final draft toyota construction safety requirements · 8/15/2019 · • decommissioning of...
TRANSCRIPT
Toyota Construction
Safety Requirements Version 3.0
08/15/19
2
Toyota Safety Requirements for
Construction, Equipment Installation,
& Equipment Decommissioning
Version 3.0
2019
August 2019
Toyota Motor
North America
Toyota Production Engineering Safety Engineering
3
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
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
4.8 Heat Illness Prevention 30
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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
11.3 GFCI 39
11.4 Cable/Wire Stripping Safety 40
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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
17.3 Other Equipment/Tools 49
17.4 Masonry Construction 49
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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 – Cranes and Derricks 60
24.1 Requirement 60
24.2 Conditions 60
24.3 General 61
24.4 Operations 61
24.5 Qualifications 61
24.5.1 Hoist Operator 62
24.5.2 Signal Person 62
24.5.3 Riggers 62
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24.5.4 Rigging 62
24.6 Critical Lift 62
24.6.1 Requirements 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.
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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 Cranes and Derricks
24.1 Requirement
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.
A detailed lift/rigging plan shall be required for all crane picks. The lift/rigging plan shall be submitted with
the JSA to the Toyota Project Leader and Toyota Safety for review 2 weeks, no later than 48 hours prior to
the scheduled pick. The plan shall accompany the JSA at the work location and shall be reviewed with all
involved personnel.
24.2 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.
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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.
24.3 General
• 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.
24.4 Operations
For all Critical lifts, the Contractor shall complete a copy of the CSF- D26. All critical lift plans shall be
submitted for review to Toyota Safety two (2) weeks prior to the lift-taking place. 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.
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24.5 Qualifications
24.5.1 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.
24.5.2 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.
24.5.3 Riggers
Contractors shall use only qualified riggers during hoisting activities for assembly and disassembly work.
Additionally, qualified riggers are required whenever workers are within the fall zone and hooking,
unhooking, or guiding a load, or doing the initial connection of a load to a component or structure.
For Critical Lifts, Contractors shall use Certified Riggers. A certified rigger is a person who has passed
stringent written and practical exams related to rigging from an accredited organization. This requirement is
not applicable in Mexico due to lack of certified rigger equivalency. In Mexico, Contractors shall ensure
riggers are qualified.
24.5.4 Rigging
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 and shall be stored in locations that shall not allow any type damage or
deterioration to occur.
24.6 Critical Lifts
24.6.1 Requirements
A lift that meets any of the following criteria shall be considered a critical lift at Toyota:
a. Load greater than 1 ton that is being upended or down-ended AND center of gravity is
moving or unknown.
b. Unbalanced load of 5 tons or greater AND does not have engineered lift points.
c. Lift exceeds 70% of the rated capacity of the crane.
d. Lift being made in poor soil or unknown ground condition.
e. Lift requires the use of more than 1 crane or the use of a crane and an additional
hoisting device.
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Critical Lift Requirements:
a. Completed D26
b. Detailed Lift Plan- Submitted at least 2 weeks in advance of planned lift.
c. JSA Review
d. Certified Rigger or PE Stamp with Qualified Rigger
Routine Lift Requirements:
a. Completed D26
b. Detailed Lift Plan or Detailed Sequential Lift Steps in JSA- Submitted at least 2 weeks in
advance of planned lift.
c. Qualified Rigger
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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 Lift
When 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
lift points
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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
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▪ 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.
