TCSR 4.1

•• PROTECTED 関係者外秘
⚫⚫⚫CONFIDENTIAL 秘
Toyota Construction
Safety Requirements
Version 4.1
3/31/2024
Toyota Construction Safety Requirements

for Non-Standard, Maintenance, and
Construction Activities
Version 4.1
2024
March 2024
Toyota Motor
North America
Toyota Production Engineering

Safety Engineering
2
Revisions:
2005-1 Mar-2005, 2006-1 May-2006, 2007-2 Mar-2007, 2009-1 Oct-2009, 2009-1.2 April-2010, 2009-1.3 July-2011,
2013-1 May-2013, 2015-1 January-2015, 2015-2.0 September-2015, 2016-2.01 January-2016, 2019-3.0 August
2019, 2020-3.1 July 2020, 2021-3.2 May 2021, 2021-3.3 June 2021, 2022, 3.4 March 2022, 4.0 March 2023, 4.1
March 2024
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 Regulación
(“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 Heal
3
Introduction
Toyota’s goal is for everyone to leave work each day as healthy as they were upon arrival. For that
reason, ensuring safe working conditions and safe work practices are top values at Toyota. Safety is
always the top priority at Toyota.
The purpose, scope and contents of this document have evolved significantly since the first revision was
published in 2005. The safety standards and best practices contained in this document have been
accumulated over the course of 19 years and shall be used as a resource to protect Toyota Team
Members and Contractors while performing construction and non-standard work activities.
An alternate version of the Toyota Construction Safety Requirements document has been developed
specifically for Toyota Team Members. The alternate version can be located at ts.toyotasupplier.com and
should be referenced by all Toyota Team Members in maintenance, skilled groups, pilot, kaizen, and
production groups while performing non-standard work.
Table of Contents
Section A .................................................................................................................................................. 11
1.0 Purpose and Scope ........................................................................................................................... 11
1.1 Toyota Safety Expectation ................................................................................................................ 12
1.2 Construction Safety Representation (CSMS 3.8, 3.9) ...................................................................... 12
1.3 Contractor’s Responsibility (OSHA CFR 1926.16) ........................................................................... 13
1.4 Toyota Acting as General Contractor/Contractor ............................................................................ 13
1.5 Monitoring of Construction Site (CSMS 6.4, 6.5, 6.6, 6.7) ............................................................... 13
1.6 Safety Training and Education (CSMS 4.2, OSHA 29 CFR 1926.21) ............................................... 13
1.7 Contractor Safety Representation (CSMS 3.8, 3.9) .......................................................................... 14
1.8 Required Documentation .................................................................................................................. 15
1.9 Apprentice/Journeyman Ratio .......................................................................................................... 15
Section B .................................................................................................................................................. 16
2.0 Glossary of Terms Used/Interpretations .......................................................................................... 16
Section C .................................................................................................................................................. 26
3.0 General Safety Requirements (CSMS Item 0) pg.143 .................................................................... 26
3.1 Contractor Safety and Health Program (CSMS 3.10) ....................................................................... 26
3.1.1 ISNetworld Requirement ................................................................................................................ 26
3.2 Contractor Safety Policy, Procedure, and Organization Charts ..................................................... 26
3.3 Contractor Site-Specific Safety Plan (CSMS 3.22, 3.25) .................................................................. 26
3.4 Contractor Environmental Policy ..................................................................................................... 26
3.5 Hazard Communication/WHMIS (CSMS 3.11, OSHA 29 CFR 1926.59) ........................................... 27
3.6 Contractor Emergency Action Procedures (CSMS 3.10, OSHA 29 CFR 1926.35) .......................... 27
4
3.7 Contractor Substance Abuse Control Program (CSMS 1.6) (Canada Excluded) ........................... 27
3.8 Job Safety Analysis (JSA) (CSMS 3.12, 3.24, 3.26, 6.1, 6.3) ............................................................ 27
3.8.1 Contractors Overall Job Safety Analysis (JSA) ............................................................................ 28
3.8.2 Daily Job Safety Analysis (D-18) .................................................................................................... 28
3.9 CPR and First Aid Trained Resource Requirement (OSHA 29 CFR 1926.23) ................................. 29
3.10 Proof of Insurance (CSMS 1.2, 3.7) (Purchasing) .......................................................................... 29
3.11 Project Coordination/Notification of Work ..................................................................................... 29
3.12 Toyota Safety Orientation (CSMS 3.16, 3.17, 3.28) ........................................................................ 29
3.13 Project Pre-Start Coordination Meetings (CSMS 6.1, 7.6) ............................................................. 30
3.13.1 Toyota Toolbox Talks (CSMS 7.2) ................................................................................................ 30
3.14 Weekly Construction Site Contractors Safety Meeting ................................................................. 30
3.15 Site Visual Control (CSMS 4.3) ........................................................................................................ 30
3.16 Means of Egress (OSHA 29 CFR 1926.34) ...................................................................................... 31
3.17 Emergencies: Evacuation/Severe Weather/Spills/Fires (CSMS 3.10, OSHA 29 CFR 1926.35) .... 31
3.18 Contractors Incident Reporting Procedures (CSMS 9.2) .............................................................. 31
3.19 Housekeeping/4S (OSHA 29 CFR 1926.25)..................................................................................... 31
3.20 Commissioning ................................................................................................................................ 32
3.21 Handover to Toyota Facility (CSMS 10.1) ....................................................................................... 32
3.22 Safety/Security Violations (CSMS 9.1) ............................................................................................ 32
3.23 Smoking and Tobacco Products Policy ......................................................................................... 34
3.24 Recording Devices ........................................................................................................................... 34
3.25 CHIPS/CAMBIO (MEXICO ONLY) .................................................................................................... 34
3.26 General Security Rules/Site Access ............................................................................................... 34
3.27 Work Hour Restrictions ................................................................................................................... 34
3.28 Speak Up Line .................................................................................................................................. 34
Section D .................................................................................................................................................. 35
4.0 Environment/Site Conditions ............................................................................................................ 35
4.1 First Aid (OSHA 29 CFR 1926.23) ...................................................................................................... 35
4.2 Sanitation (OSHA 29 CFR 1926.51) ................................................................................................... 35
4.3 Noise Exposure (OSHA 29 CFR 1926.52) ......................................................................................... 35
4.4 Illumination (OSHA 29 CFR 1926.56) ................................................................................................ 35
4.5 Ventilation (OSHA 29 CFR 1926.57) .................................................................................................. 35
4.6 Dust Control (OSHA 29 CFR 1926.55)............................................................................................... 35
4.7 Radiation (OSHA 29 CFR 1926.53) .................................................................................................... 36
4.8 Heat Illness Prevention...................................................................................................................... 36
4.9 Wind .................................................................................................................................................... 36
5
Section E .................................................................................................................................................. 36
5.0 Personal Protective Equipment (OSHA 29 CFR 1926.95) ................................................................ 36
5.1 Requirement ....................................................................................................................................... 36
5.2 Foot Protection (OSHA 29 CFR 1926.96) .......................................................................................... 36
5.3 Hand Protection ................................................................................................................................. 37
5.4 Head Protection (OSHA 29 CFR 1926.100) ....................................................................................... 37
5.5 Hearing Protection (OSHA 29 CFR 1910.101) .................................................................................. 37
5.6 Eye and Face protection (OSHA 29 CFR 1926.102) ......................................................................... 37
5.7 Respiratory Protection (OSHA 29 CFR 1910.103) ............................................................................ 37
5.8 Protective Clothing ............................................................................................................................ 38
Section F .................................................................................................................................................. 38
6.0 Fire Protection/Prevention ................................................................................................................ 38
6.1 Requirement (OSHA 29 CFR 1926.150) ............................................................................................ 38
6.2 Fire Extinguishers (OSHA 29 CFR 1926.150) ................................................................................... 38
6.3 Flammable and Combustible Liquids (OSHA 29 CFR 1926.152) .................................................... 38
6.4 Fuel Storage (OSHA 29 CFR 1926.151) ............................................................................................. 39
Section G .................................................................................................................................................. 39
7.0 Signs/Barricades (OSHA 29 CFR 1926.200) ..................................................................................... 39
7.1 Requirement ....................................................................................................................................... 39
7.2 Barricades .......................................................................................................................................... 39
7.3 Yellow Caution Tape .......................................................................................................................... 39
7.4 Red Danger Tape ............................................................................................................................... 39
7.5 Red and White Candy Stripe Tape (Used Solely for Commissioning) ........................................... 39
Section H .................................................................................................................................................. 40
8.0 Materials/Handling and Storage (OSHA 29 CFR 1926.250) ............................................................. 40
8.1 Requirement ....................................................................................................................................... 40
8.2 Trip Hazards ....................................................................................................................................... 40
8.3 Liquid Spills ....................................................................................................................................... 40
Section I.................................................................................................................................................... 41
9.0 Tools/Hand and Power (OSHA 29 CFR 1926.300) ............................................................................ 41
9.1 Requirement ....................................................................................................................................... 41
9.2 Condition ............................................................................................................................................ 41
9.2.1 Cut Off Wheels ................................................................................................................................ 41
9.2.2 Reciprocating/Band Saw ................................................................................................................ 41
9.3 Guarding ............................................................................................................................................. 41
9.4 Powered Tools ................................................................................................................................... 41
6
9.4.1 Operating Controls and Switches .................................................................................................. 42

9.5 Identification ...................................................................................................................................... 42
9.6 Powder Actuated Tools ..................................................................................................................... 42
9.7 Engineered Skates ............................................................................................................................. 42
9.8 Falling Object Protection................................................................................................................... 42
9.9 Non-Powered Cutting Tools .............................................................................................................. 43
Section J................................................................................................................................................... 43
10.0 Welding and Cutting (OSHA 29 CFR 1926.350) .............................................................................. 43
10.1 Requirement ..................................................................................................................................... 43
10.2 Clothing/PPE .................................................................................................................................... 43
10.3 Protection ......................................................................................................................................... 43
10.4 Storage and Transport/ Compressed Gas Cylinders..................................................................... 44
10.5 Restricted Hot Work ........................................................................................................................ 44
Section K .................................................................................................................................................. 44
11.0 Electrical (OSHA 29 CFR 1926.403) ................................................................................................ 44
11.1 Requirement ..................................................................................................................................... 44
11.2 Electrical Bus ................................................................................................................................... 45
11.3 Cord Sets (i.e., Extension Cords).................................................................................................... 45
11.4 GFCI .................................................................................................................................................. 45
11.5 Cable/Wire Stripping Safety ............................................................................................................ 46
Section L .................................................................................................................................................. 46
12.0 Scaffolding (OSHA 29 CFR 1926.451) ............................................................................................. 46
12.1 Requirement ..................................................................................................................................... 46
12.2 Erection/Dismantling/Access .......................................................................................................... 46
12.3 Scaffold Tags ................................................................................................................................... 46
12.4 Falling Object Protection................................................................................................................. 46
12.5 Rolling Scaffolds.............................................................................................................................. 47
12.6 Scissor Lifts ..................................................................................................................................... 47
Section M.................................................................................................................................................. 47
13.0 Fall Protection (OSHA 29 CFR 1926.501)........................................................................................ 47
13.1 Requirement ..................................................................................................................................... 47
13.2 Fall Protection Plan ......................................................................................................................... 48
13.3 Fall Protection Equipment ............................................................................................................... 48
13.4 Walking Working Surfaces .............................................................................................................. 48
13.5 Leading Edges ................................................................................................................................. 48
13.6 Warning Lines .................................................................................................................................. 48
7
13.7 Horizontal Lifelines .......................................................................................................................... 49

13.8 Floor Openings ................................................................................................................................ 49
13.9 Covers .............................................................................................................................................. 49
13.10 Roof Work/Access ......................................................................................................................... 49
13.11 Controlled Access Zone (CAZ) ..................................................................................................... 49
13.12 Working over Water ....................................................................................................................... 50
13.13 General Equipment Use................................................................................................................. 50
Section N .................................................................................................................................................. 50
14.0 Helicopter lifts (OSHA 29 CFR 1926.551)........................................................................................ 50
14.1 Requirement ..................................................................................................................................... 50
14.2 Notification ....................................................................................................................................... 50
14.3 Governing Authorities, Laws .......................................................................................................... 51
14.4 Day of Pre-Lift Meeting .................................................................................................................... 51
14.5 Operator Responsibility .................................................................................................................. 51
14.6 Static Charge.................................................................................................................................... 51
Section O .................................................................................................................................................. 51
15.0 Motor Vehicles/Mechanized Equipment (OSHA 29 CFR 1926.600,601) ........................................ 51
15.1 Speed Limits .................................................................................................................................... 51
15.2 Equipment ........................................................................................................................................ 51
15.3 Operation .......................................................................................................................................... 52
15.4 Inspections ....................................................................................................................................... 52
15.5 Forklifts ............................................................................................................................................ 52
15.6 Aerial Lifts ........................................................................................................................................ 52
15.7 Aerial Lift Operation ........................................................................................................................ 53
15.8 Duties of a Spotter ........................................................................................................................... 53
15.9 Safe Work Practices for Fueling Equipment .................................................................................. 54
Section P .................................................................................................................................................. 54
16.0 Excavation/Trenching - See Appendix for Sloping, Benching Requirements ............................. 54
16.1 Requirement (OSHA 29 CFR 1926.651) .......................................................................................... 54
16.2 Protection (OSHA 29 CFR 1926.652)............................................................................................... 55
16.3 Inspections ....................................................................................................................................... 55
16.4 Access/Egress ................................................................................................................................. 55
Section Q .................................................................................................................................................. 56
17.0 Concrete and Masonry (OSHA 29 CFR 1926.701) .......................................................................... 56
17.1 Personal Protection/Sanitation Requirements............................................................................... 56
17.2 Concrete Buckets / Working Under Loads ..................................................................................... 56
8
17.3 Other Equipment/Tools (OSHA 29 CFR 1926.702) ......................................................................... 56

