Environment, Health and SafetyPerformance Report 2012

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Environment,
H
ealth and S
afety

Performance Report 2012

















>>
Our Environment
, Health and Safety

Policy


As Farplas Auto Spare Parts Manufacturing, Export and Import Corporation, our aim
regarding environment and work
place

safety is to accomplish our responsibilities for
keep
ing
a clean environment that we can bring forward to the future and to create a healthy and safe
work environment. Therefore, we aim to minimize the environmental impact in all processes
from procuremen
t of raw materials to delivery of our products to our clients and to create safe
work environments. In these efforts, our main focus is on decreasing consumption of natural
resources,

minimizing creation of waste
and
preventing occupational accidents and
o
ccupational illnesses.


We are carrying out the control of environmental impact caused by our production processes
and
occupational
health and safety risks by procedures formed according to national and
international systems and standards and by an organiz
ational structure responsible for the
management of this issue.


Environmental and work
place

safety services that were being carried out by separate
departments at Farplas

until 2011 were brought together under the same roof in 2012 and a
more systematic and and professional

pursuit was started.


Our environmental
,

health

and
safety policy constitutes the main

framework of our
environmental, health and safety

management.


Environment
al

, Health and Safety

Policy

of Farplas


We, as Farplas A.
S.

family;


We aim to implement the requirements of Environmental Management System and
Occupational
Health and Safety Management System at our factories at Taysad and Avcılar
that
carr
y out

plastic injection, installation, painting and moulding
operations in order to
detect all negative impacts that may be harmful for environment or human health, to keep
them under control and prevent injuries and impairment of health and attain continuous
improvement.


In line with this aim; our basic principl
es are;



To implement all legal and other requirements that we have to obey for Envionmental
and
Occupational
Health and Safety,



To use energy properly and efficiently and to lower the consumption of natural
resources,



To decrease formation of waste, to pro
mote recycling and rec
overy
,




Attaining continuous improvement of our aims and targets regarding environment and
work
place

safety by determining and following
these
regularly;



As far as technical and commercial means allow, to use
the technology
that
is mo
st
reliable and
least harmful for the environment

and use raw materials that has the least
impact on the environment and that do not harm human health,



To determine work
place

safety risks that may cause occupational accidents and that
might lead to occupat
ional illnesses, to lower these risks to acceptable levels by taking
required precautions and to attain the ta
r
get of ZERO work accidents,



To determine impacts that may cause environmental accidents ahead of time and to
take necessary precautions on the ri
ght time and at the right place,



To raise awareness our employees, suppliers, sub
-
contractors and our society
continuously on environmental and
occupational

health and safety issues by means of
flow of information and trainings.


We aim to accomplish our r
esponsibilities for
keeping

a clean environment that we can bring
forward to the future and to create a healthy and safe work environment.

Rev.5.0

Revision Date: 06.08.2012






Ali RIZA AKTAY



Within the scope of this policy,
ISO 14001 Environmental Management System
standardization is being implemented at our factory since 2005. During meetings realized each
month with the coordination and initiative of upper management, all production and non
-
production operations are reviewe
d and developments regarding environmental and work
place

safety and results of
studies are evaluated, road maps regarding the ways for improvement are
designated
and all environmental and work safety activities are followed up.


Aims and targets designated

in line with policies and business strategies regarding
Environmental and
Occupational Health and
Safety are reflected to personal performances by
our Human Resources department and participation of all of our employees in this process is
realized.
Our En
vironment, Health and Safety
department make sure that national and
international requirements are fulfilled and ensures implementation of standards we follow
-
up. Effectiveness and sustainment of environmental and work
place

safety studies is attained
by internal audits planned each month in addition to external audits carried out by
independent organizations.


>>
Environmental, Health and Safety
Trainings


Farplas is aware of the fact that trainings
constitute the most impo
rtant element in the
formation the
consciousness about Environment, Health and Safety and
regards having all of
its employees, sub
-
contractors and their employees, its trainees and sub
-
industries informed
on environmental and
occupational
health and safet
y issues a
s a

principle of the company.