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Toyota Safety Requirements for
Construction, Equipment Installation,
& Equipment Decommissioning Version 2019
Appendix
04/01/19
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
CSF D-27 Contractor’s Crane Review 100
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CSF D-29 Steel Erection Plan / Checklist (A-C) 101
CSF D-30 Spotter Work Rule Decision Matrix 108
CSF D-35 Toyota Safety Construction Audit Form 109
Escalation Matrix 113
CSF D-38 Construction Area Sign 115
CSF D-40 Floor Opening Checklist 116
CSF D-42 Demolition Checklist 117
Site Control Board 118
Construction vs. Maintenance Definition 119
Heat Illness Symptoms Diagram 120
Sloping and Benching Examples 121
Job Made Wooden Ladder 128
Scaffold Tags 129
Quarterly/Monthly Inspection Tape Colors 130
Steel Erection Kanban 131
Cutting Tool Standard 133
Recommended Wind Speeds for Roofing Operations 134
Daily Ladder Inspection Sticker Template 135
Revisions 136
JSA Guidelines 137
Work Rule Process Flow Chart 144
Work Rules 145
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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
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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
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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
Environmental & Safety Eng. Approvals
GM
>2.5 2.5 2.0 1.5 1.0 <1.0
Toyota Construction Procedure
DateProcedure Section: IGN.
AGM
MGR.
Production Engineering
CSF D- 02 Excavation Review Form
8/1/18
Effective Date:
Revision Date:TCSR 3.0
Procedure Name:
Procedure Number:
Revision Number:
Date
DateName
Signature
Signature
Name
Name Signature Date
Name Signature Date
73
CSF D-02A Pre-Excavation Plan for GPR Scanning
Pre-
Exca
vatio
n Pl
an
Area
of W
ork:
Ut
ility
Pla
n an
d Ex
cava
tion
Area
Date
:
Utili
ty Id
entif
icatio
nLo
cate
dIm
pact
1Ga
s
2El
ectr
ical
3W
ater
4Co
mm
unica
tions
5Se
wer
6St
orm
7Ot
her
Utili
ty Id
entif
icatio
n M
etho
d:EM
Scan
GPR
- not
use
d du
e to
clay
soil a
nd d
istur
bed
surfa
ce
cond
ition
74
CSF D-02B Example Pre-Excavation Plan for GPR Scanning
Pre-E
xcav
ation
Plan
Area
of W
ork:
CHDY
10 Pi
tUt
ility P
lan an
d Exc
avat
ion A
rea
Date
: Wee
k of 1
0/24
Utilit
y Ide
ntific
ation Lo
cate
dIm
pact
1Ga
sO
Impa
cted
2Ele
ctrica
lO
No im
pact
3W
ater
ONo
impa
ct
4Co
mm
unica
tions
ONo
impa
ct
5Se
wer
ONo
impa
ct
6St
orm
ONo
impa
ct
7Ot
her
N/A
N/A
Utilit
y Ide
ntific
ation
Met
hod:
EM Sc
anGP
R - no
t use
d due
to cl
ay so
il and
distu
rbed
surfa
ce
cond
ition
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:
Revision Number: TCSR 3.0 Revision Date: 8/1/18 MGR.
Procedure Name: CSF D- 06 Weekly Toolbox Talk Record GM
Procedure Number: Effective Date: AGM
Toyota Construction Procedure Environmental & Safety Eng. Approvals
Procedure Section: Production Engineering IGN. Date
80
CSF D-07 (Sample) Verify with Toyota Construction Safety for correct form used at current NAMC
81
CSF D-08 Emergency Contact List
CS
F D
-08
Em
erg
en
cy C
on
tact
Nu
mb
ers
Co
mp
an
y N
am
e
Na
me
(ple
ase
pri
nt)
To
yo
ta C
on
str
uc
tio
n P
roc
ed
ure
En
viro
nm
en
tal &
Sa
fety
En
g. A
pp
rova
ls
Pro
ce
du
re S
ec
tio
n:
Pro
du
ctio
n E
ng
ine
erin
gIG
N.
Da
te
Pro
ce
du
re N
am
e:
CS
F D
-0
8 E
me
rge
nc
y C
on
tac
t N
um
be
rsG
M
Pro
ce
du
re N
um
be
r:E
ffe
ctive
Da
te:
AG
M
Re
vis
ion
Nu
mb
er:
TC
SR
3.0
Re
vis
ion
Da
te:
04
1/0
1/19
MG
R
Co
nta
ct N
um
be
re
-ma
ilLa
stFi
rst
Po
siti
on
/ T
itle
82
CSF D-09 Safety Cross Calendar
Safety Calendar
Safety Slogan
Accident 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 VIOLATION
COMPANY NAME
VIOLATION TIME (24hr Clock):
PLANT:
TOYOTA D13 Safety Violation Investigation Report
D1
3:
Th
is r
ep
ort
to
be
co
mp
lete
d b
y t
he
Su
pe
rin
ten
de
nt/
Fo
rem
an
an
d s
ub
mit
ted
wit
hin
24
hrs
MA
X.