17.4 Masonry Construction (OSHA 29 CFR 1926.706)........................................................................... 56
17.5 Concrete Formwork / Column Erection .......................................................................................... 56
17.6 Respirable Crystalline Silica ........................................................................................................... 57
Section R .................................................................................................................................................. 57
18.0 Steel Erection (OSHA 29 CFR 1926.750)......................................................................................... 57
18.1 Project Management Responsibility ............................................................................................... 57
18.2 Requirement ..................................................................................................................................... 58
18.3 SSEP: Site Specific Erection Plan Requirement (SSEP) ............................................................... 58
18.4 Erection Stability Plan Requirement (OSHA 29 CFR 1926.754) .................................................... 58
18.5 Protection from Falling Objects (OSHA 29 CFR 1926.759)............................................................ 59
18.6 Multiple Lift Rigging Procedure (Also known as Christmas Treeing) (OSHA 29 CFR 1926.753) 59
18.7 Steel Erection Kanban ..................................................................................................................... 59
18.8 Inclement Weather ........................................................................................................................... 59
Section T .................................................................................................................................................. 60
19.0 Demolition (OSHA 29 CFR 1926.850) .............................................................................................. 60
19.1 Building or Structure ....................................................................................................................... 60
19.2 Machines and/or Equipment ........................................................................................................... 60
19.3 Handover to NAMC .......................................................................................................................... 61
Section V .................................................................................................................................................. 61
20.0 Energy Control Policy and Program (OSHA 29 CFR 1926.950) .................................................... 61
20.1 Lockout ............................................................................................................................................. 61
20.2 Lockout Training .............................................................................................................................. 61
20.3 Group Lockout ................................................................................................................................. 62
20.4 Lock Abandonment ......................................................................................................................... 62
Section X .................................................................................................................................................. 63
21.0 Stairways and Ladders .................................................................................................................... 63
21.1 Requirement (OSHA 29 CFR 1926.1051)......................................................................................... 63
21.2 Mobile Ladder Stands ...................................................................................................................... 63
21.3 Ladder use (OSHA 29 CFR 1926.1053) ........................................................................................... 63
21.4 Job Made Wooden Ladders (OSHA 29 CFR 1926.1053) ................................................................ 64
Section Z .................................................................................................................................................. 64
22.0 Toxic and Hazardous Substances .................................................................................................. 64
22.1 Requirement ..................................................................................................................................... 64
22.2 Material Usage Request................................................................................................................... 64
22.3 SDS Sheets....................................................................................................................................... 64
9
22.4 Storage/Labeling/Use ...................................................................................................................... 64

22.5 Emergency Response...................................................................................................................... 64
22.6 Disposal ............................................................................................................................................ 65
22.7 Exposure .......................................................................................................................................... 65
Section AA ............................................................................................................................................... 65
23.0 Confined Spaces .............................................................................................................................. 65
23.1 Requirement ..................................................................................................................................... 65
23.2 Confined Space Procedures ........................................................................................................... 66
23.3 Responsibilities ............................................................................................................................... 67
Section CC ............................................................................................................................................... 67
24.0 Lifting Requirements (OSHA 29 CFR 1926 Subpart CC) ............................................................... 67
24.1 General Requirement ....................................................................................................................... 67
24.1.1 Lifts of loads less than 220 pounds or engineered equipment with fork pockets.................... 67
24.1.2 Lifts of objects over 220 pounds ................................................................................................. 67
24.1.3 Lifts meeting definition of critical lift ........................................................................................... 67
24.1.4 Critical Lifts ................................................................................................................................... 67
24.1.5 D-26 ................................................................................................................................................ 68
24.1.6 Fall Zone ........................................................................................................................................ 69
24.1.7 Lifting Storage Containers (Cabinets, Lockers & Other)............................................................ 69
24.2 Riggers ............................................................................................................................................. 70
24.3 Rigging Equipment .......................................................................................................................... 70
24.4 Cranes and Derricks ........................................................................................................................ 70
24.5 Conditions ........................................................................................................................................ 71
24.6 Operations ........................................................................................................................................ 71
24.7 Qualifications ................................................................................................................................... 71
24.7.1 Hoist operator ............................................................................................................................... 71
24.7.2 Signal person ................................................................................................................................ 72
25.0 Safety Qualifications for Contractor Safety Representation......................................................... 72
25.1 Supervisors/Project Managers........................................................................................................ 72
25.2 Dedicated Construction Safety Representative (CSMS 3.8) ......................................................... 72
25.3 Workers ............................................................................................................................................ 73
25.4 Designated Contractor Construction Safety Representative – See Table in Section 1.7............ 73
26.0 Toyota Team Member Performed Work .......................................................................................... 73
26.1 Non-Standard Work Activity............................................................................................................ 73
26.2 Troubleshooting............................................................................................................................... 76
26.3 Safety Qualifications for Toyota Team Member Performed Work ................................................ 76
10
26.3.1. Safety Designee ........................................................................................................................... 76

26.2.2 Project Leader ............................................................................................................................... 77
26.2.3 Job Leaders ................................................................................................................................... 77
26.2.4 Workers ......................................................................................................................................... 77
Appendix .................................................................................................................................................. 78
Appendix 79
Section A
1.0 Purpose and Scope

This Toyota Regional document has been created as a reference to assist Toyota members and Contractor
Companies. Our expectations are that we work together to create a workplace free of hazards and
potential injury while working at all Toyota North American 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 is intended to protect everyone performing Non-
Standard, Maintenance and Construction type activities on Toyota sites, the determination to follow TCSR
requirements shall be based on the activity being performed regardless of the group leading the work.
This document shall be applied to the following activities:
• All non-standard work activities.

• Construction, remodeling, or modification of buildings and facilities.
• Installation, relocation or modification of machinery and equipment.
• Decommissioning of machinery and equipment
This document does not apply to TM-led activities with a standardized work process that includes safety
key points (Examples: Preventive Maintenance, approved ACM activity, routine tasks with work
instructions, and Production Processes).
This includes Toyota Team Members, Prime or General Contractors, Subcontractors, and any Company
providing workers for purpose of construction activity. This document is not intended for companies solely
providing administrative or services such as: janitorial or cleaning services, secretarial services, inspection
services, contract engineering, forklift repair, 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 in this document shall not be considered a comprehensive list of all necessary safety standards
11
to be observed. Toyota Team Members and Contractors 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.
Contractors are held to a very high safety standard. Toyota employees will be held to the same high safety
standard.
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 not
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.
1.1 Toyota Safety Expectation

Toyota Team Members and Contractors must follow applicable TCSR standards. The most stringent
standard shall be enforced wherever a conflict arises between TCSR and other Toyota policies. Team
members must follow all applicable TCSR requirements for all Non-Standard work, Maintenance and
Construction activities.
Toyota Safety Management is built around the principle of Find It, Fix It, No Repeats.
• Find It – TOYOTA expects our Team Members and Contractors to find safety hazards and
behavioral issues by themselves before someone gets hurt. This represents that the Toyota
Management, 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 sites.
• Fix It – TOYOTA expects our Team Members and 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. Safety is the highest
priority.
• No Repeats – Sustained success at TOYOTA requires Team Members and 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.
All contractors are to ensure their workers are given free access to the Toyota Construction Safety
Requirements and the host Toyota Facility Security Requirements. Documents are to be available for
review and their location shall be conspicuous.
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 of risk or number of workers associated with the project's scope of work. The minimum safety
representation qualification requirements are in Section 25 of this document.
12
1.3 Contractor’s Responsibility (OSHA CFR 1926.16)

Contractors have responsibility for the safety of their personnel, and the responsibility to build Safety into
their projects from the start. Contractors are 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 their portion of the work. Regarding subcontracted
work, the General Contractor and any Subcontractor(s) shall be deemed 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. General or Prime Contractors must have an on-site management presence to fulfill the safety
requirements in this document. If the Prime or General Contractor is not on-site, the leading Sub-
Contractor must assume General or Prime Contractor responsibilities.
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 as found in the TCSR.
1.5 Monitoring of Construction Site (CSMS 6.4, 6.5, 6.6, 6.7)

All employers shall ensure that proper monitoring of the work site and their personnel is conducted per the
requirements of applicable sections of this document. The employer must implement a program of planned,
regular safety inspections and meetings. Inspections shall be completed using the TERA auditing system.
All Toyota Project Leaders, Safety, Managers, Contractor Supervision, and Contractor Safety shall
complete at least one D-35 per shift on their projects. (D-35).
All TM led activity follow section 26.1 for TERA auditing requirements.
Focused JSA audits are also available in the TERA auditing system.
1.6 Safety Training and Education (CSMS 4.2, OSHA 29 CFR 1926.21)
All contractors shall ensure that their workers and their Subcontractors’ workers are properly trained, fully
qualified for their work, and be prepared to provide declarations of competence (D-01), 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 contractor 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.
Toyota Project Leaders must also have OSHA 1926 Construction 10 hour or equivalent, CSMS, TCSR,
and JSA training. All Toyota Team members must complete Toyota team members construction safety
training. Retraining of Project leaders is required for CSMS, TCSR, and JSA training every three years.
13
Toyota Job Leaders must have at least the Non-Standard and Maintenance Safety Requirements and JSA
Training. Retraining of Toyota job leaders is required for Non-Standard and Maintenance Safety
Requirements and JSA training every three years.
All Toyota TMs performing non-standard work activities must take the Non-Standard and Maintenance
Safety Requirements training. Retraining of Toyota TMs is required for Non-Standard and Maintenance
Safety Requirements training every three years.
All Contractor 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 Employers shall provide, 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, The employer
with support of Toyota Safety will require the work task to cease until corrective actions have been
implemented. No person shall be allowed to perform any work at any time without the required
qualification or training.
1.7 Contractor Safety Representation (CSMS 3.8, 3.9)

Prime or General Contractors must provide Safety coverage regardless of the number of workers. An on-
site Dedicated Construction Safety Representative must be present when completing high-risk activities or
10 or greater workers on-site. A Designated Construction Safety Representative can be utilized when
completing low hazard work and less than 10 workers on-site. Toyota Safety Management will make final
determination if in question.
Any activity worth 20 points will require a dedicated safety representative. Reference Safety Ranking Matrix
in Appendix.
All safety representatives shall confirm and enforce all aspects and requirements of the Site-Specific Safety
Plan and all Toyota requirements, applicable laws and/codes, applicable standards, and best practices in
14
the scope of work. This person shall be qualified and knowledgeable in safety and how it applies to the
construction industry (Reference section 25.2 for Dedicated Safety Representative Qualifications and 25.4
for Designated Safety Representative Qualifications). Contractor Safety 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. See Visualization of Construction Contractors Matrix in Appendix.
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. General and Prime Contractors shall be ultimately
accountable for the safety representation, safety programs and performance of their Subcontractors.
Toyota Facilities 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 Toyota designee to provide immediate
direction, and to suspend activities until adequate coverage is established.
Toyota reserves the right to require additional safety coverage beyond the specifications in Table 1
at any time based on risk.
Table 1 – Expected Contractor Safety Representation
Workers Required Safety

Fewer than 10 1 Designated
10 or greater 1 Dedicated
Every additional 100 1 additional dedicated
1.8 Required Documentation

Contractors shall maintain a daily roster of all workers on site for accountability purposes.
In addition, contractors shall submit hours worked to Toyota Construction Safety using the Man Hours
Collection form found at the Toyota Construction Safety Sharepoint Site.
The Toyota Safety Cross (D-09) shall be maintained by the Contractor and displayed on the Contractors’
site visual control display for all projects. The minimum required documentation that shall be submitted
prior to beginning work are the following: D-01 Declaration of Competent Person Form, D-08 Emergency
Contact List, 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. All apprentices and non-journeymen will be easily identifiable by a black hard hat or
black band. See Visualization of Construction Contractors Matrix in Appendix.
15
Section B
2.0 Glossary of Terms Used/Interpretations

