site report 2006 - sony · commendation for outstanding corporate citizen award (1993 & ......

Our Earth, Our Home 2

Pages Message from the Managing Director ……………………………………………... 3 Corporate Profile ……………………………………………………….…………….. 4 SPEC Environmental & Occupational Health and Safety (EHS) Policy ……….. 6 Environmental, Health and Safety Organisation / Structure …………………….. 7 Environmental Aspects Evaluation System ……………………………………….. 8 Environmental Action Programme vs Progress Status ………………………….. 9 Pollutant Release and Transfer Register (PRTR) ………………………………... 17 Occupational Health & Safety and Accident Reports ……………………………. 18 Risk Management ……………………………………………………………………. 20 Compliance with Laws and Regulations …………………………………………... 21

EHS Monitoring

Environmental Audits Environmental Management Cost ………………………………………………….. 23 Community Activities ………………………………………………………………… 24 External Communication Activities …………………………………………………. 25


The year 2005 was an eventful year. Our earth faced large-scale industrial water pollution

in China and carbon dioxide levels in the atmosphere have hit record highs. The North and South poles are on the brink of a climatic disaster that could affect the world. (The Straits Times, 15-Mar-2006) As part of the living world, SPEC has been continuing to reduce environment impact through innovations. We have undertaken two projects: source for new lighting tube and recycle of rain water. These two projects enabled SPEC to reduce energy consumption and mercury content, also recycle the rain water for cooling tower usage to reduce water consumption. In our efforts as a responsible corporate citizen, we, together with Sony Group of companies in Singapore and government bodies, jointly organized an event titled “Our Home to Care” at East Coast Park in March 2006. Participants also had the opportunity chance to visit NEWater Visitor Centre to get a better insight into the treatment of recycled water. At the same time, the event aimed to impart environmental awareness to some 450 participants including SONY staff and children from various schools.

It is with great pleasure that we share this site report with you, which I believe will help you to have a better understanding of SPEC’s efforts to conserve the environment for all. We appreciate your feedback, and will use it in our relentless and continuous efforts to improve our environmental, health and safety activities.

Nyan Teck Fook Managing Director


Company : Sony Precision Engineering Center (Singapore)

(A division company of Sony Electronics (S) Pte. Ltd.) Location : 52 Tuas Avenue 9 Singapore 639193 Date of Establishment : 3 February 1987 Business Activities : Manufacture precision components: optical pick-ups, magnetic heads

(Hi-8, DVC), digital 8, drum (digital data storage and spindle motors), SMT, power supply, solution business.

Staff Strength : 350 Managing Director : Nyan Teck Fook Share capital : US$38.9 mil

- Wholly owned by Sony Corporation, Japan Factory area : 18,131.6 m² Achievements :

OHSAS 18001 Certification by PSB Certification Pte Ltd (2001 till now)

ISO 14001 & Sony Requirement Certification by BVQI (2004 till now)

ISO 14001 Certification by Singapore Productivity and Standards

Board (1996 - 2003)

Safety Innovation Team Awards by MOM (2003)

Environment Awards by Sony Environment, Safety & Health Asia (2001 till now)

Safety Awards by Sony Environment, Safety & Health Asia (2003 till

now)

Awards by the Community Chest of Singapore for contributions to the SHARE Program (1989 till now)

Safety Performance Awards by Ministry of Manpower (1991 till now)

National Productivity Award (Individual) by Singapore Productivity

and Standards Board (1992, 1994 & 2000)

ISO 9001 Certification by Singapore Productivity and Standards Board (2000 till now)


Achievements : Environmental Conservation Prize by Sony Corporation (1998)

Green Leaf Award (to Sony Group of companies in Singapore) by

Ministry of Education (1996)

Commendation for Outstanding Corporate Citizen Award (1993 & 1994)

ISO 9002 Certification by Singapore Institute of Standards and

Industrial Research & British Standards Institute (1992 & 1993)

Certification of Singapore Laboratory Accreditation Scheme (SINGLAS) by Singapore Institute of Standards and Industrial Research (1993)

National Productivity Award (Company) by Singapore Productivity

and Standards Board (1990)


Sony Precision Engineering Center (SPEC), a Division Company of Sony Electronics (S) Pte Ltd, is a manufacturer of electronic components for the audio and video industry. SPEC recognizes the need to conserve the environment in its activities. SPEC also realizes the importance of providing a safe work environment for its employees and other personnel working on behalf of SPEC. SPEC Management is committed to the continual improvement of the environmental and safety performance, so as to:

prevent pollution to land, water and air; reduce consumption of limited resources, such as energy, water, paper, etc.; and reduce Chemical, Electrical, Mechanical and Fire hazards.

