge of the EMS & OHSAS management system and their supervisors to ensure the usability and accuracy.

In addition, UMC takes into consideration all government ESH regulations to make sure they are followed during related operations. GRM&ESH Division also collects related new and modified regulations every month and distributes the information to each fab. For company policies or operations that don’t follow government regulations, GRM&ESH Division will work to align these policies and operations according to environmental, safety and health prevention procedures. UMC also reviews the conformity of ESH regulations every three years to make sure they follow government regulations.




To make the ESH initial review documents readily available to employees, UMC has developed the “EMS&OHSAS management system” to store all related documents including ESH initial review documents, government regulations and programs that help attain specific targets. This system serves as the central database for the achievement of ESH objectives.

The company sets annual ESH management objectives and targets according to its environmental, safety and hygiene policy and communicates them to each fab. Each fab is expected to achieve its objective accordingly and promote various programs within the fab to reach its target.

ESH Communication UMC’s ESH communications can be divided in internal and external units as follows:1. External communication UMC pays close attention to its corporate responsibilities for environmental safety and health, and makes every effort to reduce pollution and protect employees’ health. In addition, UMC has actively promoted its annual environmental reports since 2000 and posted them on the company’s public website since 2003. UMC has also set up a communication channel for all customers, related government agencies, local residents and other groups to gather their feedback and suggestions. 2.Internal communication UMC promotes “Safety is My Responsibility” and encourages our employees to actively propose suggestions and questions related to environment, safety and health. In addition to general communication channels, UMC also has other assistant systems as follows: (1) Improvement proposal system Improvement proposals initiated by UMC employees regarding environmental safety and health are forwarded to related departments for approval and implementation. It is more effective to make procedures and facilities improvements through employee brainstorming rather than only by GRM&ESH staff’s regular inspection. (2)ESH mailbox UMC has established an ESH mailbox on the front page of UMC’s intranet site that lets UMC employees ask questions related to environment, safety and health. Each employee inquiry will be processed efficiently and effectively in order to address the issues involved. This mailbox not only facilitates UMC employees’ willingness to participate in environmental, safety and health activities, but also serves as a portion of individual training of environmental safety and health. (3)ESH forum This forum provides employees with information regarding industrial safety and serves as an information exchange and discussion board for daily operation and environment, safety and health.


This resource ensures that every employee and every unit receives correct information, and further leverages effective communication channels as an aid to promote environment, safety and health.

ESH Inspection, Correction and Prevention To ensure the normal execution of environmental, safety and health affairs, UMC arranges both scheduled and spot inspections, including: 1. EM Inspection UMC executives and managers conduct environmental, safety and health inspections in each fab semi-annually. These inspections also demonstrate executives’ and managers’ emphasis on environmental protection, safety and health. 2. ESH Inspection ESH Inspection is led by the UMC fire brigade; an inspection theme is chosen each month, and is conducted by GRM&ESH staff in each fab. 3. EMS&OHSAS Internal Inspection EMS&OHSAS internal inspection is conducted semi-annually by trained inspectors in each fab to ensure the proper operation of the system. 4. Annual EMS&OHSAS External Inspection An external inspection is conducted annually by third-party verifiers in each fab. In addition to ensuring that operations follow standard operating procedure, this inspection also helps to gain third-party suggestions for improvement on the ESH management.




聯聯聯聯ISO14001聯聯聯聯聯聯OHSAS18001聯聯

Furthermore, each fab will arrange scheduled and spot ESH and supervisor checks to evaluate daily operations and promote specific themes. Employees also need to perform regular checks for their responsible areas, and are required to report any problems found so they may be addressed.

Any deficiency found during the inspection is recorded and categorized in the ESH audit system by the head inspectors. These deficiencies will then be transferred to the responsible departments, which determines the cause, corrective and preventive actions and expected finished date. The system will automatically notify the responsible person on the expected date, and the case will not be closed unless GRM&ESH staff confirms that all improvements have been made.