4S: Toyota’s principal that guides us in maintaining a neat and organized workplace and detecting
abnormalities.
The 4S’s: Sifting, Sorting, Sweeping, Shine
Affected Worker: A worker whose job is impacted by task specific hazards in the workplace. Specific
hazards can include lockout, confined spaces, and others.
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.
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
Toyota.
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.
Cardinal Safety Rules: Safety rules that, under no circumstances, should ever be broken. They are
designed to protect workers in areas where a small deviation from Toyota standards could lead to deadly
consequences.
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 installation, 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.
16
Commissioning Zone: The area established around the commissioning process, defined by red and white
candy-striped tape. Please see Toyota 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 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, installers, maintenance, and skilled team-members.
(Canada) Construction includes erection, alteration, repair, dismantling, demolition, structural maintenance,
painting, land clearing, earth moving, grading, excavating, trenching, digging, boring, drilling, blasting, or
concreting, the installation of any machinery or plant, and any work or undertaking in connection with a
project but does not include any work or undertaking underground in a mine. Team Members located in
Canada would not engage in construction activities.
Construction Safety Representative: 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.
Contractor(s): Any person or organization 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 this document's purposes, 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.
17
Contractor Dedicated Safety Representative: A full-time, on-site safety representative that exclusively
performs safety functions and does not physically perform construction activities. This worker must meet all
education and qualification requirements listed in Section 25.2.
Contractor Designated Safety Representative: A worker who is designated to be responsible for all
safety functions when a dedicated safety representative is not required. This worker can be a foreman,
supervisor or tradesman and must meet all education and qualification requirements listed in Section 25.4.
Controlled Access Zone (CAZ): An area where the work may take place without a guardrail system,
PFAS, or safety net system and where access to the area is controlled by an attendant.
CPR: Cardiopulmonary 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. (D-26)
CRSP: Canadian Registered Safety Professional
CSA: (Canada) Canadian Standards Association
CSP: Certified Safety Professional
CSMS: TMNA’s Construction Safety Management System
Danger Zone: The area in and around any machine, equipment, or process where there is a potential
hazard from the unexpected motion or energization of a system. Once a person bypasses and/or removes
the safeguarding or enters the safe guarded space, they are in the danger zone.
Demolition: Demolition is the dismantling, razing, destroying or wrecking of any building, structure,
machine or equipment or any part thereof. Demolition work involves many of the hazards associated with
construction.
Decommission: To remove from service and make safe.
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.
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 Limiter: The personal fall limiter (PFL) is a compact, lightweight SRL of limited working length of
between 6 and 9 feet and weighs between 1-2 pounds. Unlike the regular SRL, which is mounted at the
18
anchor point, the PFL attaches to the D-ring on a user’s body harness and is light enough to be carried on
the user’s back.
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.
Fire Watch: A person whose only job duty is observing and extinguishing if needed, Hot Work being
performed with an appropriate size and type of fire extinguisher, extending a minimum of 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.
Free rigging: The direct attachment to or placement of rigging equipment (slings, shackles, rings, etc.)
onto the forks/tines of a powered industrial truck for a below-the-tines lift.
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
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.
Ground Fault Circuit Interrupter (GFCI): a fast-acting circuit breaker designed to shut off electric power
in the event of a ground-fault within as little as 1/40 of a second 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.
Governing Authority: (USA-OSHA) (CANADA-OHSA) (Mexico NOM) the agency prescribed to administer
and enforce compliance with applicable law.
19
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; Walking or climbing on
structural steel or exiting an aerial lift basket, fire suppression bypass, energized electrical work, permit
required confined space entry, excavation requiring sloping and shoring, helicopter lifts, steel erection,
restricted hot work, lifting loads over 220 lbs. w/o engineered fork pockets. See Safety Ranking matrix for
point values.
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
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, working on a project under this document's scope.
ISNetworld: Third Party Safety grading system (ISN) used to prequalify contractors for service.
Job- Any Toyota TM performed work task assigned by a job leader for any non-standard, construction, or
maintenance work task.
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 leader: A Person leading a Toyota TM-led job. Job Leaders must have at least the Non-Standard and
Maintenance Safety Requirements and JSA Training. Job Leaders can approve Toyota TM-led jobs that
have been identified as low risk according to the non-production job ranking matrix.
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 D-16 & D-18)
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
20
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 lasts 14 or more working days. (Note: working Saturday and Sunday
for 2 weekends equals 4 working days.)
Maintenance: The act of performing servicing or maintenance to keep a piece of equipment or structure in
its normal operating condition.
Mendomi: Japanese word meaning to "take care of your workers like family"!
MOL: (Canada) Ontario Ministry of Labour
MSHA: Mine Safety and Health Administration
NAMC(s): Toyota North American Manufacturing Company(s)
Near Miss: An acute incident that does not result in an injury but had the potential to do so. Material
damage (to the building or equipment) may have resulted from the incident.
NEC: National Electrical Code
NOM: (Mexico) Official Mexican Standards
NFPA: National Fire Protection Association
NIOSH: National Institute for Occupational Safety and Health
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. (US ONLY)
(Sample D-19)
21
Non-Standard Work: Any work not part of a standard production process, preventive maintenance task, or
routine activity. Non-standard work requires a Job Safety Analysis to be completed prior to starting the
task.
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 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)
Planned Activity-Foreseeable work activity performed as a result of being scheduled or work that is not
performed as part of a response to equipment malfunctioning or breakdown. (Reference: Non-Standard job
ranking matrix)
PLHCP: Physician or Other Licensed Health Care Professional
Preventive Maintenance: the act of performing regularly scheduled maintenance activities to help prevent
unexpected failures in the future. All preventive maintenance activities have a developed work instruction
sheet or manual with recognized safety key points.
Prime Contractor: Any contractor on a project having a contract directly with the owner. Also known as
General Contractors
Project: Any work, or group of work that is performed during construction, installation, maintenance, non-
standard work and/or decommissioning.
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, pipeline, duct or well, or any
combination thereof.
22
(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: One who leads projects and anyone who has the authority to make decisions on the
project. Every Toyota Project will have a project leader assigned and on site. 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 (US Only), CSMS Project Leader
training, TCSR and JSA 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 objects
that require rigging or securing of loads.
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.
Responsible Party: Contractor is responsible for their employees and activities. For Toyota performed
work with Toyota Team members, Toyota is Responsible.
Rigging: Any type of ropes, cables, hooks, clamps, slings, or other lifting accessories, used for lifting of
materials and equipment.
Routine: performed as part of a regular procedure rather than for a special process
Safety Designee: A Toyota Team Member designated to be Safety Approver for Daily JSA’s with a project
leader. Safety designees are only applicable to Toyota TM-led non-standard work. Safety Designees must
have training as outlined in 26.3.1.
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.
Self-Retracting Lifelines (SRL) - A deceleration device which contains a drum wound line which may be
slowly extracted from, or retracted onto, the drum under slight tension during normal team member
23
movement, and which after onset of a fall, automatically locks the drum and arrests the fall and is only
intended to be anchored to an anchorage connector.
SRL-P – a self-retracting device that encompasses all the same features as a type SRL but is intended to
be worn by the end user on a full-body harness also known as a personal fall limiter.
SRL-R – a self-retracting device that encompasses all features as a type SRL but includes a retrieval mode
intended for rescue by raising or lowering the rescue user.
Spotter: A person responsible for observing and directing a specific task or tasks and shall perform a
spotter's duties. (see D-44 and D-30). See duties of a spotter
Shall: Without exception; a requirement.
Shutdown: The extended non-production period (4 days or greater) when production has stopped, and
projects are performed at Toyota facilities. All Shutdown work should be entered/recorded in the Shutdown
reporting system.
Significant Incident: An incident that involves potential to cause fatality or disability (life-changing). This
standard defines criteria, along with injury severity, to assist with TMNA determination.
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 aligns the contractor company’s policies and procedures
with the requirements of the TCSR for the work being performed on that specific job site.
Skates: Equipment/Machine Skates are designed/engineered to move heavy equipment and machinery
Standard work: Work performed as part of a normal production process, preventive maintenance activity,
or routine task with recognized safety key points.
STOP 6 Incident: An incident that involves potential to cause fatality or disability (life-changing). This
standard defines criteria, along with injury severity, to assist with TMNA determination. A recordable
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 those of the General Contractor.
24
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, works 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.
TERA (Toyota Event Response Andon): Electronic auditing program used by Toyota for Construction
Safety Audits (D-35 Construction Safety Audit and focused audits).
Three (3) point ladder contact: When climbing or descending, 2 feet and 1 hand on the rungs or 2 hands
and 1 foot on the rungs.
TMNA: Toyota Motor Engineering & Manufacturing North America, Inc.
Toyota Safety: A team member from the One Toyota Safety group.
Toyota Team Member: Any person working directly for Toyota.
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).
Troubleshooting: A diagnostic activity, which may include testing, to identify the source of a problem with
a machine or piece of equipment. If entry into the danger zone is required, lockout is the primary method of
control. Entry via ACM must be approved by a TaBRA or approved D-18(JSA).
Troubleshooting does not include repairing or making any physical alteration of any part of the equipment,
such as the following:
• Unjamming and eleventh finger use (using an additional tool held in hand)
• Moving components inside the cell (such as carrier, jigs, or parts)
• Making, tightening, or loosening connections
• Removing or replacing components
• Adjusting any part of the safety system (such as light curtains, mats, or scanners
Unplanned Work: Unforeseen activity performed by maintenance and/or facilities related to equipment
malfunction (for Example: Breakdowns, Fault Recovery). Failure to plan work does not justify unplanned
work.
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.
Worker: A person who performs work as part of Non-Standard work, Maintenance, Construction,
equipment installation, or decommissioning.
25
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 (CSMS Item 0) pg.143
3.1 Contractor 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 ISNetworld at
least two weeks (determination based on the size, scope, and risk) prior to the contractor beginning work
on the project.
3.1.1 ISNetworld Requirement

ISNetworld enrollment is a requirement for all General Contractors and Prime Contractors. All
Subcontractors enrollment to ISN is required for High-risk activities(US-MEX Required). Use Safety
Ranking matrix for point values when determining subcontractor entry. Project leaders will Review
Contractors ISNetworld Grading.
• Companies with A or B grade may bid and work on Toyota projects.

• C or F may not bid or work without approved variance. (Variance Request form for contractors
pg.144)
3.2 Contractor 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 Toyota Safety when requested. General/Prime Contractors are
required to obtain an organization chart from each of their subcontractors along with their own which shall
be available on site. All Supervisors and Safety representatives shall be identified on each chart.
Contractors are responsible for their employees. Contractors must maintain accountability for each
employee while on Toyota property to include lone workers.
3.3 Contractor 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
policies, procedures, and training for identifying and mitigating the hazards anticipated for their scope of
work. The contractor shall identify all tasks associated with the project (Incident reporting, meetings, record
retention, inspections, etc.). The SSSP shall be submitted to the Toyota Project Leader and 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.
All Site-Specific Safety Plans must be reviewed and updated annually by the project leader and Site Safety
Representative. (Sample available upon request) (CSMS Item 12 check sheet)
3.4 Contractor 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 Toyota Facilities, local,
State, Provincial, Site-Specific Environmental Guidelines, and Federal environmental laws and
requirements. Required forms may be obtained from the host Toyota Facility.
26
3.5 Hazard Communication/WHMIS (CSMS 3.11, OSHA 29 CFR 1926.59)

Potentially hazardous or restricted substances on the project site shall ensure that the proper Toyota forms
have been submitted. Approval from the local Toyota Facility shall be required prior to bringing these
substances onto the project site. The forms are available from the local Toyota Facility. The employer 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 are readily available for inspection.
3.6 Contractor Emergency Action Procedures (CSMS 3.10, OSHA 29 CFR 1926.35)
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 enough people 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
• Plan to resume work
3.7 Contractor Substance Abuse Control Program (CSMS 1.6) (Canada Excluded)
Toyota has zero tolerance for drug and alcohol use/possession at all sites. Toyota is a drug free workplace
and insists that its contractors maintain the same. The Contractor shall implement an effective substance
abuse control program that shall include a minimum of 5 drug screening, “post-incident,” and “for cause”
testing, while under contract at Toyota. Prior to the worker being issued a badge, or reactivating a badge,
workers shall be in the Contractor’s drug control program. Toyota shall not be liable for any delays caused
through the drug screen process prior to the receipt of negative test results.
3.8 Job Safety Analysis (JSA) (CSMS 3.12, 3.24, 3.26, 6.1, 6.3)
The Contractor may use its own JSA forms in place of the Overall JSA (D-16) and Daily JSA (D-18) if they
meet or exceed Toyota’s requirements. 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 Toyota Project Leader.
27
4. Name of task/job/activity.
5. Steps to complete the task in sequential order.
6. Potential hazards associated with each step of the task.
7. The countermeasures or preventive action associated with each hazard.
The local Toyota Safety Representative will review the Contractors JSA forms to determine if they meet or
exceed Toyota criteria.
3.8.1 Contractors Overall Job Safety Analysis (JSA) (D-16 & D-17)
Contractors shall be required to develop an overall Job Safety Analysis (JSA) (D-16) for any activities
physically being performed during the project. The overall JSA shall be formally documented in writing. An
overall 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 overall JSA should be trade specific and cover the entire scope of work (recommended to cover no
more than two weeks in length without updates).
The overall JSA (D-16) shall be submitted to Project Management for review. Project Management will
forward to Toyota Safety for review 2 weeks (recommended), but not less than 48 hours prior to the
scheduled work.
A JSA Review Checklist (D-17) must accompany the overall JSA. Toyota Project Leaders or Toyota Safety
will check and record the ISN Grade. Toyota project leader and Toyota Safety must sign and return the
JSA Review Checklist (D-17) with the overall (JSA D-16) to the Contractor after review. Where the JSA
content is substandard, Toyota requests the JSA to be resubmitted with additional information. If work is
discovered being performed without a Toyota project leader and Safety reviewed JSA, Toyota reserves the
right to stop the work until the situation is rectified.
The JSA and signed JSA Review checklist must be kept in the field and accessible. The overall JSA (D-16)
shall be communicated to all workers involved with the task, and signatures of each worker shall be
acquired prior to starting work. All JSA’s must be physically or digitally signed by the project leader and
Toyota Safety.
3.8.2 Daily Job Safety Analysis (D-18)

Toyota Team Members and Contractors must complete a Toyota Daily JSA (D-18) before each work shift
begins. Daily JSA (D-18) is to be written by crew completing the work.
The Contractor’s Daily JSA (D-18) does not require Toyota Safety review prior to work beginning, however
the completed form must be reviewed and signed by the contractors Supervisor/Foreman, the contractor
safety representative, and all workers involved for one shift of work. The daily JSA must be kept
accessible at the worksite. All JSA’s must be physically or digitally signed.
28
For all Toyota Team Member Led projects, the D-18 will be used. Project Leader will sign off on A & B
Rank JSAs per Non-Standard Job Ranking Matrix. If there is a Toyota Safety available, they will sign for
safety portion if no safety, Safety Designee will sign. Job Leaders are required for C Rank Jobs per Non-
Standard Job Ranking Matrix.
3.9 CPR and First Aid Trained Resource Requirement (OSHA 29 CFR 1926.23)
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 Declaration of Competency (D-01)
of their candidate(s) for this position to Toyota Safety or their designee for review before any work begins
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. A 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) (Purchasing)

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 Purchasing, or their designee.
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.
(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/project leaders are responsible for coordinating their work with all existing Toyota
Engineering, Facilities, Safety and Security departments.
When required by the Toyota Facility, a job planning form must be completed (D-15 or Form 4.0 Notice of
Work Permit) (Canada), prior to beginning work on-site.
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 comply with the Toyota Orientation
Requirements by viewing the appropriate Toyota Safety Orientation videos.
All contractors & visitors to Toyota Facilities must watch ‘Part 1 - Visitor & Contractor Safety Review’.
All Contractors physically performing construction work at Toyota Facilities must watch ‘Part 2 -
Construction Safety Requirements’.
29
Documentation verifying orientation completion must be provided for every worker prior to visiting site or
beginning work.
Orientation materials must be reviewed annually for all workers.
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 Project Pre-Start Coordination Meetings (CSMS 6.1, 7.6)

The employer is required to host a coordination meeting with all affected workers before a project starts.
Coordination meetings shall include the following:
• JSA’s, High-Risk activities and countermeasures for the day’s work
If applicable topics include:
• Work coordination specific to that day’s activities

• Safety Alerts, Safety Incidents (if applicable)
• General safety practice reinforcement (if applicable)
• Results of previous day’s safety audits (if applicable)
3.13.1 Toyota Toolbox Talks (CSMS 7.2)

Toolbox talks focused discussion topics intended to educate workers on specific hazards and work
practices in the construction environment. Toolbox talks can be found on the Toyota Safety Sharepoint
under toolbox talks.
Contractors shall conduct Toolbox Safety Meetings at least weekly with their personnel for safety
awareness and discussion of special safety topics. Copies of the Toolbox Talks shall be available to Toyota
Safety upon request.
For any Toyota TM performed activity, Toolbox talks should be conducted when weekly work activity is
being performed.
3.14 Weekly Construction Site Contractors Safety Meeting

The Contractor Safety Representative or member of management from each contractor shall participate in
a weekly Safety Review Meeting conducted by the Toyota Construction Safety team. This meeting is to
discuss Safety Performance Levels found from auditing, provide updates on changing safety standards,
review incidents and other pertinent safety information. The Safety Review Meeting is mandatory for all
Contractor Safety Representatives or their designees. Materials from the meeting should be shared with
all parties invited to the meeting.
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.
30
3.16 Means of Egress (OSHA 29 CFR 1926.34)

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, OSHA 29 CFR 1926.35)

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 procedures to be followed throughout all
project phases.
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 (D-08) shall be submitted to the Toyota Project lead
and Toyota Safety and posted on the Contractor’s Site Control Board.
3.18 Contractors Incident Reporting Procedures (CSMS 9.2)

All injuries and injury-free incidents (First Aid, Recordable, Near Miss, Property Damage etc.) shall be
reported immediately to Contractor Supervision, Toyota Project leader, and Toyota Safety. Host Toyota
management reserves the right to review all incidents. The Toyota Initial Report (D-12) shall be completed
for all incidents and submitted to Toyota Project Manager and Safety within 24 hours of the incident. The
Toyota Final Incident Report (D-12) shall be completed for all incidents and submitted to Toyota Project
Manager and Safety within 5 days. The incident shall be communicated to all workers at the project site to
prevent re-occurrence. Reference CSMS Item 6 (Appendix Page 121) for Construction Safety Incident
Notification Procedures Flowchart.
3.19 Housekeeping/4S (OSHA 29 CFR 1926.25)

Good housekeeping shall be always maintained in all work areas. 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 workday. 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.
The housekeeping plan must account for safe management of cords based on site-specific layout and
conditions.
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 the floor.
Hard barricades sufficient to prevent vehicles from entering soft or uneven surfaces must be utilized if a
minimum of 20' hard flat surface around dumpster can't be achieved. (See appendix for Roll-Off Staging
Work Rule)
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,
31
State and Local laws and regulations. Notify Toyota Environmental for disposal requirements, where
applicable.
3.20 Commissioning
The Project Leader is responsible for commissioning activities. 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 commissioning activities shall have a designated JSA (D16 or D18), which shall be signed by
the Project Leader, Toyota Safety and all involved workers.
• 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 Project Leader or Contractor to Toyota
Engineering, Toyota Safety, and other affected Stakeholders, 72 hours prior to initial equipment
activation.
• Commissioning Tape (Red and White Candy Stripe tape) dimension shall create a 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 (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).
• 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 Toyota Facility (CSMS 10.1)

A plan must be in place to ensure the construction work zone is safe before handover to the Toyota Facility
for startup of production activity.
• 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 4S 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 Toyota Team Members, Contractor, its workers,
Subcontractors or Suppliers. The employer and Toyota Management shall be immediately notified.
32
Contractors shall immediately notify Toyota Project Management and Toyota Safety regarding violations of
any applicable legal requirements by its own workers, Subcontractors or Suppliers. (D-13) If contractor is
found to be in violation of a Toyota specific safety or security requirement, Toyota shall investigate the
incident with the host Toyota Facility Security 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 that will trigger immediate Toyota review to determine corrective actions:
Behavior
• Working without a JSA.