To fulfill our commitment, SPEC will:

Comply with the legal requirements on safety and environment, as well as Sony Group Environmental Vision and other Corporate Requirements.

Prohibit the use of ozone depleting substance in our operations. Ensure that SPEC employees and other personnel working on behalf of SPEC are aware of their

role in ensuring their own safety as well as that of others and protection of the environment. This will be achieved through the following:

establish and maintain in-house standards and effective safe operating procedures, provide the necessary information, training and supervision to all personnel encourage participation from all affected personnel in promoting environmental and safety

awareness Review and set EHS objectives and targets annually so that it is in line with GM2005 and SPEC

operational requirements. Carry out EHS audits and Policy review annually. Invest relevant capital and resources in implementing and enforcing this policy.

This policy will be documented, implemented and maintained, communicated to all employees and affiliates, and be made available to members of the public upon request.

Nyan Teck Fook

Managing Director 24 November 2005


Managing Director

Env. / Safety Management Representative (EMR /

SMR)

Division Managers

Green Partner (GP) Committee

Env. / Safety Section Fire Safety Manager (FSM)

Managers

EHS Committee Internal Auditors

PD1 EHS Committee

PD2 EHS Committee

Service EHS Committee

EMS

OHSMS

GP

Supervisors

Shift Leaders


In SPEC, each EHS Comittee shall identify all environmental aspects related to their activities, products and services. The identified environment aspects will be approved by the steering committee. The purpose of identifying environmental aspects and impacts are to reduce or eliminate the source of aspects through a series of activities. This will help to reduce the impact to our environment.


FY00 FY01 FY02 FY03 FY04 FY05 Electrical (kWh) 10,182,324 9,501,469 9,990,975 9,928,167 10,784,500 11,224,000Quantity (K-QTY) 55,367 59,555 80,228 108,019 89,940 108,318 Index (kWh/K-QTY)

183.91 159.54 124.53 91.91 119.91 103.62

Target (GM2005) 183.91 178.39 172.87 167.35 161.84 156.32 % Reduction (GM2005)

11% 28% 45% 26% 34%

Environmental Activity

Reduce lighting tube mercury contain & energy

Our clean room production lighting fixtures are using conventional ballast and 500 unit of 36W lighting tubes which consumed about 155,520kWh yearly. With the introduction of this technology, the existing design of lighting tube was made shorter and a component added which enabled the reduction of energy consumption by 6W. Therefore, clean room production lighting consumption has been reduced to 129,600kWh with a saving of 25,920kWh. At the same time, the mercury content inside the new design lighting tube has been reduced by a total of 30000ml from 37500ml.

Electrical Energy Usage

183.91

159.54

124.53

91.91

119.94

103.62

0

20

40

60

80

100

120

140

160

180

200

Fy00 Fy01 Fy02 Fy03 Fy04 Fy05

kWh/

K-Q

ty

Index (kWh/K-Qty) Target (GM2005)

3% 6% 9%

12% 15%


10% Reduction in power consumption for Lens thru better equipment productivity utilization for Fy2005

Current Process

55.05 TOTAL 1.24 Mold die close 8 3.0 Interval 7 3.27 Ejection 6 1.22 Mold die open 5 29.0 Cooling 4 8.05 Holding 3 7.56 Injection start 2 1.71 Mold die close 1

Time (sec) Process No.