Equipment and Operation Safety

Equipment Safety ManagementUMC’s Equipment safety management begins by requiring that UMC’s vendors propose a third-party SEMI S2-2000 report and improvement plan during equipment procurement. Or, vendors may also fill in self-evaluation forms and self-improvement plans provided by UMC instead. After the company’s assessment, equipment engineers and GRM&ESH staff will evaluate the presence of any unacceptable risks, and if any exist, will ask vendors to address.

When moving and positioning equipment in the fabs, UMC conducts many safety control programs, such as finding the best path for transport, moving safety control and equipment unloading direction. UMC employees and vendors who are responsible for moving equipment must wear appropriate personal protective equipment to avoid any injury and accident.

To ensure all equipment strictly follows government regulations, UMC also conducts a three-stage equipment sign-off program for equipment installation. The first stage is to test if the equipment is functioning as designed. The second stage includes checking built-in fire control mechanisms protection tools, and the completion of various protective equipment installations and labels. The final stage includes verifying the readiness of its standard operating procedure, the completion of the training programs for those who operate it, and if deficiencies found in the previous two stages have been corrected. Equipment will not be released unless it passes all three stages of the equipment sign-off program.

For equipment that operates normally, UMC conducts regular infrared thermal image temperature examinations in addition to normal maintenance and inspections. Reports need to be logged and tracked whenever an abnormality is found.



Job Safety Observation and AnalysisIn addition to conducting safety control on equipment, UMC also requires proper training for the employees who operate them Task items listed below must strictly follow standard operating procedure and be included in GRM&ESH’s observation plans:● Tasks with higher frequency of injury ● Tasks that carry a risk of severe of injury● Tasks with significant potential risk● Temporary or irregular tasks ● New tasks ● Regular tasks● Tasks with a history of accidents

Each operating department is required to assign an observer in conjunction with the GRM&ESH staff to observe and record minutes down the final results. Improvements will be made based on these results, including operating procedure review, training and equipment. The results of the improvement will be recorded in the database of “Job Safety Analysis and Observation System” for further reference when conducting future improvement or department training.

Measurement of Work Environment UMC conducts a semi-annual measurement of its working environment. In addition to sampling the work environment, UMC also samples individual operators for workers exposed under similar circumstances. Samples are then analyzed and examined, and relative preventive measures and operation control is taken accordingly. This procedure ensures the efficiency of equipment management and ensures that the hazard potential in the workplace is lower than the government’s regulations. Furthermore, it also prevents excessive exposure to potentially hazardous situations by UMC employees.

Process Alteration ManagementIn addition to equipment safety management, UMC also pays significant attention to changes in chemical use, process equipment and fab facilities. An alteration application must be filed according to company regulation before any adjustments are made. Changes will not be put into practice unless it is evaluated and is confirmed by on-site engineers and the GRM&ESH staff that there will be no hazard to either work safety or the environment.

Equipment and Operation Safety



UMC pays special attention to its emergency response plan and preparation, since fire response procedures for UMC fabs differ from that of traditional fires due to the unique properties found in the semiconductor fab that include complex gas and water piping, chemical transmission, and the airtight environment of the cleanroom.

Establishment of UMC Fire Brigade UMC established a hi-tech Fire Brigade in April 1994, becoming the only electronics company in Taiwan with its own fire department. The Fire Brigade is operated under the GRM&ESH Division and has 118 members, 10 full-time employees and 108 voluntary firefighters. Several staff members graduated with master degrees, complementing the highest quality rescue team in Taiwan.

The team members consist of individuals from ESH Department, Facility Engineering Department, Equipment Resource Department, and other areas of UMC. Over 40% of the voluntary firefighters are from Equipment Resource Department. Voluntary firefighters not only dedicate themselves to their normal daily work, but are also able to rapidly mobilize into action during emergencies. Their training is based on 88 hours of professional rescue training upon entry, followed by scheduled monthly training to ensure their rescue skills and safety knowledge remains sharp.