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 No
Was 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 No
Were 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)
Revision Number: TCSR 3.0 Revision Date: 8/1/18 MGR.
Procedure Name: CSF D- 14 Lock Surrender / Abandonment Form GM
Procedure Number: Effective Date: AGM
Toyota Construction Procedure Environmental & Safety Eng. Approvals
Procedure Section: Production Engineering IGN. Date
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
Toyota Construction Procedure Environmental & Safety Eng. Approvals
Procedure Section: Production Engineering IGN. Date
Revision Number: TCSR 3.0 Revision Date: 8/1/18 MGR
Procedure Name: CSF D- 15 Notice of Work Form GM
Procedure Number: Effective Date: AGM
89
CSF D-16 (Sample) Job Safety Analysis (JSA)
CSF
D-1
6 Jo
b S
afe
ty A
na
lysi
s (J
SA)
sam
ple
Co
mp
an
y N
am
e:St
art
Da
te:
Pag
e 1
of
Task
Des
crip
tio
n:
Sup
ervi
sor:
Ph
on
e:
Task
Lo
cati
on
:Sa
fety
Rep
:P
ho
ne:
SAM
PLE
Task
(in
seq
uen
tia
l o
rder
)P
ote
nti
al H
azar
ds
Pre
ven
tati
ve M
easu
res
Co
un
term
easu
res
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 Write method of control / Elimination
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: o Inspection o Repairs o Cleaning o Installation o o 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
Toyota Construction Procedure Environmental & Safety Eng. Approvals
Procedure Section: Production Engineering IGN. Date
Revision Number: TCSR 3.0 Revision Date: 8/1/18 MGR
Procedure Name: CSF D- 19 Confined Space Entry Checklist GM
Procedure Number: Effective Date: AGM
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 competent
person and are considered to be in competent operating condition in accordance with the manufacturer's
design, maintenance and testing criteria. All known defects and deficiencies have been corrected prior to use
on the project. A list of inspected items, operator's manual, logbook (if applicable) , engineers reports (if
applicable) , non-destructive test report (if applicable) , manufacturer's approvals (if applicable) and other
SAMPLE
Toyota Construction Procedure Environmental & Safety Eng. Approvals
Procedure Section: Production Engineering IGN. Date
Revision Number: TCSR 3.0 Revision Date: 8/1/18 MGR
Procedure Name: CSF D- 20 Contractor Equipment Inspection Form GM
Procedure Number: Effective Date: AGM
98
CSF D-25 Commissioning Warning Sign
99
CSF D-26 Critical Lift Checklist
MOBILE CRANE FORKLIFT/ VERSA LIFT COME-A-LONG HELICOPTER
SPECIFIC PLAN
FIXED CRANE CHAINFALL OTHER- REQUIRED
NEAREST
DEPT:________________ COLUMN #:_______________ LIFT ROOF PLANT GROUNDS PIT
LOCATION
PLANT:________________ AREA:________________ MEZZANINE GROUND FLOOR PENTHOUSE
BRIEF LIFT DESCRIPTION:
OK NG NA Countermeasure if NG OK NG NA
Does Lift plan identify and mitigate the following: NO N/A Comment
PE Stamp for l ift plan
If Rigger does not possess Recognized Degree or Certification
Center of Gravity- known or moving
How to Upended or / Down-ended load
Specified Rigging Points
Engineered Lift Points
Type of Softeners used
Number of Taglines used and location
Number of Spotters required and location
High Visibil ity Vest Worn in Lift Area
Areas Inside Building Secured/Controlled
LIFT PLAN CHECKLIST
Rigging
Other
Crane Capacity Based on Angle of Lift, Extension of Boom and Load Chart
Item Weight
Lifting Beam
Jib
Hoist Rope
Certified Lift Team Verification
EQUIPMENT USED:Check all that apply
LOCATION OF LIFT:
YES
Item Weight
Confirmation of Load
CapacityModel
Main Block
Load
Load Support-
Engineered DeviceForklift / Versa Lift
Auxiliary Block
Mobile Crane
Bridge Crane
Gantry
Chain Fall
Signal Person/Spotter Name:- Signal Person/Spotter Name:- Signal Person/Spotter Name:- Signal Person/Spotter Name:-
Certified Rigger Name: Rigger Certification #: Operator Name: Operator License #:
Overhead Hazards Other
Proximity to Electrical Energy Sources Crane Assembly Area Clearly Identified
Weather (Ice, Lightning, etc.) Other
Day: Month: Year:Date of LiftCompany Name:
Contact Name:Phone
Number
Floor Structure Capacity