4.287 Qty/mth/12mc(milpcs) 12.32 Molding output/mc(kpcs)

29 Operation Day/mth Max. Molding Capacity

4.447Qty/mth/12mc(milpcs) 12.78 Molding output/mc(kpcs)

29Operation Day/mthMax.Coating Capacity

To reduce energy usage by 10 % (55 53s

Target

Result : 1. Power saving/mth:US$5.76k ( TTL: 12mc – 288hrs ) completed June 06


FY00 FY01 FY02 FY03 FY04 FY05 Water (m³) 37,589 28,351 29,154 29,394 31,620 22,205 Quantity (K-QTY) 55,367 59,555 80,228 108,019 89,940 108,318 Index (m³/K-QTY) 0.68 0.48 0.36 0.27 0.35 0.20 Target (GM2005) 0.68 0.65 0.62 0.60 0.57 0.54 % Reduction (GM2005)

27% 42% 54% 38% 62%


Rain Water Collection Project

Previously our cooling tower system was using PUB water supply for topping up the evaporated water in Cooling Tower everyday and average per day consumption was about 43m³.

Water Usaged

0.68

0.48

0.36

0.27

0.35

0.2

0

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0.8


m³/K

-Qty

Index (m³/K-Qty) Target (GM2005)

4% 8% 12%16% 20%


By modifying the rain gutter to divert the rain water into rain water tank as shown in the diagram, the rain water will be the first to be used instead of using PUB water. If the rain water used up, the system will switch over to PUB for continuous supply of water. From the rain water saving project, we are able to save 9,468m³ yearly. To be in-line with NEA regulation on prevention of mosquito breeding, we have a control system to monitor the rain gutter.

1. Bi-weekly check on gutter to ensure no chokage 2. Bi-weekly check on the condition of roof drainage system


FY00 FY01 FY02 FY03 FY04 FY05 Reams 3,038 2,436 2,226 1,856 1,289 1,353 Quantity (K-QTY) 55,367 59,555 80,228 108,019 89,940 108,318 Index (Reams/K-QTY)

0.055 0.041 0.028 0.017 0.014 0.012

Target (GM2005) 0.055 0.053 0.050 0.048 0.046 0.044 % Reduction (GM2005)

22% 45% 64% 69% 72%


Close monitoring of paper usage.

A4 Size Paper Usage

0.055

0.028

0.0170.014

0.012

0.041

0.000

0.010

0.020

0.030

0.040

0.050

0.060


Ream

/K-Q

ty

Index (Ream/K-Qty) Target (GM2005)

4% 8% 12% 16% 20%


FY00 FY01 FY02 FY03 FY04 FY05 Total Solid Waste Generated (Kg)

806,080 206,593 208,611 233,873 193,960 188,977

Quantity (K-QTY) 55,367 59,555 80,228 108,019 89,940 108,318 Index (Kg/K-QTY) 14.56 3.47 2.60 2.17 2.16 1.74 Target (GM2005) 14.56 13.39 12.23 11.06 9.90 8.74 % Reduction (GM2005)

76% 82% 85% 85% 88%


Separate dustbins to segregate types of waste at source in PED. Close monitoring of waste generated.

Total Solid Waste Generated

14.56

3.472.6 2.17 2.16 1.74

0

2

4

6

8

10

12

14

16


Kg/K

-Qty

Index (kg/K-Qty) Target (GM2005)

6% 12%

18%24%

30%


FY00 FY01 FY02 FY03 FY04 FY05 Class III IPA Disposed (Kg)

14,059 8,874 6,530 4,040 4,155 6,388

Quantity (K-QTY) 55,367 59,555 80,228 108,019 89,940 108,318 Index (Kg/K-QTY) 0.254 0.149 0.081 0.037 0.046 0.059 Target (GM2005) 0..254 0.229 0.203 0.178 0.152 0.127 % Reduction (GM2005)

35% 60% 79% 70% 54%


Close monitoring of IPA usage Recycle IPA for general cleaning

Class III IPA Disposed

0.254

0.149

0.081

0.037 0.0460.059

0

0.05

0.1

0.15

0.2

0.25

0.3


Kg/

K-Q

ty

Index (Kg/K-Qty) Target (GM2005)

10% 20%

30%40%

50%


FY00 FY01 FY02 FY03 FY04 FY05 Class IV Acetone Disposed (Kg)