UMC Fire Brigade is acclaimed for both its equipment and experience in Taiwan. The team is equipped with thermal vision helmets so that firefighters can rapidly search for and extinguish sources of fire in smoked-filled environments. Moreover, the internally invented and nationally patented portable water mist system can be easily transported through

Fire Protection and Emergency Response

Fourth Rally of the UMC Fire Brigade

Advanced Rescue Equipment in Hi-tech Factories



cleanrooms and High-Risk areas. This unique firefighting tool is also environmentally friendly as it is non-polluting and uses water conservatively. UMC also operates a high performance chemical firefighting truck that is equipped with state-of-the-art equipment that allows it to become a command station on location. UMC’s Fire Brigade has other advanced equipment such as high temperature chemical protection suits, personal alarm safety systems, flame detectors, Emergency Response Containment Vessels (ERCV), sealing equipment for liquid chemical leaks, etc.

Emergency Response and DrillsUMC schedules several regular internal firefighting trainings, fire drills, and evacuation drills to ensure all employees have basic fire safety and emergency response skills. For example, each of UMC’s 12,000 employees undergoes a 2 to 4 hour training program. For each fab, regular training is also held for ERT members to familiarize them with the response flows and rescue equipment. Other areas covered include specific duties such as commander training, rescue team training, logistic team training, and announcement control team training. The scope of the drill covers firefighting, chemical disasters and gas leaks.

In addition to the internal training program, UMC Fire Brigade provides rescue support and disaster drill support for other local corporations. UMC has so far provided firefighting and rescue assistance for Taiwan Power Company Lon-Song Substation, WSMC, XAC Automation Corp., Powerchip Semiconductor Corp., Fu-Guo Chemical, Motech and UTA. UMC Fire Brigade members attend advanced firefighting programs in the United States, Austria, and Singapore in order to learn about new chemicals, special industrial gases and firefighting techniques for cleanroom environments. UMC also aligns with local Fire Bureaus for training and equipment to help reach its goal of zero incidents and safety enhancement for the society as a whole.

Fire Protection and Emergency Response

Various Fire Drills and Emergency Response Training

UMC Fire Brigade Participates in Various Rescue Training



Disabling Injury Frequency Rate(F.R.)

0

0.5

1

1.5

2

2.5

2003 2004 2005 years

Electronic Industry

Taiwan ManufacturingIndustryUMC

0

50

100

150

200

2003 2004 2005 years

UMC

Disabling Injury Severity Rate (S.R.)

Taiwan ManufacturingIndustryElectronic Industry

Occupational Accident Statistics and Analysis

The safety of UMC’s employees is a top concern for the company. Therefore, UMC aggressively promotes Safety and Hygiene management in all fabs and sets up occupational accident prevention program annually, efforts that have resulted in a significant decrease in occupational accidents in recent years. The severity level of accidents has decreased as well. Currently, UMC has shifted its focus to the prevention of accidents due to human negligence, instead of the enhancement of equipment safety. UMC’s notable statistics on occupational accidents in the past three years:

The statistics show that UMC’s Disabling Injury Frequency Rate and Disabling Injury Severity Rate are far lower than the industry average. In the future, UMC will continue its occupational accident prevention work by implementing work safety management through risk analysis and engineering improving. Furthermore, UMC will continue to lower its occurrence of occupational accidents by emphasizing the importance of work safety.

(1) Disabling injury Frequency Rate (disabling accident times×106/total working hours)

(2) Disabling injury Severity Rate (total loss working days×106/total working hours)



EPIs 2005

Energy & Resource Savings

*Power Consumption, KWH/cm2

*Tap-water Consumption, L/cm2

*Total Water Recycling Ratio, %*Water Recycling Ratio for Manufacturing Process, %

1.6110.2

64.8%85.0%

Waste Water Pollutant Reduction

*Fluoride Control in Plant, ppm Regulated 15ppm 7.0

Air Emission Pollutant Reduction

*Volat i le Organic Compound Removal Efficiency, % Regulated Greater than 90%

96%

Waste Management

*Total Ratio Recycling, g/cm2

*General Waste Recycling Ratio, %*Hazardous Waste Recycling Ratio, %

14.074.1%94.0%

UMC has posted environmental protection information and other performance indicators on its website since 2001. UMC’s Environmental performance indicators in 2005 are listed below.