• 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
• Failing to follow LO Procedures
• Not following safe work requirements when working from heights
• Not complying with confined space working requirements
• Bypassing, removing, or altering a safeguarding device without authorization
• Unauthorized, distracted, or reckless driving operations
• Unauthorized or careless crane operation.
• Not following hot work requirements
• Failing to report SAFETY Incidents
• Not following all molten liquid handling procedures (TMMTN, TMMMO)
• Failure to follow all bonding and grounding procedures. (TMMC)
All violations shall be reviewed by the employee’s management, Site Safety Management, and
Construction Safety management.
• 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.
• Operating equipment without proper qualifications
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
33
• 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 chewing tobacco, electric cigarettes,
clove cigarettes, and tobacco pouches shall follow local Toyota 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 Toyota 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 Toyota
Security.
3.25 CHIPS/CAMBIO (MEXICO ONLY)

All workers on all job sites are expected to follow CHIPs. CHIPS stands for:
C - No Cell Phone While Walking
H - No Hands in Pockets
I - Cross at designated Intersections
P - Stop, Look, and Point
S - Use Stair Handrails
3.26 General Security Rules/Site Access

Please contact the local Toyota representative for a comprehensive list of security requirements. A badge
request form and Safety Orientation verification shall be required from security before entering any Toyota
Facility.
3.27 Work Hour Restrictions

The maximum number of hours a worker can 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. The
maximum weekly work hours will be capped at 70 hours. The Toyota Project Leader must be informed if
work hours exceed 70 hours for the week (Saturday-Friday) or 16 hours in one day. Toyota Management
will make final determination for schedule.
3.28 Speak Up Line

All team members and contractors are expected to report any suspected unlawful or unethical activity. All
activity that violates Toyota’s ethics and Compliance Standard should be reported by contacting the Toyota
Speak Up line at (844) Speak-99 or by visiting Toyota.ethicspoint.com.
34
Section D
4.0 Environment/Site Conditions
4.1 First Aid (OSHA 29 CFR 1926.23)

Provisions shall be made prior to the project's start by the contractor to ensure prompt medical attention in
case of injury. First aid supplies must 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 (OSHA 29 CFR 1926.51)

An adequate supply of potable water shall be provided for drinking. Hand washing/ hand cleansing stations
must be provided and maintained.
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.
4.3 Noise Exposure (OSHA 29 CFR 1926.52)

Protection against the effects of noise exposure shall be provided by the employer. The proper protection
shall meet or exceed OSHA/ANSI/OHSA requirements (See Section E, 5.0).
4.4 Illumination (OSHA 29 CFR 1926.56)

The employer 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 the minimum
illumination intensities required by 29CFR 1926.56(a), Table D-3.
4.5 Ventilation (OSHA 29 CFR 1926.57)

The employer 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.
4.6 Dust Control (OSHA 29 CFR 1926.55)

The employer shall develop and implement a dust control program that contains a description of the
methods to be used for controlling dust. Any variance shall be approved by Toyota Safety. Contractors
shall have this program on file and submit it to Toyota Safety when requested. Considerations for dust
control methods shall include, but are not limited to the following:
• Wet cutting and water suppression when cutting, grinding, or coring concrete.
• Dust extraction using vacuums with specialized filters when cutting, grinding, or coring concrete.
• Respiratory protection as needed if dust cannot be controlled with other methods.
• Using water trucks to control site dust.
• Using flame retardant materials when constructing dust walls.
35
4.7 Radiation (OSHA 29 CFR 1926.53)

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

The employer shall develop and implement a program to prevent heat illness. Facilities must be provided
for outside workers to take in shaded rest breaks areas. See Appendix for signs and symptoms of heat
related illnesses.
4.9 Wind
The employer must have a plan for monitoring weather conditions and wind speeds, with a clear plan for
stopping elevated activities (aerial lifts, crane operation, roof work) once wind speeds reach a certain
threshold. All elevated activities with potential to be impacted by winds must be suspended if sustained
winds reach 20 mph or 35 mph gusts.
Never operate machinery when wind speeds exceed manufacturers recommendations. Always follow
OSHA recommendations regarding safe wind speeds for elevated work.
Section E
5.0 Personal Protective Equipment (OSHA 29 CFR 1926.95)
5.1 Requirement
It is important to note that each Toyota Facility may have specific PPE requirements within its production
areas that all workers must comply with. Proper clothing (shirts with minimum 4” sleeves etc.), safety-toed
boots, and safety eyewear shall be worn when accessing the plant/work site. The overall or daily JSA will
identify the task specific PPE that is to be worn based on the hazards present.
The employer shall ensure their workers, 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 employer shall be responsible for ensuring 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 Toyota Facility. Verify the additional PPE
requirements with the local Toyota Facility prior to arrival at the plant.
5.2 Foot Protection (OSHA 29 CFR 1926.96)

Safety-toed work boots, covering the ankle, appropriate for the work activity, and approved by applicable
law, shall be worn 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.
Contractors shall verify with the local Toyota Facility of any additional foot protection requirements outside
the construction areas (ANSI Z41.1).
36
5.3 Hand Protection

The employer 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 Toyota Facility.
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) (D-16/D-18).
Reference Glove Cut Resistance Guide in appendix as a guide to determine proper hand protection.
5.4 Head Protection (OSHA 29 CFR 1926.100)

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.
When operating with D-44 Requirements, chin strap/ climbing hardhat must be used. 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 (OSHA 29 CFR 1910.101)

When noise levels exceed 85dba, the proper hearing protection shall be worn and provided by the
employer.
5.6 Eye and Face protection (OSHA 29 CFR 1926.102)

Approved eye protection (ANSI Z87/CSA Z94.3) with fixed side shields or safety rated goggles shall be
always worn properly. 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. Dark
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 (OSHA 29 CFR 1910.103)

The employer shall take all necessary actions to ensure air quality standards are met on the project and in
its work areas. The employer 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.
• 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.
37
• 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 always worn, including full length pants and shirts with a minimum of 4”
sleeves. Approved high visibility shirts, vests, or jackets shall be worn in construction areas. 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 (OSHA 29 CFR 1926.150)

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 Fire/Security and Toyota Safety or designee and according
to local requirements. The Contractors shall verify with the host Toyota Facility of 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 (OSHA 29 CFR 1926.150)

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 listed or approved by a nationally recognized testing laboratory shall be used to meet this
guideline's requirements. Contractors shall provide their own fire extinguishers meeting all applicable
standards. Toyota Facility fire extinguishers will only be used in emergency situations and shall not be
factored in to satisfy construction requirements. Any discharge of a Toyota fire extinguisher, whether by
accident or in the event of extinguishing a fire, shall be reported to the Toyota Fire/Security Department.
All extinguishers shall have a documented annual and monthly inspection. Refer to local Toyota Hot Work
requirements for size of appropriate fire extinguisher.
6.3 Flammable and Combustible Liquids (OSHA 29 CFR 1926.152)

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). Only listed (UL) or FM approved fuel cans are allowed on site
and, when required, must contain spark arrest features.
38
6.4 Fuel Storage (OSHA 29 CFR 1926.151)

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 (OSHA 29 CFR 1926.200)
7.1 Requirement
All work areas shall be posted with appropriate signs and shall be positioned conspicuously around the
perimeter of the protected area (D-38). In addition to the warning information, signs shall contain the
Company/Toyota group 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 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 Yellow Caution 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 specific and immediate hazard 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. (D-38(a) Caution Construction Area Sign) Yellow
Caution signage tape shall be maintained between 42 inches (1.1 m) plus or minus 3 inches (8 cm) above
the walking/working level.
7.4 Red Danger Tape

Red Danger tape shall only be used to designate work areas that contain a specific and immediate danger
to workers within. Areas barricaded with red danger tape must include D-38 signage with contact
information for the controlling party. Permission must be received from the controlling party before entering.
Additionally, the entering worker shall fully understand the hazards in the area (review of the JSA is
recommended) and Red Danger tape shall have signage (D-38(b) Danger Construction Area Sign)
indicating specific hazards (ex: overhead work). Areas shall only be barricaded with Red Danger for as
long as necessary to perform the work.
The area designated by Red Danger 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 tape shall be
maintained between 42 inches (1.1 m) plus or minus 3 inches (8 cm) above the walking/working level.
7.5 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 under the
commissioning process to indicate the unique hazards experienced during the commissioning procedure.
39
The designated area shall fully encompass the area under commissioning including any adjacent areas
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, (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 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 (OSHA 29 CFR 1926.250)
8.1 Requirement
The perimeter of the designated areas shall be barricaded, roped-off, or otherwise identified.
The area must have proper signage, which includes:
• Responsible Party Name

• Purpose of the lay-down area
• Contact Person and Phone number
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 Matrix (See Appendix).
The contractor shall only store material in the “lay-down” area(s) approved by Toyota.
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.
8.2 Trip Hazards

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

Report all spills to the appropriate Toyota member immediately. Spill Kits shall be provided by the
employer, readily available, and fully stocked while working with or around oils, liquids, and chemicals.
40
Section I
9.0 Tools/Hand and Power (OSHA 29 CFR 1926.300)
9.1 Requirement
The employer shall be responsible for ensuring hand tools, power tools, and equipment are maintained in a
safe working order. Ensure that all potential sources of hazardous energy that could potentially be
contacted by hand and power tools have been removed or isolated before starting work (e.g., electrical
wiring in walls, cabling inside Unistrut, cable trays, etc.)
9.2 Condition
Electrical tools shall be maintained per the manufacturers’ requirements and inspected before each use.
Corded 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.
9.2.1 Cut Off Wheels

Supervisor shall review and issue the appropriate media for the task. Wheels designed for cutting or
grinding must be manufacturer approved for the tool being used and only used per manufacturer
instructions. The minimum thickness shall be provided by the manufacturer of the tool. 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. Multipurpose wheels are designed for both cutting and grinding shall
be used only with Toyota Safety and/or Toyota Management approval and used as a last resort if
alternative methods are not feasible.
9.2.2 Reciprocating/Band Saw

Reciprocating/band type saws shall only be used when determined to be the proper tool for the job being
performed. Always follow all manufacturer requirements for the specific type of saw being used. All
Portable Band Saws Must have dual switches/triggers.
• Operator must keep both hands on provided handles and stay clear from falling pieces.
• Material to be cut shall be held in place not requiring the tool's operator.
• Never remove work stops or modify tool in any way outside of manufacturers guidelines.
• Ensure that all potential sources of hazardous energy have been removed or isolated before
starting work (e.g., electrical wiring in walls, cabling inside Unistrut, cable trays, etc.)
9.3 Guarding
Proper guards shall be installed on all power tools before being used. 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 shall be inspected by a competent
person on a regular planned basis and before use.
41
9.4.1 Operating Controls and Switches

All power tools shall be equipped with a constant pressure switch or control that shuts off the power when
pressure is released.
9.5 Identification
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 shall be maintained in a safe working condition according to
manufacturer’s requirements.
• 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 Toyota Facilities. Check
with local Toyota Fire for hot work requirements.
9.7 Engineered Skates

When using skates to move objects, the employer must ensure the safe movement of the load. Employer
must use skates that are rated for the material being moved or have a PE stamp if built in house. All
materials supported by skates must be secured using a tie down strap, come along, or C-Clamp Device
(Vice Grips style clamps are not allowed). When possible, utilize bracing to prevent load separation from
skates. A D-26 is required to lift loads greater than 220 lbs. onto skates.
Ensure all body parts are kept clear of pinch point hazards when load is in motion. Determine safe distance
to stand away from load based on height and potential for falling. Never put hands or feet under the load.
When the load is not in motion, proper chalking or cribbing of the load is required.
Any contractor attempting to utilize skates must file a D-01 Competent person form to identify who can rig
loads skates. Minimum qualifications for competency:
• Qualified Rigger
• Knowledge, training, and experience utilizing skates to move loads
• Demonstrates problem solving skills related to utilizing skates.
The use of skates to move loads is not applicable to TM led non-standard work activities. If loads need to
be moved with skates, contact a competent contractor to perform the task.
9.8 Falling Object Protection

Falling object hazards should be highlighted in the Job Safety Analysis along with effective controls to
mitigate the risk. This includes materials being used in the screen-guard, next to guardrails or in lifts.
Examples of falling object controls include, but are not limited to, tethering tools, laying plywood or plastic
in screen guarded mezzanines or barricading an area. At completion of job, a 4S truss sweep must be
performed to ensure all tools and material are removed.
42
Standing materials shall be secured so to prevent a falling object hazard at any working surface.
9.9 Non-Powered Cutting Tools

Reference Cutting Tool Standard Chart in Appendix for approved cutting tools.
Section J
10.0 Welding and Cutting (OSHA 29 CFR 1926.350)
10.1 Requirement
A “Hot Work Permit” shall be issued by the local Toyota Facility for any work that produces an arc, spark,
flame and/or could ignite flammable or combustible materials. All team members and contractors shall
follow the local Toyota “Hot Work” requirements. Hot Work training may be required at some Toyota
Facilities before a permit will be issued.
If flammable or combustible materials are not able to be moved at least 35 feet from the hot work area, a
plan shall be implemented to protect the material from the heat, sparks, and/or slag.
The same precautions shall be taken when hot work is performed on walls, floors, and ceilings where direct
penetration of sparks or heat transfer may introduce a fire hazard (Example: fire watch may be needed on
both floors).
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 employer shall provide an employee to serve as Fire Watch during hot work operations. The Fire
Watch shall be equipped and trained by the employer, with an appropriate fire extinguisher per local Toyota
hot work requirements. The Fire Watch shall be maintained for a minimum of 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, lower levels, or roofs where
materials may be ignited.
The Fire Watch shall know the following information.
• Locations of the nearest manual fire alarm box and/or phone.