All
employees recruited are held subject to a one day
s

orientation training on Environment and
Health&Safety

issues.


In 2012, a total of 2200 hours of training were given to our 820 employees by authorized
experts of Farplas on Basic
Occupational

Health and Safety, ISO 14001

Environmental
Management System, Personal Protective Equipment Usage, Emergency Situations/Fire,
Near
-
miss/Hazardous Situation Notification System, Risk analysis,
Responsibilities and duties
of Work Health and Safety board, Waste Disposal issues.
In addition to the above, 2230 hours
of non
-
company training on Emergency Conditions, Crane usage, forklif
t usage, welding, first
aid, Personal Protective Equipment Usage issues were provided to employees by experts
outside of Farplas.


Besides training of its own employees and employees of sub
-
contractors, Farplas regards
training of sub
-
industries too as a
principle and training of 6 hours*man were provided to
main supplier company representatives at Farplas Gebze premises on Environmental
L
egislation and General ISO 14001

Environmental Management System


>>
Consumption of Natural Resources


2012 was a year when new projects were started to be implemented. A work period was
realized during which new product tests were carried out, their approvals were obtained and
put into production which required changing of 60% of production line.
Although
total
production capacity has increased 50%

in 2012
, quantity of products that were sold to the
market had decreased in comparison to year 2011, due to test works of new products. In
addition to the above mentioned works, studies for increasing productivit
y and decreasing of
consumption at the source, in line with 5S works, were speeded up in all of our factories.


>>
Water Usage


Water is not used in Farplas production processes. Water consumption consist of water used
for household consumption and water

used in paint shop. Waste water used at Paint shop is
recirculated in a closed system. As a result of improvement studies realized at paint
-
shop in
2012
, amount of water consumed per spare parts delivered to the market has decreased 27%
compared to 2011.


Consumption of Water
in
year
s



Years

Total Consumption

(m
3
)

Spare parts delivered
to market
(
pieces
)

Quantity of water consumed
per each unit of spare part

(m
3
)

2010

47104


29.711.994

16x10
-
4

2011

46343


31.711.993

15x10
-
4

2012

33177


30.711.994

11x10
-
4


Qu


Quantities of water consumed per unit of spare part in years (m
3
/piece)


>>
Consumption of Electric
it
y


Renewal of products to a great extent in 2012 and replacement of injection
machines with
injection machines with much greater capacities has led to an increase of electricity
consumption.

Procurement of electricity requirement for the new capacity was made possible
with increasing of amount of electricity transmitted from TOSB power line by 2
-
fold. Besides
these improvements, studies continue on projects for the use of energy more efficien
tly.
Studies are carried out for the prevention of energy losses of motors of production equipment.


As a result of new product tests carried out in 2012, quantity of spare parts delivered to the
market has decreased. In 2012, consumption of electricity pe
r unit of spare parts delivered to
the market has increased 11% compared to 2011.



Electricity Consumption in Years



Years Electrity Consumed Units of parts delivered to mar
ket Quantity of Energ
y


(kwh)

(
pieces
) consumed per unit of
p
arts


2010


16.851.690



29.711.994




0,567


2011


17.512.137



31.711.993




0,552


2012


18.819.253



30.711.994




0,613




Quantities of Energ Consumed per Unit in years (kwh/
piece
)








>>
Consumption of Natural Gas


At Farplas

premises, natural gas is used at mould heating stage of the production process and
in heating of the offices. After the improvement works made in t
he boilers
in 2012 quantity of
natural gas consumed has decreased 25% compared to 2011.