Wind Speed Pick Point, Set Point and Swing Path area controlled
Site Conditions Site Control
Solid Level Surface Safety Perimeter Established (min 2 m from swing path)
Soil Type Known & Adequate
Other
Lifting Equipment
100
CSF D-27 (Sample) Contractor’s Crane Review
CSF D-27 (Sample) Contractor's Crane Review
TOYOTA SAFETY REVIEW INITIALS:
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:
Revision Number: TCSR 3.0 Revision Date: 8/1/18 MGR
Procedure Name: CSF D- 27 Contractor's Crane Review GM
Procedure Number: Effective Date: AGM
TOYOTA Construction Procedure Environmental & Safety Eng. Approvals
Procedure Section: Production Engineering IGN. Date
101
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 Diagrams
Foundation 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 Interface
The SS Detailer and Joist Detailer are Responsible to Coordinate Seats, Connections, Bearing Lengths/Widths/Depths, etc.
OSHA Required Details
Bolted 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.
102
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 Without
Approval of EOR and Toyota.
If a "Shared" or "Double" Connection is Required, the Connection Must be Detailed so That it can be Erected in Any
Sequential Order (Having Extra Bolts or Seats on Both Sides of the Column/Beam Web).
Painting & Cleaning of Steel
SP-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/QA
Reports
3rd 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
103
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/complete
prior 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 prior
review 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
104
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 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.
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 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.
105
Safety Representation
Must have at minimum: OSHA 30 Hour, CPR, First Aid, OSHA Subpart R - Steel Erection,
OSHA Subpart M - Fall Protection, OSHA Subpart N - Cranes & Derricks
Minimum 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
106
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
107
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 each
instance?
Controlling Contractor
Name Signature Date
Struc. Steel Contractor
Name Signature Date
Toyota Project
Leader Review Name Signature Date
Toyota Construction
Safety Review Name Signature Date
108
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
109
CSF D-35 Toyota Construction Safety Audit Sheet
Contractor Name Audit Date
Location NAMC Department
100.00%
No. Question ResponsePoints
Received
Point Value
PossibleComments
1 Reviewed by workers, signed (JSA) Yes
2 Follows Work: Applicable Yes
3 Updated: being followed Yes
4 Hot Work Requirements Met: issued
5 100% tie off in use
6 Leading Edges: Identified, protected
7 Floor openings: permit issued, followed
8 Excavation over 5ft; sloped, benched, shored
9 Energy Sources: Identified, isolated, locked out
10 Crane Operator Certified: Card checked
11 Confined space air quality tested
13 Additional Comments for this section:
Section Points 30 30
1 Posted, easy access Yes 1 1
2 Required documents on control board Yes 1 1
3 Additional Comments for this section:
Section Points 2 2.0
1 First Aid Kit: Stocked, Eye Wash, Accessible Yes 0.5 0.5
2 Sanitation: Toilets clean, stocked (portables) 0 0
3 Noise: Below 85dba, protection used 0 0
4 Lighting: General, Task Yes 0.3 0.3
5 Ventilation: Heat, Odors 0 0
6 Dust Control 0 0
7 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 0
2 Other: Correct for area, task, department 0 0
3 Additional Comments for this section:
Section Points 0 0
1 Extinguishers: Sized for task, inspected Yes 1.5 1.5
2 Flammable Liquids: Controlled, stored properly 0 0
3 Additional Comments for this section:
Section Points 1.5 1.5
4. Section E - Personal Protective Equipment
5. Section F - Fire Protection
110
1 Proper Barricades: Placement 0 0
2 Signs: Correct, posted, phone number, red, yellow 0 0
3 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 0
2 Guarding: Used, adjusted correctly 0 0