13,310 8,518 5,430 4,760 2,200 1,792

Quantity (K-QTY) 55,367 59,555 80,228 108,019 89,940 108,318 Index (Kg/K-QTY) 0.240 0.143 0.068 0.044 0.024 0.017 Target (GM2005) 0.240 0.216 0.192 0.168 0.144 0.120 % Reduction (GM2005)

34% 65% 74% 83% 86%


Close monitoring of Acetone usage

Class IV Acetone Disposed

0.24

0.143

0.068

0.0440.024 0.017

0

0.05

0.1

0.15

0.2

0.25

0.3

FY00 FY01 FY02 FY03 FY04 FY05

Kg/K

-Qty

Index (Kg/K-Qty) Target (GM2005)

10% 20%

30%40%

50%


Unit : Kg / Year Substance Isopropyl Alcohol Acetone

Classification III IV

Handled Amount 15,320.06 4,763.70

Release to air 4,113.40 483.48

Release to water - -

Release to soil - -

Consumed Amount - -

Treated Amount 6,388.33 1,791.72

Transferred Amount - -

Recycled Amount 4,818.33 2,488.50

Result of survey for PRTR substances. These hazardous substances are identified and classified according to GM2005.


OHS Programmes The following activities and pogrammes were carried out to enhance the occupational safety and health of our employees:

Committee Meeting & Inspection

Committee Training

Basic Safety Training for

New Employees

Refresher Safety Training for ‘Older’ Employees

Executive Orientation – Safety & EAP

First Aid Course

Fire Fighter Training

Chemical Spill Response

Training

Management on Site

Respiratory Protection Programme

Hearing Conservation

Programme

EHS Week

Internal Safety Audit

Management Review Accident Statistics 1995 – 2005


Chemical Spill Response Training Fire Evacuation Exercise

Monthly Inspection Safety Training

AED Training Basic Safety Training


Floor coating at Chemical Store A coat of chemically resistant protective layer is coated on the chemical storage area. This is to prevent soil contamination when there is spillage.

Exhaust Fan at Chemical Store

Exhaust fan will be activated if there is air contamination detected inside the chemical store.

Hump outside Chemical Store

The hump is built to contain any chemical spillage outside the chemical store to prevent chemical leak into the drainage system. (1st line of defence)

Storm Water Drainage

Emergency shut off gates are installed at various rainwater discharge outlets. This is to ensure that the hazardous substances such as lubricating oil and solvents do not get out of the premise when there is spillage. (2nd line of defence)

Machinery Guarding

All the machines used in the production are installed with sensors, limit switch and guarding which help to protect employees from moving mechanical parts.

Thermal scan on Electrical Panels

Thermal scan on electrical panels are done every half-yearly. This is to ensure that hot spots are detected and rectified immediately to prevent fire from occuring.

Monthly and Half-yearly inspection of fire protection system

Fire alarm system inspection is conducted monthly to ensure the system is functioning. Half-yearly inspection on the fire extinguisher and hose reel is carried out to ensure the equipments are usable during an emergency.

Emergency gas shut-off valve behind canteen

In case of any fire occur inside the canteen, the emergency gas shut-off valve is to isolate the gas from supplying to the fire.

Training

Annual fire drill and chemical spill training is conducted to educate our employees and create the awareness of fire and chemical emergencies.


Our operation is in compliance with Singapore’s Environmental Laws, The Factories Act and their subsidiary regulations. In addition, SPEC examines its control measures and test regularly to ensure the permissible limits are not exceeded. EHS Monitoring Environmental Public Health (Cooling Towers and Water Fountains) Regualtions 2001 This regulation came into effect on 1st February 2001. SPEC has carried out regular maintenance and checks on cooling towers which in accordance with Ministry of the Environment’s Code of Practice on Standard Plate Count and Legionella Bacteria. SPEC Cooling Tower Measurements

Cooling Towers Location Standard Plate Count (colony-forming units per milliliters)

Legionella Bacteria Count (colony-forming units per milliliters)

Allowable limit Less than 100,000 Less than 10

SPEC 1 < 1 Not Detected

SPEC 3 < 1 Not Detected

Exhaust Outlet Measurements

Sampling Location

Pollutant Date / Time Sampling Period

(mins)

Sampling Flow Rate

(l/min)

Concentration(mg/Nm³)