43
• Local Toyota 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 indicator on their hard hat during Fire Watch
activities. At the end of the Fire Watch activity, the indicator must be removed. See Visualization of
Construction Contractors Matrix in Appendix.
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
Employer’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-resistant rating of at least one-half hour.
Cylinders must never be stored next to a heat source of any type. Verify with local Toyota Fire/Security 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 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 Toyota Facilities have been designated as “RESTRICTED or HIGH HAZARD HOT
WORK AREAS” due to extremely high fire and/or explosion risks. Local Toyota Facility 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.
Section K
11.0 Electrical (OSHA 29 CFR 1926.403)
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 (e.g., placed into an Electrically Safe Work Condition (ESWC)) unless performing diagnostics
testing/troubleshooting or where energized work is unavoidable. If work is required on an energized
conductor or circuit, a D-45 Energized Electrical Work Permit (EEWP) shall be utilized. 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 TEMA SEI 2001-001(Toyota Electrical Safety
44
Standard) 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.
11.2 Electrical Bus

The following energized work tasks are not permitted.
• Insertion or removal of plug-in devices into or from energized busways (e.g., no hot stabbing
bus with bus plug)
• Drilling holes, cutting openings, removing knock outs, etc. in bus plugs installed in an
energized busway (e.g., no compromising the external integrity of electrical enclosures or
plug-in devices while installed on a “hot” bus)
If an unavoidable condition exists where either must be completed the following steps must be taken:
• Job safety analysis conducted and reviewed with each worker for each specific task.
• D-45 energized electrical work permit (EEWP) with Affected SHOP General Manager
signature.
11.3 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
with ground prongs damaged or removed shall not be used. Cord sets that damage the outer insulation or
strain relief shall not be used. Cord sets shall be visually inspected for damage prior to use and removed
from service if defective.
Cord sets shall not be used as “permanent wiring” and shall be checked/removed at a frequency not to
exceed 90 days.
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.
11.4 GFCI
Ground fault circuit interrupters (GFCI) shall be UL Listed/CSA approved and used on all cord sets, and
corded 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. All portable and receptacle GFCI’s shall be tested prior to
each use to ensure proper operation.
All portable generators shall have ground-fault circuit-interrupter protection for personnel integral to the
generator or receptacle or GFCI adapters or cord sets incorporating GFCI protection at the supply end
shall be permitted when plugged directly into the generator.
45
11.5 Cable/Wire Stripping Safety

Reference Cutting Tool Standard Chart in Appendix for cable/wire stripping safety guidelines.
Section L
12.0 Scaffolding (OSHA 29 CFR 1926.451)
12.1 Requirement
All scaffolding equipment, installations, and inspections shall comply with applicable laws and regulations.
Employers 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 work performed from scaffolding must recognize safety hazards while working at heights. All hazards in
proximity to work being performed shall be identified on your JSA and ensure proper controls are in place.
Any scaffolding activity performed within 25’ of a large ceiling mounted fan must perform lockout of that fan.
Any scaffolding inside of a crane bay requires the lockout of the cranes capable of operating in that area.
12.2 Erection/Dismantling/Access
A Competent Person Declaration Form (D-01) shall be completed by the contractor for the worker(s) who
shall be supervising the assembling and disassembling of scaffolding.
Personal fall protection required during scaffolding erection and dismantling. It must be attached to an
approved anchorage point.
Employers shall not permit their workers to climb on (unless a ladder is part of the handrail 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 always have a Scaffold Status Tag attached to it. A competent person shall complete and
apply this tag. The tags shall be supplied by the employer. (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. Scaffold shall be provided with additional protection from falling
hand tools, debris, and other small objects through the installation of toe boards, screens, or guardrail
systems, or through the erection of debris nets, catch platforms, or canopy structures that contain or deflect
the falling objects. When the falling objects are too large, heavy or massive to be contained or deflected by
any of the above-listed measures, the employer shall place such potential falling objects away from the
edge of the surface from which they could fall and shall secure those materials as necessary to prevent
their falling.
46
12.5 Rolling Scaffolds

Riding on a rolling scaffold is not allowed at any time. All tools and material on the deck shall be removed
or secured before moving. All wheels (and if applicable, outriggers, stabilizers, extendable axles, etc.) shall
be locked prior to working from rolling scaffolding. Only use a rolling scaffold on flat even surfaces. A
competent worker must be tasked with rolling scaffold erection, dismantling, and daily inspections (see
12.3 Scaffold Tags).
12.6 Scissor Lifts

Only qualified 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. Designed or pre-engineered
tie-off points shall always be used as the fall restraint tie-off point. Handrails 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.
If you must exit the Scissor lift to drive through a man door, drive from outside the basket in the safest
means possible. This process must be outlined in the JSA.
See Spotter Determination Matrix in Appendix to determine when a spotter shall be used.
Section M
13.0 Fall Protection (OSHA 29 CFR 1926.501)
13.1 Requirement
The Employer shall develop a detailed Fall Protection Plan to cover all work conducted where the workers’
feet are at or higher than 6 feet (1.8 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.). Fall protection plans
should include methods to control hazards. The fall protection hierarchy of controls includes: elimination,
guardrails, fall restraint, fall arrest, or any other combination.
All connections required to be installed at height including electrical, mechanical, and pneumatic shall be
designed such that their installation can be made from an aerial lift or other at height device (scaffolding).
Leaving the basket, ladder, or scaffold exposing workers to a fall hazard or climbing on top of any non-work
platforms or structures is a last resort. This includes, but is not limited to, exiting a ladder to climb onto
structural steel. If the need arises then STOP-CALL-WAIT, contact Toyota Safety and initiate form D-44
form before proceeding with work. For work requiring leaving the basket, scaffold, or climbing on top of
any non-work platforms or structures, a double lanyard system shall be used to maintain 100% tie-off.
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.
47
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. The fall protection
plan shall include a fall calculation that provides adequate
protection in the event a fall should occur. The calculation
should include length of lanyard, deceleration(free-fall)
distance, harness stretch (1’), Height of workers’ D- Ring,
and a 3’ safety factor. The plan 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 the
Project lead and Toyota Safety at least four (4) working
days in advance of work beginning. When applicable the Fall protection plan should be included in the
SSSP.
13.3 Fall Protection Equipment

Full body harnesses, lanyards, locking snap hooks and proper anchorage points are the minimum
requirements for a personal fall arrest system. All components shall be inspected prior to and after each
use. An annual documented inspection procedure shall be put in place and verified by a competent person,
and every 6 months for facilities located in California. Any component of a fall protection system subjected
to in-service loading shall be immediately removed from service and from the jobsite.
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.
Project Leaders shall confirm 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 working near 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. All
SRL’s used for leading edge protection must be designed by the manufacturer for leading edge use.
Exception: When it is infeasible or creates a greater hazard to use these systems, the employer 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.
48
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 employer 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.
13.8 Floor Openings

No floor hole covers, grating, or access hatches greater than 6’ above a hazard shall be opened or
removed without first contacting Toyota Safety or its designee and completing a Floor Opening Checklist
(D-40). Prior to removal and start of work, Toyota Safety (or designee) shall review the checked
procedures and protective measures on the permit. After completion of work or the end of shift, the floor
covering shall be replaced and clearly marked and easily identifiable.
13.9 Covers
During construction, if an opening is made in a walking/working surface, then it shall be covered. All covers
in roadways and vehicular aisles shall be able to support, 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 the employer(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 employer(s) 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 Toyota Facility, the employer(s) shall obtain a Roof Access Permit or similar before allowing workers
on the roof. Some Toyota Facilities require Roof Access Training.
13.11 Controlled Access Zone (CAZ)

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
49
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.
13.12 Working over Water

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 manufacturer approved purposes. (For
example, fall protection equipment shall not be used for rigging purposes.)
Section N
14.0 Helicopter lifts (OSHA 29 CFR 1926.551)
14.1 Requirement
When the need for a helicopter service is established, a pre-lift meeting shall be held at least one month
prior to the 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
50
designee two (2) weeks prior to the lift taking place with appropriate confirmations and notices by
Governing Authorities.
14.3 Governing Authorities, Laws

Helicopter lifts 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.
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 (OSHA 29 CFR 1926.600,601)
15.1 Speed Limits

All posted Speed limits on Toyota property(s), shall be followed. The on-site construction zone speed limit
will not exceed the posted speed limit. Toyota production equipment has the right of way.
15.2 Equipment
All vehicles and mechanized equipment shall prominently display the employer’s name and on-site contact
number. For rental equipment temporary signs may be used. All equipment not designed for “over the
51
road” use shall be equipped with an operable horn, headlights (if equipped), back-up alarm, and a fire
extinguisher as required by the manufacturer. Some Toyota Facilities may have Site Specific Guidelines
regarding equipment and vehicles on site.
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. All vehicles/equipment when parked without operator will have brakes applied, placed in park, or
wheels choked. Forks and/or bucket must be lowered all the way to ground when operators exit equipment.
All vehicle and equipment exhaust are adequately controlled to maintain safe concentrations of carbon
monoxide and other exhaust components.
All vehicle/equipment operators must be fit for duty and for operating mobile equipment daily.
15.4 Inspections
All mobile equipment shall be inspected and documented upon delivery to the project site. Any repairs shall
be completed prior to use. 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 employer 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 Toyota Facilities, and/or federal/state policies when operating outside of a
designated construction area. Minimum 2 points of rigging contact from the forklift truck to the
machine/crate/equipment/load is required. Approved rigging must be of sufficient size and strength to
secure the load. Free rigging to forks/tines is never allowed. 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 Decision Matrix for rules
regarding spotters and forklifts.
15.6 Aerial Lifts

All Aerial Lifts shall follow the standards in “Section O” in this document pertaining to Equipment,
Operation, and Inspections in addition to the following:
• Use of a Fall Restraint system must comply with manufacturer requirements of both the aerial
lift and the fall restraint device, or equipment manufactured supplied fall protection shall be
required in Aerial Lifts.
52
• A fall restraint device shall always be worn according to the manufacturer while operating
and/or working in any aerial lift.
• All Aerial Lifts must be equipped with a designated or pre-engineered tie-off point. That point
shall be used as the fall restraint connection point.
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.
All work performed from aerial lifts must recognize safety hazards while working at heights. All hazards in
proximity to work being performed shall be identified on your JSA and ensure proper controls are in place.
Any aerial lift activity performed within 25’ of a large ceiling mounted fan must perform lockout of that fan.
Any aerial lift work inside of a crane bay requires the lockout of the cranes capable of operating in that
area.
Red danger tape shall be used to identify the hazard area below the elevated work platform. If red danger
tape is not practical, contact Toyota Safety to discuss other options such as cones and signs.
See Spotter Decision Matrix for rules regarding spotters and aerial lifts.
15.8 Duties of a Spotter

Spotters shall be used in accordance with the Spotter Decision Matrix (D-30) when applicable mobile
equipment is being used on Toyota property. All spotters and Operators shall be able to safely complete all
the required duties listed and must be trained. Examples include forklifts, cranes, aerial lifts, scissor lifts,
dump trucks, etc. Tuggers, golf carts, Cushmans, are exempt from the spotter requirement. The duties of a
spotter are as follows:
• Watch out for yourself first, other people, and property.

• Fully understand plan and rescue if needed.
• Fully understand the use of equipment with ground controls.
• 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. (Trenches, Floor Holes, Fans, Etc.)
• Plan for sufficient stopping distance and clearance.
• Concentrate on the task at hand.
• If spotter does not have full view (Vertical and Horizontal Planes) of entire work zone, then
additional spotters may be required. Stop, Call, Wait.
53
• No cell phone use while performing spotter duties.

• While equipment travels in aisleways, spotters shall never walk directly in front of the
equipment.
• Spotters shall never position themselves to create a hazard. (Caught in or between
moving/fixed objects)
• All spotters must be easily identified with a Blue indicator. (Examples: Blue Hard Hat Bands,
Blue Arm Bands, Blue Vests) See Visualization of Construction Contractors Matrix in
Appendix.
• Flashlights, flags, whistles and other devices may also be used to direct operators or
pedestrians.
• After the equipment has stopped movement, the spotter may complete other duties but must
remain in the immediate work area and be able to perform rescue if needed.
While travelling from one work location to another or in designated work areas, spotters must also be
outside of the known equipment blind spots (Reference to Appendix Visual: Known Equipment Blind Spots)
If no red danger tape is used, then a spotter can spot for only one piece of equipment at a time.
If red danger tape and a D-38 B Danger Sign is used, one spotter can be used for all equipment inside the
tape (If they can fulfill all required duties of a spotter.) This must be specified in the approved JSA.
Refer to Form D-30 Spotter Decision Matrix.
15.9 Safe Work Practices for Fueling Equipment

When fueling equipment, the following precautions must be taken:
• 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.
• Fire Extinguishers or other control means shall be accessible when fueling equipment.
Section P
16.0 Excavation/Trenching - See Appendix for Sloping, Benching Requirements

As-built drawings shall be reviewed and the work areas shall be surveyed prior to work beginning to
determine the locations of underground lines (pipe, electrical, or otherwise). Ground Penetrating Radar
shall be used to inspect all outdoor excavation work zones, and any indoor excavation work zones where
54
current as-built drawings cannot be verified. If a known utility exists or is located by GPR Scanning, then it
must be identified (flags or paint).
Hand digging only does not require Ground Penetrating Radar. If hazardous energy exists, then hand
digging shall be performed within a three-foot radius of the buried utility and lockout shall be performed on
hazardous energy. 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 before starting the
excavation work. (D-02, D-02A). All soil shall be classified as Type C soil until classification is determined
by a competent person. All soil that has been previously disturbed shall be classified as Type C soil.
16.2 Protection (OSHA 29 CFR 1926.652)

All soil shall be considered Type C soil and shall be adequately protected (Sloping or shoring device) until
Soil type has been determined by a competent person. All soil that has been previously disturbed shall be
classified as Type C soil. While the excavation is open, underground installations shall be protected,
supported, or removed as necessary to safeguard workers. All excavations shall be sloped, benched, or
shored, depending on soil conditions, as determined by a competent person, and 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.
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. Contractors are responsible for communicating good or
no good entry conditions.
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.
55
Section Q
17.0 Concrete and Masonry (OSHA 29 CFR 1926.701)
17.1 Personal Protection/Sanitation Requirements