3 Proper Usage: Correct tool for the job 0 0
4 Identification on gang boxes, tools, equipment 0 0
5 Additional Comments for this section:
Section Points 0 0
1 Proper PPE: Non-flammable clothing 0 0
2 Shields, Barriers: Equipment, area protected 0 0
3 Gas Equipment: Proper storage, flash arrestors used 0 0
4 Additional Comments for this section:
Section Points 0 0
1 GFCI Protection: tested Yes 1.5 1.5
2 Extension Cords: Condition, Protected, Inspected 0 0
3 Additional Comments for this section:
Section Points 1.5 1.5
1 No missing planking, bracing, guardrails 0 0
2 Inspected: Tagged, hazards noted 0 0
3 Falling Object Protection: Toe boards 0 0
4 Rolling Scaffolds: Wheels locked 0 0
5 Basket: Floor cleaned, materials loaded properly 0 0
6 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 0
2 Proper Anchorage: Clamps, Straps, Lines 0 0
3 Workers tied off in scissor lifts 0 0
4 Warning Lines: Used, proper distance 0 0
5 Roof work: Permitted, weather conditions 0 0
6 Additional Comments for this section:
Section Points 0 0
12. Section M - Fall Protection
111
1 Daily inspections, equipment identified Yes 0.5 0.5
2 Safety Devices: Seat belts, lights, alarm 0 0
3 Operators: Certified, authorized, licensed 0 0
4 Forklift operated correctly 0 0
5 Additional Comments for this section:
Section Points 0.5 0.5
1 Over 4 ft: Ladder access, every 25 ft. 0 0
2 Spoils: Back 3 ft. 0 0
3 Water Intrusion: Rain, seepage 0 0
4 Excavation Protected: Equipment, workers 0 0
5 Additional Comments for this section:
Section Points 0 0
1 Rebar / rods capped, protected Yes 1.5 1.5
2 Masonry walls supported, limited access zone 0 0
3 Additional Comments for this section:
Section Points 1.5 1.5
1 Area protected from overhead lifts 0 0
2 Site specific erection plan in place 0 0
3 Area will support equipment and load 0 0
4 Additional Comments for this section:
Section Points 0 0
1 Engineer survey by Competent Person made Yes 1.5 1.5
2 All Serv: Shut off, capped, disc, removed 0 0
3 Additional Comments for this section:
Section Points 1.5 1.5
1 Sign In/Out Sheet: Used and correct 0 0
2 Group LO: Key box used / key inside 0 0
3 Locks: Labeled, contain required information 0 0
4 Arc Flash: Proper PPE, workers trained 0 0
5 Additional Comments for this section:
Section Points 0 0
1 Secured: Used properly, right type for work 0 0
2 Non-Conductive: No metal side rails 0 0
3 Good Condition: rungs, rails, bracing 0 0
4 Additional Comments for this section:
Section Points 0 0
1 Chemicals: Identified, labeled Yes 1 1
2 Stored Properly: Correct containment Yes 1 1
3 SDS Sheets: Available, correct Yes 0.5 0.5
4 Proper PPE being used 0 0
5 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
112
1 Crane Inspection: Certifications current 0 0
2 Rigging: Condition, inspected, rating tag 0 0
3 Rigger Qualified: Checked 0 0
4 Signal Person: Qualified, checked 0 0
5 Additional Comments for this section:
Section Points 0 0
1 Permit / Checklist Posted 0 0
2 Workers Trained / Rescue notified Yes 3 3
3 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
113
D-35 Escalation Matrix
114
115
CSF D-38 Construction Area Sign
116
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 Construction Procedure Environmental & Safety Eng. Approvals
Procedure Section: Production Engineering IGN. Date
Procedure Name: CSF D- 40 Floor Opening Checklist GM
Procedure Number: Effective Date: AGM
Revision Number: TCSR 3.0 Revision Date: 8/1/18 MGR
Toyota Safety Reviewed:
117
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
Revision Number: TCSR 3.0 Revision Date: 8/1/18 MGR
P/LContractor
Toyota Construction Procedure Environmental & Safety Eng. Approvals
Procedure Section: Production Engineering IGN. Date
Procedure Name: CSF D- 42 Demolition Checklist GM
Procedure Number: Effective Date: AGM
118
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
119
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
120
Section D- Environment/Site Conditions
Heat Illness Symptoms
Follow Local NAMC
Emergency Procedures
121
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:
122
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.