UMC continues to promote numerous energy and water saving measures. The recycling ratio of UMC’s water consumption for manufacturing processes maintains as high as 85%. UMC’s waste gases and wastewater volume conservation on end-pipe emission is far beyond what the government requires. UMC’s first priority for treating waste is on its recycle/reuse.

UMC’s Environmental Protection Performance in 2005

Environmental Performance Indicators



Energy and Resources Saving UMC’s major energy and resource saving measures in 2005 are:

Major Measures

1. Implement energy saving policies; establish an energy management audit unit and review and revise implementation measures.2. Monthly meetings to review and track energy usage and perform consumption analyses in each fab. 3. Review the rationality of energy usage and draft energy saving plans. 4. Results of energy saving plans and benefits analysis: -Power factor is raised from 0.96 to 0.99 to lower reactive power. - Optimized setting of the air - compressors to reduce operating hours. - Reasonable consumption of VOCs gas to conform to government’s regulations and to avoid excessive combustion. - Review and control air conditioning. - Fab lighting control: unnecessary lights must be turned off. - Tune down the positive pressure in clean rooms.5. Conduct regular equipment maintenance to ensure efficient energy use. 6. Implement energy saving measures and promote energy saving education in all fabs.

Overall Benefits

Unit power consumption throughout the company is1.61 KWH/cm2, and continues to stay at a low level.

Company energy saving promotion website



Air Pollution ControlUMC’s major air pollution control measures in 2005 are:

Major Measures

1. Add more equipment for VOC control. 2. Optimize the operational parameters in control equipment targeting central scrubbers to raise operating efficiency.

Overall Benefits

1.Efficiency rate of handling volatile organic substances maintained at 96.4%.2.Total quantity of hydrocarbon pollutants reduced to 303.48 tons/year.

VOC control equipment





Water Pollution Control UMC’s major water pollution control measures in 2005 are:

Major Measures

1.Wastewater from manufacturing equipment is sorted, recycled and reused; adjust the manufacturing process recipe to maximize water consumption efficiency.

2.Adopt recycled water for secondary water use, such as cooling and cleansing. 3.Expand the cleansing wastewater handling system in local scrubbers to

significantly increase LSR recycled water volume. 4. Use ozone to disinfect within the DI system pipes to reduce water

consumption during flush.5. In DI system, end-pipe rinsing water is recycled and used in the front-end

processes of resin recycling or filtering material cleansing. 6.Adjust 2B3T parameters in DI system to significantly reduce the frequencies

of recycling and chemical consumption. 7.Chemicals used in wastewater handling system such as PAC are replaced

with recycled acidity products to demonstrate UMC’s efforts in resource recycling.

8.Rainwater is recycled and reused to replace tap water for gardening and secondary water use.

Overall Benefits

1. Reduce wastewater discharge to 14,536,794 tons/year, which equals to 2.7 times that of Bao Shan Reservoir

2. Average discharge concentration of F maintained at 7.0ppm

Rainwater recycling and watering system

Wastewater recycling and reuse system



Waste Management Compared to the waste treatment methods in 2004, the changes and improvements made by UMC in waste management in 2005 are as follows:

Major Measures

1. Recycling Waste Hydrofluoric Acid: Waste Hydrofluoric Acid is gathered from separate pipes and outsourced to recycling vendors. Waste Hydrofluoric Acid is then added with calcium carbonate and turned into fluorite, which is used as the material for fluid flux. 2. Reusing waste EBR cleansing solvent Originally waste EBR resulting from coating flushing was treated as waste solvent; now it is gathered from separate pipes and outsourced to recycling vendors and is distilled. Ether and ester resulting from distilled EBR are used in the optronics industry and other industries. 3. Implement the reduction of source waste to lower handling cost.

Overall Benefits

1. Alleviate the loading of wastewater treatment and reduce the volume of waste calcium fluoride sludge.2. Implement resource recycling and reuse.3. Expense in waste treatment in 2005 was reduced by NTD9.6 million compared to 2004.