The employer shall provide adequate means of washing/flushing of exposed areas when workers contact
wet concrete. Workers shall wear the proper PPE for working with concrete materials.
17.2 Concrete Buckets / Working Under Loads

No 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 (OSHA 29 CFR 1926.702)

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.
17.4 Masonry Construction (OSHA 29 CFR 1926.706)

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.
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

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 induced during construction. 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
56
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 can support the loads.
17.6 Respirable Crystalline Silica

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 vehicle-mounted drilling rigs.
• Using heavy equipment for demolition.
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.
Section R
18.0 Steel Erection (OSHA 29 CFR 1926.750)

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 ts.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
57
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 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. (D-29)
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, contact Toyota Safety and initiate form D-44 form before proceeding with work.
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 (OSHA 29 CFR 1926.754)

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.
58
• 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 (OSHA 29 CFR 1926.759)

No activity is allowed below steel erection activities. 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) (OSHA 29 CFR 1926.753)
A multiple lift shall only be performed if the following criteria are met. A detailed plan for this procedure
must be in JSA.
• 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
ts.toyotasupplier.com for example of the latest Steel Erection Kanban document.
18.8 Inclement Weather

No steel erection work shall be performed outdoors during bad weather (lightning, wind, severe weather).
Work shall cease if crane operator cannot maintain adequate visual contact with connectors fastening steel
due to weather conditions.
59
Section T
19.0 Demolition (OSHA 29 CFR 1926.850)

Prior to permitting workers to start demolition operations, the D-42 must be completed and submitted to
Toyota Safety. Toyota Team Members and Contractors must identify and visualize all affected equipment,
structure, and utilities. Project Leaders will determine the visuals (colors, flagging, tape) to be used for
demolition.
Project Lead and Shop representative will review and approve all aspects of the D-42 to include
utilities/connections and abandoned in place utilities. Two party verification is required. (See D-42
Demolition Checklist)
19.1 Building or Structure

An engineering survey shall be completed by a competent person (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 the Project lead and 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 Project Lead, 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 and
air gapped of 12 inches or more, if not air gapped contractor must provide Toyota written control measures
for control provided outside the building or in the specified area(s) of demolition before demolition work is
started. Review Toyota Site Specific Environmental Guidelines.
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 the floor in a controlled
method to prevent injury of personnel and property damage. It is permissible to drop items into dumpsters.
For all demolition or relocating of equipment where utilities will be removed or re-routed the D-42 is
required. Excludes equipment relocation that is not permanently installed (examples: plug in, quick
disconnects)
19.2 Machines and/or Equipment

Follow the manufacturers or Toyota PE/Maintenance 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. This standard would include relocation of equipment where
demolition or removal of utilities is required.
Excludes equipment relocation that is not permanently installed (examples: plug in, quick disconnects)
60
19.3 Handover to NAMC

A plan must be in place to ensure that the demolition work zone is safe before handover to the Toyota
Facilities. 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 4S truss inspection must be performed.
Section V
20.0 Energy Control Policy and Program (OSHA 29 CFR 1926.950)
20.1 Lockout
Lockout is required where the unexpected energizing, startup, or release of stored energy could occur and
cause injury, the employer 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 (D-16/D-18) shall be completed and submitted to
Toyota Project Leader (or designee) prior to beginning the work.
• The employer shall identify all sources of energy, using the Lockout Placard, which may affect their
work such as hydraulic, pneumatic, thermal, electrical, gravitational, residual, chemical, radioactive,
etc., with host Toyota Facility and Toyota Project Leader (or designee) prior to locking out.
• All lockout points must be identified and documented.
• 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 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;
• Label affixed to the lock with the required information.
Prior to locking out any existing equipment, the Contractors shall contact the Toyota Project Leader to
coordinate lockout activities with existing Toyota 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 and
61
qualified personnel shall work on equipment requiring lockout. Toyota reserves the right to review training
records for any employee.
20.3 Group Lockout

Group lockout shall be applied when the following conditions exist (not all inclusive):
• Multiple crews
• Multiple crafts
• Multiple Groups
• NAMC members working with contractors
• Work involving multiple shifts
Each group lockout/shall have a Primary-Authorized-Individual (PAI) with the responsibility for the group or
trade working under the protection of the group lockout. Each site shall have the responsibility for the
process to develop the group lockout procedures which shall meet the following criteria:
• Application – Used only when individual lockout is not practical, e.g. due to the number of locks
required.
• Requirement – Only one Primary-Authorized-Individual per group lockout application, even if
multiple groups or trades are working together.
• Written Procedure – Requires a specific written procedure for each occasion where group lockout is
implemented.
• Each trade, group, or other authorized individual(s) shall be identified in this procedure.
• Control – Uses a group-lockout-box or multi-hasp, etc., for control per procedure.
• Group Safety-Locks – A single safety-lock applied to each
For group lockout, a lockout sign in sheet or roster is required to be used. Refer to the Host Toyota Facility
for the appropriate form to be used for group lockout.
General Hardware Requirements Energy isolating devices, and all other hardware such as safety-locks,
multi-hasps, wedges, chains, information tags, limiting blocks, locking pins, cribbing materials, etc., shall be
confirmed for suitability (environment and application) to include any safety factors by applicable standards,
by either the TMNA PE Safety, or the responsible Safety departments. The hardware shall be substantial
enough to prevent removal unless excessive force (no less than 50 lbs.) or tools (such as bolt cutters or
other metal cutting tools) are used.
Safety-Lock Requirements:
There shall be a single key per set.
Only standardized colors listed below may be used:
• RED – Personal Safety-Locks

• YELLOW – Group Lockout Safety-Locks (To be used on Isolating Devices)
• GREEN – Project Control Locks
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 Toyota
62
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 D-14 form or Toyota Facility form shall
be completed and signed prior to lock removal. Check with local Toyota Security to determine if their
assistance in the removal of the lock is required.
Section X
21.0 Stairways and Ladders

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 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
that are faulty or defective shall be removed from the project/jobsite immediately.
21.2 Mobile Ladder Stands

Where practicable, mobile ladder stands are acceptable for use instead of step ladders. Mobile ladder
stands shall not be used for or near energized electrical work.
21.3 Ladder use (OSHA 29 CFR 1926.1053)

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.
The use of a personal fall arrest system shall be required when performing work at a height of 6’(1.8m) or
greater on a ladder on 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). The use of a PFAS should
be considered when working near guardrails while on ladders.
Personal fall arrest systems are REQUIRED when ascending/descending a fixed ladder which has a
continuous climbing distance of 10 feet or more, unless the ladder is a fixed ladder equipped with a cage.
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 perform work while
facing toward the ladder.
63
Supporting heavy or bulky objects and over-reaching and exerting excessive force by pushing or pulling
objects can cause loss of balance and ladder instability. If needing to perform these tasks, consider a safer
alternative method.
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 6’(1.8m). 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 (OSHA 29 CFR 1926.1053)

Job made ladders are allowed on the construction project for short term use only. Wooden ladders are not
allowed on jobsites in Canada. Job made ladders shall not exceed 10’ in length. 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. (See appendix page 134 for job made wooden ladder
requirements)
Section Z
22.0 Toxic and Hazardous Substances (OSHA 29 CFR 1926 Subpart Z)
22.1 Requirement
The employer 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 Toyota Environmental Department shall review and approve all chemicals prior
to their arrival on site.
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 Toyota Security/Fire for procedures and requirements regarding Emergency Response to
release of toxic or harmful chemicals at the project site.
64
22.6 Disposal
The employer 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 Toyota Environmental
department.
22.7 Exposure
Employer 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 employer’s responsibility to monitor for these substances and to communicate and protect its
workers if exposure is possible. Employer 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 (OSHA 29 CFR 1926.1203)
23.1 Requirement
All Confined spaces shall be considered “Permit Required,” unless otherwise identified as a (Non-Permit
Required Space US Only). Testing and verification are the employer’s responsibility.
(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 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.
65
• 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.
In advance of 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 Toyota Facility for specific requirements regarding
confined space procedures.
23.2 Confined Space Procedures

Employers 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.
The employer shall document the testing results and have them available for Toyota Safety review.
(Sample D-19). If the space meets the criteria for a non-permit required confined space, the employer may
proceed with 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 Toyota Facilities require additional confined space entry
instruction. Please consult your Toyota Safety contact for possible requirements. The checklist/permit
(Sample 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 employer.
66
23.3 Responsibilities
It is the responsibility of the employer to understand the duties and responsibilities of the entrant, attendant,
and entry supervisor.
Section CC
24.0 Lifting Requirements (OSHA 29 CFR 1926 Subpart CC)
24.1 General Requirement

All lifts, including upending or down ending, performed with the use of chain falls, come-a-longs, hoists,
cranes, and/or forklifts/versa lifts and/or other lifting devices or means must follow Toyota lifting and rigging
requirements as defined in this section.
24.1.1 Lifts of loads less than 220 pounds or engineered equipment with fork pockets
• Sequential job steps documented in daily JSA
o Control measures to secure load
• No D-26 Required
24.1.2 Lifts of objects over 220 pounds

• Completed D-26 submitted with JSA
• Qualified Rigger is required
24.1.3 Lifts meeting definition of critical lift

• Completed D-26 submitted with JSA
• Certified, Qualified Rigger or PE Stamp with Qualified Rigger
24.1.4 Critical Lifts

A lift that meets any of the following criteria shall be considered a critical lift at Toyota:
• Load greater than 1 ton that is being upended or down ended AND center of gravity is moving or
unknown.
• Unbalanced load of 5 tons or greater AND does not have engineered lift points.
• Lift exceeds 70% of the rated capacity of the crane.
• Lift being made in poor soil or unknown ground condition.
• Lift requires the use of more than 1 crane or the use of a crane and an additional hoisting device.
67
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 i s bei ng upended AND center of gravi ty i s
movi ng or unknown
Load greater than 1 Ton i s bei ng down-ended AND center of gravi ty

i s movi ng or unknown
Unbal anced l oad of 5 tons or greater AND does not have engi neered
l i ft poi nts
Li ft exceeds 70% of the rated capaci ty of the crane
Li ft bei ng made i n poor s oi l or unknown ground condi ti on.
NOTE: Previous excavation, noticeable standing or ponding

water, underground pits, tanks, vaults
Li ft requi res the us e of more than one (1) crane or the us e of a
crane and an add'l hoi s ti ng devi ce
24.1.5 D-26
The D-26 shall be submitted with the JSA to the Toyota Project Leader and Toyota Safety or Safety
designee for Team member-led work, prior to the work being performed.
The D-26 shall accompany the JSA at the work location and shall be reviewed with all involved personnel
performing the lift.
It is permitted to perform a single D-26 for lifts of same/similar equipment or objects when a single D-26
can cover the hazards of each lift.
Examples of lifts that can be performed using single D-26:
• Lifting same/similar robots utilizing the same lifting points, rigging methods, and lifting equipment
and no unique hazard is present between lifts. (Example of unique hazard: different end effectors
that change center of gravity)
68
• Lifting same/similar structural steel members utilizing the same rigging methods and lifting
equipment where no unique hazard is present between lifts. (Example: One project with lifts of
Beams, Columns, Joists, and Decking would require- (1) D-26 for all Beams, (1) D-26 for all
Columns, (1) D-26 for all Joists, (1) D-26 for all Decking)
Any deviation from the lift plan must require STOP, CALL, WAIT, the D-26 revised and communicated to all
personnel involved in the lift.
For Emergency repairs, a D26 Lift plan and Daily JSA(D18) shall be completed and reviewed with the
group performing the work at the time of repair.
24.1.6 Fall Zone

No worker is permitted to be in the fall zone at any point during any lift unless they are receiving the load.
Area must be properly barricaded with danger tape.
24.1.7 Lifting Storage Containers (Cabinets, Lockers & Other)

Lifting storage cabinets, lockers, or similar containers pose risks due to shifting loads. When attempting to
lift containers, remove contents before performing the lift unless unloading creates an additional hazard
(Example: Loading/Unloading >50lbs. object). Total weight of loads being lifted (cabinet & contents) can be
impacted if materials are not removed causing a change in center of gravity during transit. Loads must be
secured to the lifting device prior to lifting. Secure contents in container and consider modifications
(wheels) to the container that could change the center of gravity for the load when being lifted.
Any cabinets, lockers or similar type storage containers or a combination thereof greater than 4’ in height
that weigh greater than 220lbs. (including contents), or the overall weight is unknown, require a Daily
JSA(D-18), Lifting Checklist (D-26) completed and a qualified rigger to lift the load.
All loads shall be considered in transit until the load has been lowered and landed safely. No persons,
including spotters shall position themselves within 1.5 m away (5’ minimum) from the load and at 45* offset
around the load when the load is in transit. Never position yourself between the load and a fixed object.
If using a forklift and you are removing the load, always ensure forks are level and disengaged from the
cabinet to prevent tipping over.
All lockers with wheels must be secured to the lockers when installed. All lockers with wheels must account
for the additional hazards of wheels. To include the potential changing/shifting of load.
Locker Stickers
(ENG)
69
24.2 Riggers
A qualified rigger is defined as:
• possesses a recognized degree, certificate, or professional standing, or
• has extensive knowledge, training, and experience, and
• can successfully demonstrate the ability to solve problems related to rigging loads.
A certified rigger is defined as:
• A person who has passed stringent written and practical exams related to rigging from an
accredited organization.
• This requirement is not applicable in Canada and Mexico due to lack of certified rigger equivalency.
In Canada and Mexico, employers shall ensure riggers are qualified.
24.3 Rigging Equipment

Each day prior to being used, all rigging equipment 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 conditions warrant. Damaged or defective rigging equipment shall be immediately
removed from service. The rigging equipment shall have permanently affixed, and legible identification
markings as prescribed by the manufacturer that indicate the recommended safe working load. The rigging
equipment shall be stored in such a manner as to prevent a hazard to workers, or damage to the rigging
equipment.
24.4 Cranes and Derricks