ENV National Emission

Standards for Air Pollutants

(mg/m³)

MOM PEL (LT) (mg/m³)

Isopropyl Alcohol 21-Nov-2005 0.1 219 N.A. 983 1015hrs – 1120hrs

SPEC 1 Exhaust Outlet

(65) Acetone 21-Nov-2005 0.1 24 N.A. 1780

Isopropyl Alcohol 1025hrs – 1110hrs 0.1 8 N.A. 983 SPEC 3 Exhaust Outlet

(45)


Environmental Audits In SPEC there are 3 types of Environmental audits carried out to ensure conformance to the desired standards. Internal audit SPEC has a team of 4 trained environmental internal auditors who conduct annual audits for the operational and service divisions. Surveillance audit BVQI, our external certification body for SONY GEMS & ISO 14001, conducts biennial surveillance audits to verify that SPEC maintains its system and procedure in conformance to SONY GEMS and ISO 14001 requirements. Corporate audit ESHA team from Sony Corporate will conduct biennial audit. The scope of this audit is wider and more in-depth, as compared to GM 2005, an internal requirment set by Sony HQ in Japan. Qualfied Persons Category No. of Persons Are they Qualified? Specialisation

Safety Officer 1 Yes Industrial Safety and Health

Fire Safety Manager 1 Yes Fire Safety Management and Regulations

Environmental Specialist

1 Yes Environment Management System, Environment Audit (System, compliance and risk) and Environmental Law

Internal Auditor 4 Yes Environmental Internal Audits


SPEC has invested on its environmental activiities to achieve the target set by its Management and Corporate. Item FY 2005 (US $)

Pollution Prevention

Air Pollution Prevention $896 Sampling and analysis of exhaust outlets at SPEC 1 & SPEC 3 for Acetone and Isopropyl Alcohol.

Water Pollution Prevention $581 Sampling and analysis of underground water & Waste Water discharged.

Reduction of Environmental Impact (manufacturing and service activities)

Energy Conservation $308 Reduce the lighting tube mercury content and energy.

Resource Conservation (including waste disposal, recycling and usage reduction)

$1,200 Recycle waste resin.

Reduction of water consumption

$4,070 Rain water collection project.

Green Procurement and Purchasing

Green Procurement of non-production materials (green purchasing)

$3,679 Purchase of recycled paper.

Environmental Management Establishment and operational

environmental management system

$231 Purchase of Environmental Management update.

Environmental Communication and Social Contribution

Community-based environmental contributions, tree planting, etc.

$3,000 Sony’s “Our Home to Care” 2005.

Other $4,102 Printing of Site Report. Using exchange rate of US$1=S$1.62165


Sony’s “Our Home to Care” in March 2006 The event “Our Home to Care”, at East Coast Park was organised by Sony Precision Engineering Center with supporting committee coming from various Sony companies in Singapore. Participants also had the opportunity to visit NEWater Visitor Centre to gain more understanding on how recycled water is treated.


SPEC has actively participated in various environmental related activities such as workshops, group meetings with Electronic Industries in Singapore, plant tours and conferences, etc. Matters related to ISO 14001 is communicated to interested parties upon request. Information Disclosure “Our Earth, Our Home” is the official report on SPEC’s efforts towards Environmental conservation. SPEC has attempted to address all applicable areas of the Site Report Guideline, which is developed by SONY Corporation. It is not possible to include all the information on SPEC’s environmental affairs in this report. For additional information, questions or components on the reports, please contact: Tan Kon Tee Sony Precision Engineering Center (S) (A division company of Sony Electronics (Singapore) Pte Ltd) 52 Tuas Avenue 9 Singapore 639193 Tel : (65) 6860 2901 E-mail : [email protected] Please fill in the feedback form and post it to us:

FEEDBACK FORM Name: NRIC No.: Gender: M / F Age: Tel no.: Address: 1. Content Too detail Sufficient Not detail enough 2. Design Good Fair Poor 3. Layout Good Fair Poor 4. Information flow Good Fair Poor 5. Overall quality of report Good Fair Poor Any Comments / Suggestions on this report?

site report 2006 - sony · commendation for outstanding corporate citizen award (1993 & ......

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