Others

Vocabulary Interpretation

1. Corporate Social Responsibility, CSR The previous corporate pursuit of self-benefit and benefit to shareholders has gradually shifted towards and altruistic view of benefiting the society and other stakeholders. CSR refers to efforts to improve and benefit the society, the environment and the local economy, as well as creating social harmony and the pursuit of fair-trade.

2. ISO14001 Environmental Management System The Environmental Management System was regulated by the International Organization for Standardization aimed at protecting the earth’s environment through the adoption of environmental management methods.

3. OHSAS18001 Occupational Health and Safety Assessment Series “Occupational Health and Safety Assessment Series: Occupational Health and Safety Management Systems – Specification” is the international standard originally developed by seven large multinational companies. It is the specific basis for corporations to establish their occupational safety and hygiene management system.

4. Failure Mode and Effects Analysis (FMEA) FMEA is used to evaluate possible failure or effects resulting from improper equipment operation. Employing this method can provide different alternatives that will help improve equipment reliability and raise overall process safety.

5. SEMI S2 A safety standard and guide set by Semiconductor Equipment and Materials International, which regulates environmental, health and safety conditions in semiconductor processes. To be specific, SEMI S2 covers many areas such as electricity, machinery, fire fighting, chemistry, radiation and aseismatic designs.

6. High Risk Operations Operations with high potential risk, for example: Operations on the scaffold, Operations with fire, Operations at hanging, Operations s with electricity, Operations in oxygen- deficient places and others


Others


7. Green Supply Chain Suppliers are required to implement environmental protection management, which means environmental protection efforts are included and evaluated in supplier management system. This is to make products more environmental friendly and more competitive in the market. 8. Scrubber Equipment normally used for air pollution control. It intercepts and removes pollutants in the exhaust using water or absorbents. Local scrubbers are mainly installed behind the machines for the purpose of exhaust pre-treatment.

9. Volatile Organic Compounds, VOCs Refers to all organic compounds used in the manufacturing process, but does not include methane, carbon monoxide, carbon dioxide, carbonic acid, carbide, carbonate, ammonium carbonate, etc.

10. Kyoto Protocol Legally bonded document that was approved during COP3 (the third Conference of the Parties) of UNFCCC (United Nations Framework Convention on Climate Change). Kyoto Protocol includes 28 articles, Annex A and Annex B, which aims to control six greenhouse gases (CO2, CH4, N2O, HFCs, PFCs and SF6).

11. Etching operation A step in the manufacturing process where chemicals (wet etching) or plasma (dry etching) remove the area not covered by photoresist on the oxide film of the wafer.

12. CVD Chemical Vapor Deposition

13. Perflourinated Compounds, PFCs Refers to six gases containing fluorine that contribute to the greenhouse effect, including CF4, CHF3, C2F6, C3F8, SF6 and NF3, according to American and Japanese semiconductor associations. They are mainly used in IC manufacturing process stages such as dry etching or chamber cleaning.


14. MMTCE Million Metric Tons Carbon Equivalent. This unit is used to estimate the emission volume of PFCs.

15. Global Warming Potential, GWP This is the indicator used to calculate the impact that specific gases have on the greenhouse effect. For example, The GWP of carbon dioxide is 1. Such calculation depends on the molecule, the life cycle and the concentration in the atmosphere of a specific gas.

16. WEEE Waste Electrical and Electronic Equipment Directive set by the European Union. WEEE aims to minimize the impact of electrical and electronic equipment on the environment during their life times and when they become waste. It encourages and sets criteria for the collection, treatment, recycling and recovery of waste generated by electrical and electronic equipment.

17. RoHS Restriction of the Use of Certain Hazardous Substances in Electrical and Electronic Equipment set by the European Union. Its major objective is to limit the use of certain hazardous substances in electrical and electronic equipment, and to promote resource conservation and final management of waste generated by electrical and electronic equipment. These hazardous substances include Pb, Cd, Hg, Cr+6, PBB, and PBDE.

Others


Much Appreciation to UMC Employee Lisa Chen for Her Contribution of Photos on the Front and Back Covers

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