Prior to any crane, derrick, hoist, elevator, or temporary conveyor being placed into service at the Toyota
site, a copy of the current annual third-party inspection shall be provided to Toyota Safety. Records of
required frequent and periodic inspections shall be readily available while equipment is on site. All mobile
cranes shall be inspected before its first use and comply with the most current version of ANSI or the
equivalent and with applicable law. The annual inspection report shall be provided to Toyota Safety prior to
use.
General Requirements Cranes and Derricks
• Prior to moving a crane into an area, the contractor must evaluate the underground conditions
for crane stability and the possibility of damage to the underground facilities or injury to
personnel.
• Access to areas where lifting operations are carried out shall be restricted by barriers and signs
must be posted.
• The swing radius of the load must be known, and unauthorized personnel shall be restricted
from accessing the area.
• Where hand signals are used, they shall be those prescribed in the relevant standard.
• A copy of the manufacturer’s manual for each make, and model, logbook, 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.
• Outdoor lifting operations shall be carried out during daylight hours only.
70
• Cranes should only be moved with the boom extended or with a load attached according to
manufacturer’s guidelines.
• 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.
24.5 Conditions
Upon arrival, before first use, if the crane changes possession, or is reconfigured the operator is
responsible for completing the Crane Operator’s Review (D-27) to ensure equipment is safe for use.
Operators shall verify and document that equipment placement areas shall support the weight of the
equipment and loads prior to any hoisting(D-26). The documentation shall be submitted to Toyota Safety.
The Operator 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.
Operators 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 Toyota Facility local rules shall apply as to
weather and lightning conditions.
24.6 Operations
The operator shall maintain a 20-foot (6.5 meters) clearance from any power line (up to 350 Kilovolt). A
qualified rigger and a qualified signal person shall be used on all lifts. For all critical lifts, a certified rigger
must be used.
Where caught between hazards 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 must use a spotter per the Spotter
Decision Matrix (D-30) in the Appendix of this document.
24.7 Qualifications
24.7.1 Hoist operator

Certified Crane Operator (CCO) certificate or other third-party recognized crane certification organization is
required to operate any crane (excluding Canada). 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.
71
24.7.2 Signal person

The signals used (hand, voice, or audible) and means of transmitting the signals to the operator (direct, line
of site, radio, etc.) shall be appropriate for the site conditions. The types and means of signaling shall be
determined prior to hoisting by all involved. The signal person shall be qualified.
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 and/or PROCADIST NOM-031
Construction Industry Standards (Mexico) 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 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 Representative.
Education & Certification
Required – OSHA 30 Construction Industry Outreach Program (U.S.)
Required – OSHA 510 Construction Industry Standards (U.S.)
Required – National Construction Safety Officer (NCSO) Designation (Canada)
Required – PROCADIST NOM-031 Construction Industry Standards (Mexico)
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, CRSP, 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.
1. Example - If the contractor will perform site prep, the contractor’s Safety Representative 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:
72
• 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
• 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:
1. Writing a contractor safety manual, Site Specific Safety Plan, etc.

2. Developing a process for JSA review and approval
3. Developing a construction safety orientation program
4. Developing a site audit program
5. 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 Contractor Construction Safety Representative 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 Representative badges and Dedicated Subcontractor Safety
Representative badges will be deactivated when their current assignment is complete.
25.3 Workers
All Contractor construction workers shall possess proof of training in an OSHA 10-hour Outreach Course
for the Construction Industry (U.S.).
25.4 Designated Contractor Construction Safety Representative – See Table in Section 1.7
Required – OSHA 30 Construction Industry Outreach Program (U.S.)
Required – PROCADIST NOM-031 Construction Industry Standards (Mexico)
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.
26.0 Toyota Team Member Performed Work
26.1 Non-Standard Work Activity

All Toyota TM-led non-standard work shall follow the procedure outlined in this section.
Work being performed has any type of work instructions (Standardized Work, Alternative Control Methods
(ACMs) etc.) with safety key points, Team Members will follow that work plan. For the work that does not, a
Daily JSA(D-18) is required.
All non-hazardous work does not require a JSA. Non-hazardous work can be defined by answering “No” to
the following questions:
73
• Does your job involve jammed parts, parts under pressure, gravity, or stored energy present in a
machine?
• Are you working from heights that require fall protection to be worn (>6' or >10' in Canada)?
• Are you troubleshooting with guards removed or bypassed while the machine has power?
• Does the job require you to lift objects that require rigging?
• Do you need to wear more than your shop required PPE?
• Are tools required to perform the task (Production tasks Only)
• Does your job require you to use more than hand (A Tools) and power Tools (B Tools) Only (for
Maintenance tasks only)?
• Do you need to lift any objects greater than 50 lbs.?
If you answer yes to any of the questions above, a JSA (D-18) must be completed.
All jobs/projects are required to be classified using the Non-Standard Job Safety Rankings Matrix (below).
74
After ranking the job, The JSA must be approved. The project leader and Toyota Safety/designee is
responsible for approving all Rank A and B jobs. The Job leader is responsible for approving all C-Rank
job activity. Once approved, work can begin. All applicable D-forms must be completed before starting
work. For all A&B ranked planned activity a D-35 audit shall be completed using the TERA application.
STEP to Safe Work

STEP to safe work
Slow down, Take a Minute, Evaluate environment with JSA, Proceed Safely
1a. Is there standardized work(WIS, MIS) or ACM
for task with safety keypoints? 1b.Answer all of the questions below
YES NO
•Does your job involve jammed parts, parts under pressure, gravity
or stored energy present in a machine w/o approved ACM?
•Routine fault recoveries(approved ACMs) •Are you working from heights that require fall protection to be
•Preventive maintenance worn(>6' or >10' in Canada)?
•ANY unplanned routine breakdown with work •Are you troubleshooting with guards removed or bypassed while
instructions and TM trained to the task the machine has power?
• Standardized Work can be followed w/o any •Does the job require you to lift objects that require rigging?
modifications
•Do you need to wear more than your shop required PPE?
(Example:Lift plan changes)
•Are tools required to perform the task (Production tasks Only)
•Does your job require you to use more than hand (A Tools) and
power Tools (B Tools) Only(for Maintenance tasks only)?
•Are you needing to lift any objects greater than 50 lbs.?
YES
Not applicable to TCSR . NO Answer YES to ANY question you MUST
Answer NO to ALL questions, NO JSA required
Follow WIS. Go to 1b. complete a D-18
No Additional Requirements
2. Classify the risk of your job.

Use Job Hazard Classification Matrix and Examples (Located on Back of Card) A B C
3. Confirm Safety Check for all required permits and training needed.
Use Safety Check per TCSR Section. On back of card. Deviation
4. Get approvals for JSA based on Job Hazard Classification
Rank A and B -Project leader and Safety or Designee from JSA
Rank C - Job Leader
5. Perform D-35 Audit for T ERA based on Job Hazard Classification
=
A & B-Rank Activity- Project Leader, Safety or Designee
STOP, CALL,
C-Rank Activity- No Audit Required WAIT
Rank your Job based on the work activities Safety Check per TCSR
ãConfirm Proper PPE

Job Rank Examples
· Troubleshooting w/power on and guards removed/bypassed within 6' of
ãJSA(D-18 Daily JSA)
crush/pinch point w/o approved ACM
· Lifting any Cabinet/locker/ storage bin >4' & >220 lbs. or unknown weight
ãProper PPE
·Non-Production Lifts > than 220 lbs. w/o engineered lift points or non-
palletized load without known center of gravity (D-26 required)
ã COHE Training
A
· Swapping Robots with Rigging >220 lbs.
· Fall Protection Equipment used w/o certified anchorage point
ã Machine/Tool Safety Cert
·Permit Required Confined Space Entry
·Rigging loads > 220 lbs.
· Trenching/Excavation
ã Energized Electrical Work
· Live Electrical Work > 50 volts or when energized work permit req'd (D-45 EEWP)
· Heavy Equipment Operation
·D-44 Exiting Aerial Lift Walking or Climbing Strucural Steel ã Rigging, Lifting, Hoisting, Crane Activity
· Stored Energy(gravity) or parts under pressure(jammed)
(D-26Lift Checklist)
· Building Karakuri/Minomi w/ external power or counterbalance
· Hanging screens/Andon displays
ã Confined Space Entry(w Permit)
· Moving/installing/removing guardrails/logistics fencing
· Hot Work
B · Demolition
· Elevated work from a lift (fall protection required)
· Fall protection used with a certified anchor point
ã PIV (Spotter Decision Matrix)
ãBarricading
· Ladder Usage > 6' (10' Canada) (fall protection required) (Danger/Warning Signage and Tape)
· All jobs using tools from the "C and/or D" Tool Classification
· Commissioning
ãHot Work(Hot Work Permit)
· Building Karakuri/Minomi -simple motion devices without power
· Painting (floor level)

ãFall Protection
C
· Hanging general signage (floor level)
· All jobs using tools from the B Tool Classification (Maintenance Tasks N/A)
ãAerial Lift Usage
· Lifting/Rigging Objects <220 lbs. but > 50 lbs. or lifting object >220 lbs.
with engineered fork pockets
(D-44 If leaving work basket or walking on structural
· Non-Permit required confined space entry steel)
ãUtility Tie Ins (D-03 Utility Tie In Request Form)
75
26.2 Troubleshooting
For all troubleshooting that involves the removal of covers/guards or bypassing a safety device with power
on, while within 6’ of crush and/or pinch point of equipment, the following conditions must be met:
Utilize approved ACM or D-18 (JSA) approval process for A-rank work tasks.
• Considerations that must be included in the approved ACM or JSA:

1. Controls must be in place to eliminate potential interaction with the crush and/or pinch point of
equipment. Examples include but are not limited to:
• Additional guarding in place over hazard area,
• Cameras to view from a safe distance,
• Grip switch enabling devices, pulse generators, teach pendants etc. for all entrants,
• Etc.
2. Procedure in place for TM interaction with residual or stored energy
3. Tape off the uncovered or unguarded area with Danger tape or use barricades to visualize the
crush or pinch point.
4. Apply approved ACM or isolate the equipment to prepare equipment for removal or bypass of
covers/guards.
5. Must have a procedure in place (including planned communication method for call out and
response) if manually moving components (stinging valves) to prevent hand, fingers, etc. from
being in the crush and/or pinch point of the equipment included in D-18.
• Once covers/guards are removed, only necessary power for troubleshooting shall remain on. All other
hazards shall be isolated.
• Troubleshooting area must be controlled to prevent unauthorized TMs from entering the work area.
If repairs are needed or covers/guards need to be reinstalled, follow CoHE using isolation or approved
ACM for the specific task needing to be performed.
No repair or modification is to be performed as part of troubleshooting.
26.3 Safety Qualifications for Toyota Team Member Performed Work
26.3.1. Safety Designee

The Safety designee can be any Toyota employee that completes the listed training and deemed
competent by Shop Manager.
• OSHA 10 for Construction (US ONLY)

• TCSR
• JSA
• CSMS
Required when applicable work being performed:
• Skilled COHE
• Fall Protection
• Hot Work
• Rigging/Lifting
• Mobile Equipment/PIV
76
• Aerial Lift
• Crane
• ESWP
• Confined Space
• Scaffolding
26.3.2 Project Leader

The Project Leader can be any Toyota employee that completes the listed training.
• OSHA 10 for Construction (US ONLY)

• TCSR
• JSA
• CSMS
26.3.3 Job Leaders

Job Leaders can be any Toyota employee that completes the listed training.
• Toyota Non-Standard and Maintenance Safety Requirements Training or TCSR

• JSA
Job Leaders are only able to approve low-risk jobs.
26.3.4 Workers
Any TM that is performing non-standard work activity must take the following training:
• Toyota Non-Standard and Maintenance Safety Requirements Training
77
Toyota Construction Safety Requirements

for Non-Standard, Maintenance, and
Construction Activities
Version 4.1
2024
Appendix
03/31/2024
78
Index Forms
The forms in the Appendix are to be used as needed to provide information and
Planning. These forms are available electronically.
Each Toyota Facility may have their own forms for specific activities. Check with
Toyota Safety before beginning work to determine which form should be used.
D-01 Declaration of Competent Person Form 81

D-02 Excavation Review Form 83
D-02A Pre-Excavation Form for GPR Scanning 84
D-02B Example Pre-Excavation Form 85
D-03A Utility Tie-In Request Form 86
D-07 Contractors Weekly Manpower Report 87
D-08 Emergency Contact List 88
D-09 Safety Cross Calendar 89
D-12 Incident Report 90-91
D-13 Safety Violation Form 92
D-14 Lock Surrender / Abandonment Form 93
D-15 Toyota Notice of Work Form 94
D-16 Contractor’s Overall JSA Form (sample) 95
D-17 Toyota JSA Review Checklist 96
D-18 Toyota Daily JSA 97
D-19 Confined Space Entry Form (sample) 98
D-20 Contractor Equipment Inspection form 99
D-25 Commissioning Warning Sign 100
D-26 Lifting Checklist 101-102
D-27 Crane Operator Review 103
D-29 Steel Erection Plan / Checklist (A-C) 104-110
D-30 Spotter Decision Matrix 111
D-35 Toyota Safety Audit Form 112-115
Escalation Matrix 116-117
D-38(a) Caution Sign 118
D-38(b) Danger Sign 118
D-40 Floor Opening Checklist 119
79
D-42 Demolition Checklist 120

D-44 Exiting Aerial Lift / Walking or Climbing
Structural Steel Check sheet 121
D-45 Energized Electrical Work Permit 122
Construction Incident Reporting Procedures 123

Site Control Board 124
Glove Cut Level Ratings Guide 125
Heat Illness Symptoms Diagram 126
Sloping and Benching Examples 127-133
Job Made Wooden Ladder 134
Scaffold Tags 135
Steel Erection Kanban 136-137
Cutting Tool Standard 138
Safety Ranking Matrix 139
Known Equipment Blind spots 140-141
Visualization of Construction Contractors 142
Use of Engineered Skates 143
Work Rules
Roll-Off Containers 144
Lineman’s Belt 145
Loading and Unloading Equipment to Delivery Trucks 146
ISN Variance Request (US) 147
Summary - Find It. Fix It. No Repeats. 148
80
D-01 Declaration of Competent Person Form
81
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
82
D-02 Excavation Review Form
83
Pre-Excavation Plan
Area of Work:
Utility Plan and Excavation Area

Date:
Utility Identification
Located Impact
1 Gas
2 Electrical
D-02A Pre-Excavation Plan for GPR Scanning
3 Water
4 Communications
5 Sewer
6 Storm
7 Other
Utility Identification Method:

EM Scan
GPR - not used due to clay soil and disturbed surface
condition
84
Pre-Excavation Plan
Area of Work: CHDY 10 Pit Utility Plan and Excavation Area

Date: Week of 10/24
Utility Identification
Located Impact
1 Gas O Impacted
2 Electrical O No impact
3 Water O No impact
D-02B (Example) Pre-Excavation Plan for GPR Scanning
4 Communications O No impact
5 Sewer O No impact
6 Storm O No impact
7 Other N/A N/A
Utility Identification Method:

EM Scan
GPR - not used due to clay soil and disturbed surface
condition
85
D-03A Utility Tie In Request Form (Verify with local Toyota Facility for current form)
86
D-07 Manpower Report
87
D-08 Emergency Contact List
88
D-09 Safety Cross Calendar
89
D-12 Toyota Construction Incident Report- Initial
90
D-12 Toyota Construction Incident Report- Final
91
D-13 Safety Violation Investigation Report
TOYOTA D13 Safety Violation Investigation Report
VIOLATION DATE:
VIOLATION TYPE:
VIOLATION TIME (24hr Clock):
PLANT:
DEPARTMENT:
PERSON OBSERVING VIOLATION
COMPANY NAME
WORKERS NAME:
SUPERVISORS NAME: PHONE:
D13: This report to be completed by the Superintendent/Foreman and submitted within 24hrs MAX.
WAS AN INJURY A RESULT OF THIS VIOLATION: YES (attach to form CSF D12) No
VIOLATION DESCRIPTION
WORKERS STATEMENT:
SUPERVISOR/FOREMAN BRIEF SUMMARY:
ACTION BY CONTRACTOR: Length:
ACTION BY TOYOTA:
PICTURES, SKETCH, COMMENTS:
92
D-14 Lock Surrender/Abandonment Form
93
D-15 Notice of Work Form
94
D-16 (Sample) Job Safety Analysis (JSA)
95
D-17 Toyota JSA Review Checklist
96
D-18 Daily Job Safety Analysis
97
D-19 (Sample) Confined Space Entry Checklist/Permit
98
D-20 (Sample) Contractor Equipment Inspection form
99
D-25 Commissioning Warning Sign
100
D-26 Lift Checklist
101
102
D-27 Crane Operator’s Review
103
TOYOTA Construc tion Proc edure PLEE & Safety Approvals
Proc edure Department: Produc tion Engineering PLEE PLEE SAF Date
Proc edure Name: Struc tural Steel Pre- Detailing Meeting GM
Proc edure Number: Effec tive Date: AGM
D-29A Revision
Pre-Detail
Number:
Meeting
Revision Date: MGR
Structural Steel Pre-Detail Meeting Agenda

Meeting 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 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.
The topics listed below shall be discussed during the meeting at a minimum.
General
Roles and Responsibilities
Key Contacts
Communication Protocol
RFI Process
Distribution
Shop Drawings
What to Submit
Format Requirements
Shop Drawing Submitted by Sequence
How Many Copies
Sealed Calculations (if applicable)
Shop Drawing Approval Timing
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.
104
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 Record
Representative Name Signature Date
Controlling Contractor
SS Contractor
SS Detailer
SS Fabricator
Joist/Decking Mfg.
Toyota Prj. Lead

Toyota Safety
105
D-29B Pre-Erection Meeting
106
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 for
both a competent and qualified person?
Are there any Critical Lifts?
Has the CSF D-26 been completed?
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 not
limited 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 all
affected persons to ensure understanding of the elements, procedures and timing required by the plan.
Indoor Structural Systems

Must have Erection Stability Plan developed and signed by a Qualified Person including but not
limited 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.
107
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 Members
Ladders Aerial / Scissor lifts Horizontal Lifeline Guardrails Free Climbing
Erection of Horizontal Structural Members
Installation of Roofing and Associated insolation
Installation of Decking
Installation of Wall Openings
Name Signature Date
Structural Steel Cont.

Name Signature Date
Toyota Project
Leader Review Name Signature Date
Toyota Construction
Safety Review Name Signature Date
108
TOYOTA Construction Procedure PLEE & Safety Approvals
•• PROTECTED Procedure
関係者外秘 Section: SAF PLEE Date
Procedure Name: Structural Steel Daily Pre- Start- up Meeting GM
Procedure Number: Effective Date: AGM
D-29C Daily Start Up Meeting

Revision Number: Revision Date: MGR
Daily Structural Steel Erection Pre-Start Meeting Agenda

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/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 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 N
both a competent and qualified person?
109

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?
Name Signature Date
Struc. Steel Contractor

Name Signature Date
Toyota Project
Leader Review Name Signature Date
Toyota Construction
Safety Review Name Signature Date
110
D-30 Spotter Decision Matrix

D-30 SPOTTER DECISION MATRIX
Criteria for spotter requirement Required Not required Comment
Forklift with no load √
Forklift w/ load or attachment √

Cranes √
Detail in JSA if
Working in a Civil Equipment √ pedestrian must be in
construction area taped area
Scissor Lifts √
Interior (Within Aerial Lift √

manufacturing Commercial Vehicles √
building)
Civil Equipment √
Driving in
established Cranes √
aisleway Aerial Lift √
Scissor Lifts √
Commercial Vehicles √
Working in a Cranes √
Detail in JSA if
construction area Civil Equipment √ pedestrian must be in
taped area
Scissor Lifts √
Exterior
Aerial Lift √
Forklift √
Civil Equipment √ No pedestrians
Driving on an
Vehicle Escort permitted on
established Cranes √ established
w/ flashing light
roadway roadways.
Scissor Lifts √
Aerial Lift √
Civil Equipment:
• Dedicated spotter is required for loaders, bulldozers, skid steer, and other civil equipment operating outside of designated construction area but not on established roadway.
• Areas with significant construction traffic require traffic control person in addition to spotters when accessing established roadways or aisleways
• JSA to dictate use of any additional spotters based on risk
• No pedestrian permitted inside designated construction area where civil equipment is in operation without specific tasks documented on a JSA.
•If pedestrians must enter, an escort is required.
Note:
No spotters permitted inside taped work zone unless performing rescue or specific instructions per JSA
Spotters are not required when operating forklifts as part of a normal production process.
A 1:1 spotter oper ratio is required when no barricading tape is used around a work zone.
If danger tape is used, one spotter can be used for all equipment if all spotter duties can fulfilled.
111
D-35 Toyota Construction Safety Audit Sheet

TCSR - CSF D-35 Toyota Construction Safety Audit Sheet
Contractor Name Audit Date MM/DD/YYYY

Audit Score
Location NAMC Department Shop
100.00%
Points Point Value
No. Question Response Comments
Received Possible
1. Section C - Major
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 30 30
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
2. Section C1 - JSA
1 Posted, easy access Yes 1 1
2 Required documents on control board Yes 1 1
Section Points 2 2.0
3. Section D - Environment / Site Conditions

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
Section Points 0.8 0.8
4. Section E - Personal Protective Equipment

1 Stand: Hard hat, glasses, high vis clothing, boots 0 0
2 Other: Correct for area, task, department 0 0
Section Points 0 0
5. Section F - Fire Protection

1 Extinguishers: Sized for task, inspected Yes 1.5 1.5
2 Flammable Liquids: Controlled, stored properly 0 0
112
6. Section G - Signs, Barricades

1 Proper Barricades: Placement 0 0
2 Signs: Correct, posted, phone number, red, yellow 0 0
Section Points 0 0
7. Section H - Materials / Handling / Storage / SS

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
8. Section I - Tools: Hand and Power

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
Section Points 0 0
9. Section J - Welding, Cutting, and Grinding

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
Section Points 0 0
10. Section K - Electrical

1 GFCI Protection: tested Yes 1.5 1.5
2 Extension Cords: Condition, Protected, Inspected 0 0
11. Section L - Scaffolds

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
Section Points 0 0
113
13. Section O - Motor Vehicles / Mechanized Equipment

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
14. Section P - Excavations

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
Section Points 0 0
15. Section Q - Concrete and Masonry Construction

1 Rebar / rods capped, protected Yes 1.5 1.5
2 Masonry walls supported, limited access zone 0 0
16. Section R - Steel Erection, Equipment Placement

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
Section Points 0 0
17. Section T - Demolition

1 Engineer survey by Competent Person made Yes 1.5 1.5
2 All Serv: Shut off, capped, disc, removed 0 0
18. Section V - Power Transmission / Distribution / LO

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
Section Points 0 0
19. Section X - Ladders

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
Section Points 0 0
20. Section Z - Toxic / Hazardous Substances

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
Section Points 2.5 2.5 114
21. Section CC - Cranes and Derricks

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
Section Points 0 0
22. Section A1 - Confined Space

1 Permit / Checklist Posted 0 0
2 Workers Trained / Rescue notified Yes 3 3
Section Points 3 3
Total Score: 100.00% 46 46
115
D-35 Escalation Matrix
116
117
D-38(a) Caution Construction Area Sign
D-38(b) Danger Construction Area Signage
118
D-40 Floor Opening Checklist
119
D-42 Demolition Checklist
120
D-44 Exiting Aerial Lift / Walking or Climbing Structural Steel Check Sheet
121
D-45 Energized Electrical Work Permit (EEWP)
122
CSMS Item 6 - Construction Incident Reporting Procedures
123
Site Control Board
1. Safety Cross 4. Daily Change Points

2. Project Site Layout 5. Toolbox Talks
a. Emergency/Evacuation 6. Job Safety Analysis
Routes 7. Project Schedule
3. Incident Reporting Procedures 8. Audit Results/TERA Trends
a. Emergency Contact 9. D-Documents/Relevant
Information Forms
b. Contractor Project 10. Project Specific Information
Contacts 11. Extra/Miscellaneous
c. Toyota Project Contacts
d. Toyota Security Contacts
*Binder can be kept in place of Site Control Board when space is not available.
124
Glove Cut Level Ratings Guide

ANSI/ISEA 105-2016 cut standard
The updated ANSI/ISEA 105-2016 standard, based on the ASTM F2992-15 testing method,
measures cut resistance for Industrial work gloves on a 9-level scale of A1-to-A9. Updated from
the ANSI/ISEA 105-2011 standard using a 5-level scale, the current standard allows for more
accurate identification of protection in PPE.
EN 388:2016 cut standard

The original Blade Cut test score in position“b”is measured on a scale of 0-to-5 as determined
by the EN Coup test. The new EN ISO Cut Resistance score in position“e” measures on a scale of
A-to-F based on the ISO 13997 testing method.
125
Section D- Environment/Site Conditions

Heat Illness Symptoms
Follow Local NAMC

Emergency Procedures
126
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:
127
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.
128
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:
129
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).
130
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
permitted in § 1926.652(b)
131
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.
B OVER A
C OVER A
C OVER B
A OVER B
132
A OVER C
B OVER C
permitted in § 1926.652(b).
133
Section X- Stairways and Ladders

Job Made Wooden Ladder – Single Cleat
134
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.
135
Section R-Steel Erection

Steel Erection Kanban
See ts.toyotasupplier.com for latest structural steel erection forms.
136
137
Cutting Tool Standard Chart
138
Safety Ranking Matrix
139
Known Equipment Blind Spots
140
141
Visualization of Construction Contractors Matrix
142
Using Engineered Skates
Work Requirements Use of Skates Transporting Materials over 220 LBS

Basic Concept: Yorisoi, treating Contractors as Family. We recognize that we have had several incidents at Toyota
Facilities involving the use of equipment moving skates.. Together with our Contractors we must find the safest method
when using skates to transport heavy materials.
Key Considerations:
1 Ensure that utilizing skates is a last resot and all other methods to move materials have been considered.
2 Skates must be rated for the weight of the material being moved and designed for planned use.
3 Manufacturer rating must be visible on skates or PE stamp must be obtained for shop built skates.
4 Appropriate method must be used to secure material to skates - no vice grip style clamps.
5 Identify all parts of the skate move on JSA.
• Skate to be used(multidirectional, fixed wheel, etc.)
• Determine the travel path
• Identify hazards (uneven floors, dips in concrete, etc.)on the route
• Develop CM plan for hazards
6 Utilize bracing between skates when necessary to prevent separation - 4 post Gantry, etc.
7 Ensure all body parts are kept clear of equipment being moved at all times. Determine safe distance to stand
away from load based on height and potential for falling. No hands/feet under suspended load.
8 Perform Stop, Call, Wait if need to reach in or under load arises. All 4 corners of load must have proper
chalking and cribbing.
9 D-26 Lifting form required for setting on/removing from skates.
If load gets stuck, STOP,CALL WAIT. Determine next steps to move load safely. Review JSA and D-26. Update
10 JSA where needed and create D-26 for lifting from skates.
This work requirement does not apply to TM-led non-standard work. If loads need to be moved with skates, contact a
competent contractor to perform the task.
Not Acceptable Acceptable
No PE Rating
143
Work Rules
Roll-Off Container Work Rule
144
Lineman’s Belt Work Rule
145
Loading and Unloading Equipment to Delivery Truck
146
ISN Variance Request Form
147
In summary, remember the following:
Toyota Safety Management is built around the principle of Find It, Fix It, No Repeats.
• Find It – TOYOTA expects our Team Members and Contractors to find safety hazards and
behavioral issues by themselves before someone gets hurt. This represents that the Toyota
Management, 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 sites.
• Fix It – TOYOTA expects our Team Members and 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.
Safety is the highest priority.
• No Repeats – Sustained success at TOYOTA requires Team Members and 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.
148

TCSR 4.1

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

TCSR 4.1

Uploaded by

Copyright:

Available Formats

•• PROTECTED 関係者外秘

Toyota Construction Safety Requirements

Toyota Production Engineering

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.

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

Mexican Federal Security, Hygiene and Environmental Regulación

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

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 Heal

9.4.1 Operating Controls and Switches .................................................................................................. 42

13.7 Horizontal Lifelines .......................................................................................................................... 49

17.3 Other Equipment/Tools (OSHA 29 CFR 1926.702) ......................................................................... 56

22.4 Storage/Labeling/Use ...................................................................................................................... 64

26.3.1. Safety Designee ........................................................................................................................... 76

1.0 Purpose and Scope

This document shall be applied to the following activities:

• All non-standard work activities.

1.1 Toyota Safety Expectation

1.2 Construction Safety Representation (CSMS 3.8, 3.9)

1.3 Contractor’s Responsibility (OSHA CFR 1926.16)

1.4 Toyota Acting as General Contractor/Contractor

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

1.7 Contractor Safety Representation (CSMS 3.8, 3.9)

Table 1 – Expected Contractor Safety Representation

Workers Required Safety

1.8 Required Documentation

1.9 Apprentice/Journeyman Ratio

2.0 Glossary of Terms Used/Interpretations

ANSI: American National Standards Institute

1. The accumulation of flammable, combustible or explosive agents, or

CHST: Construction Health and Safety Technician

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

• In which atmospheric hazards may occur because of its construction, location or

CPR: Cardiopulmonary 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.

CRSP: Canadian Registered Safety Professional

CSA: (Canada) Canadian Standards Association

CSP: Certified Safety Professional

CSMS: TMNA’s Construction Safety Management System

Decommission: To remove from service and make safe.

FLL: (México) Mexican Federal Labor Law

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

IDLH: Immediately Dangerous to Life or Health

Lockout: (LO) Placement of a lock on an energy-isolating device in accordance with an established

MOL: (Canada) Ontario Ministry of Labour

MSHA: Mine Safety and Health Administration

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

NEC: National Electrical Code

NOM: (Mexico) Official Mexican Standards

NFPA: National Fire Protection Association

NIOSH: National Institute for Occupational Safety and Health