123
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:
124
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).
125
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.
126
B OVER A
C OVER A
C OVER B
A OVER B
127
A OVER C
B OVER C
2. All other sloped excavations shall be in accordance with the other options
permitted in § 1926.652(b).
128
Section X- Stairways and Ladders
Job Made Wooden Ladder – Single Cleat
129
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.
130
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
131
Section R-Steel Erection
Steel Erection Kanban
See www.ToyotaSupplier.com for latest structural steel erection forms.
132
133
Sci
sso
rs /
Sh
ears
/ T
in
Sn
ips
Sel
f-R
etra
ctin
g S
afet
y
Kn
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Sid
e C
utt
ers
Fo
ldin
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tilit
y K
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able
Ski
nn
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ife
Cab
le S
plic
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itIn
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tor'
s K
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ch f
ilm &
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Cu
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w V
olt
age
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Str
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Flip
Uti
lity
Kn
ife
or
'Jac
k' K
nif
eB
ox
Cu
tter
1C
uttin
g In
sula
tion.
XX
XX
XX
OX
XX
X
2S
trip
ping
Wire
s.X
OX
OO
*O
XX
OX
X
3R
emov
e P
last
ic
Pac
kagi
ng /
Tar
psO
XX
XX
XX
OX
XX
4
Cut
Mat
ting,
Gas
kets
,
Hos
es o
r R
ubbe
r
Mat
eria
lsO
OO
XX
XX
XX
XX
5C
uttin
g R
opes
OO
OX
XX
XX
XX
X
6C
ardb
oard
OO
XO
XX
XX
XX
X
7R
emov
e T
ie W
raps
OX
OX
XX
XX
XX
X
8C
ut M
etal
/ S
trap
ping
OX
OX
XX
XX
XX
X
9C
ut L
abel
s / P
rofil
esO
OO
XX
XX
XX
XX
#C
utt
ing
Pro
cess
Cu
ttin
g T
oo
l
( O
= B
est
Pra
ctic
e
X =
Un
acce
pta
ble
)
Use
as
Sh
ow
nN
ever
Use
Min
imal
bla
de
expo
sure
Clos
ing-
type
bl
ade.
Clo
ses
into
a p
rote
ctiv
e pl
astic
hou
sing
fo
r saf
e st
orag
e
Prot
ectiv
e le
athe
r ho
lder
cove
rs
expo
sed
blad
es w
hen
not i
n us
e
Butt
on u
sed
to
expo
se b
lade
Min
imal
bla
de
expo
sure
, sel
f-re
trac
ts w
hen
butt
on
is re
leas
ed
Spec
ializ
ed,c
ut re
sist
ant
hand
, wris
t and
arm
PPE
re
quire
d fo
r use
. Mus
t be
stor
ed in
pro
tect
ive
hold
er w
hen
not i
n us
e.
Mai
ntai
n3'
spac
ing
from
ot
her w
orke
rs. U
se o
nly
on ri
gid
cutt
ing
surf
ace.
Poin
ted-
tip
easi
ly
punc
ture
s th
roug
h pl
astic
.
No
blad
e ex
posu
re
to u
sers
Full
leng
th o
f bla
de
can
be e
xpos
ed a
t an
y tim
e; in
crea
sed
risk o
f cut
s/br
oken
bl
ades Bu
tton
per
mits
full
blad
e ex
posu
re to
be
lock
ed in
pla
ce
Not
ched
cutt
ing
tool
opt
imiz
es
user
-con
trol
Inte
rior
cutt
ing
blad
e re
duce
s w
orke
r ex
posu
re
*To
be u
sed
at
jour
neym
an's
disc
retio
n fo
r thi
cker
dia
met
er o
r tr
eate
d ca
bles
.
Inte
riorc
uttin
g bl
ade
redu
ces
wor
ker e
xpos
ure
Use
rs
have
be
tter
co
ntro
l &
Full
blad
e ex
pose
d.
Lack
s inh
eren
t saf
ety
feat
ures
whi
le in
-use
.
Inte
riorc
uttin
g bl
ade
redu
ces w
orke
r ex
posu
re
Use
rs h
ave
bett
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clea
n cu
ts
Nev
er
Use
Nev
er
Use
134
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.
135
Section X- Stairways and Ladders
Daily Ladder Inspection Sticker Template
136
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
137
Toyota PE
Safety Engineering
Job Safety Analysis
(JSA)
Guidelines
(For Construction,
Equipment Installation,
& Decommissioning Projects)
August 1st, 2018
138
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.
139
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.
140
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.
141
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.
142
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?
143
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.
144
Work Rule Process Flow Chart
Imm
ediat
en
+1 D
ayn
+ 1-5
Day
sn
+11
Days
n +1
2 Da
ysn
+15
Days
Sust
ainm
ent
Incident Site, Project Team & Safety TMNA PE Safety TMNA PE Safety Executives
Wor
k Rul
e Pr
oces
s Flo
wn
+10
Days
Revi
ew, F
eedb
ack
& A
ppro
ve
Deve
lop
Incid
entR
ecur
renc
e Pr
even
tion
> TM
NA S
afet
y >
Site
Lead
ers
> TM
NA P
E Sho
ps
> NA
M Sa
fety
Lead
ers
Nem
awas
hi a
nd D
eplo
ymen
t
> Co
nstr.
Safe
ty Re
ps>
TMNA
PE S
afet
y>
Site
Lead
ers
> NA
M Sa
fety
Lead
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> NA
M Sa
fety
Dire
ctor
s>
TMNA
PE G
M
Appl
y Exe
cutiv
e
Feed
back
Syst
emic
Chan
ge P
oint
s
> Ap
plica
ble R
egio
nal S
tand
ards
tand
a>
TCSR
/ CS
MS
> TS
MS
> C
oHE
> No
tify P
urch
asin
g>
Upda
te to
yota
supp
lier.c
om
Incid
ent O
ccur
s
Is in
ciden
t Fat
al,
Near
Fata
l or
Sign
ifica
nt N
ear
Miss
?
Revi
ew In
ciden
t
Wor
k Ru
le
Need
ed?
Follo
w in
ciden
t rep
ort p
roce
ss in
Toyo
ta C
onst
ruct
ion S
afet
y Re
quire
men
ts
Initi
al Re
port
n +1
FIna
l Rep
ort n
+5
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No
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Yes
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ainm
ent
> Fo
cuse
d Aud
itng
> CS
MS
> TSM
S
Plac
e ho
lder
for H
eade
r
145
146
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.
147
148
149
Work Rule
CONSTRUCTION SAFETY
Visualization of Construction Contractors
***IMPLEMENTATION DATE 7/14/18***
FIRE WATCH
BLACK HARD HAT
or 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
3"
3"
3"
150
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.