Quantity of Natural Gas Consumed per units of spare parts delivered to market in years


Years

Quantity of Natural
Gas Consumed


(kwh)

Units of parts
delivered to
market


(
pieces
)

Quantity of energy consumed
per unit of parts

2010

4.981.519

29.711.994

0,168

2011

6.304.110

31.711.993

0,199

2012

4.624.699

30.711.994

0,150



Quantity of Natural Gas consumed per unit of parts in years (kwh/unit)


>>
Integrated
Waste Consumption


Farplas

is fully aware of the importance of keeping a clean environment that we can delivered
to the future and effective works are being carried out for the protection of natural resources
and for decreasing of consumption.
Activities t
hat are in line with the triple principles of
“decrease consumption at the source, re
-
use, recycle”
are being carried out at Farplas
. Waste
materials that are obtained after production are classified and collected separately at the
source according to type

of the waste and legal regulations and transported with transportation
vehicles suitable for the type of waste that are licensed, they are recycled in licensed plants or
they are disposed of.
Process that will be applied on the waste is determined within
the
framework of legal legislation and only waste recycling or recovery of which are impossible
are disposed of.



RECOVERY


Disposal

Percentage of Recycling




Unhazardous Waste

(ton)


587


320*

65



Hazardous Waste

(ton)

151


5

97

Total


738


325

70

*Mostly Household Waste








Recoved Waste


Disposed
Waste

>>
Unhazardous Wastes

Every day more waste ma
terials that are obtained at Farp
las production plants are recycled. Trainings

given

to
employees on this issues, in
-
plant arrangements and productivity works carried out in line with 5S studies
enable a more effective classification of waste materials.



Years

Total Paper

(kg)

Total Plastics
(kg)


Units
Produced
(Pieces)

Quantity

of Paper sent
for recycling per unit of
parts

Quantity of plastics
given to recycling per
units of parts

2011

19.440

12.760

31.711.993

6x10
-
4

4x10
-
4

2012

115.120

72.880


30.711.994


37x10
-
4

24x10
-
4








Years

Total wooden
palettes

(kg)

Total Wedges


(kg)

Units of parts
produced
(pieces)



Quantity of Wooden
palettes given to
recycling per units of
parts



Quantity of wedges
given to recycling per
unit of parts








2011

77.794

64.353

31.711993

25x10
-
4

20x10
-
4

2012

117.900

73.900


30.711.994


37x10
-
4

24x10
-
4












Paper

Plastic Wooden Mixed İron


/Cartoons Packing Palette Wedges










>>
Hazardous Wastes




Hazardous wastes that come out from operations of Farplas

are collected separately at their
source, stored at Hazardous wastes warehouse for periods not exceeding the periods stipulated
in legal terms and shipped to recycling plants or disposal plants by licen
s
ed transportation
companies.






Recovered waste



Disposed Waste




















Main types of hazardous waste coming out of our operations are dyestuff sludge, contaminated waste,
contaminated packaging materials, greased iron chips, waste thinner, boric oil, hydraulic oil, fluorescent
waste, waste
batteries and medical waste.












>> Workplace Health and Safety


At Farplas, besides environment, great importance is also attached to employee’s health and
workplace safety issues. Zero work accidents principle is targeted at Farplas

for occupational
health and workplace security and works are being continued with the participation of
employees from all levels and with the necessary resource support in order to reach this
target.


In addition to parameters followed up by performance
system, accident frequency rates and
accident weight rates, employee of the month elections, training hours and days missed
indicators are being followed up under the scope of Occupational Health and Safety.


>> Workplace Accidents


In 2012 no occupational

illness and fatal workplace accident cases were experienced among
our employees working at our factories at Gebze and Avcılar.


ISG Indicator

2012

Accident Frequency Rate

10.0

Accident Weight Rate

0.15



Accident Frequency Rate=(Total number of work
accidents/total work hours)*1000000

Accident Weight Rate=(Total work days missed/total work hours*1000



>> Health Screenings

Recruitment check
-
ups, periodical tests, periodic examinations of our employees are being
performed regularly by our health unit.
In 2012, chest radiography, audiogram, respiratory
function test, phenols in urine, TCA, lead in blood, liver function tests, hemogram tests were
performed on our employees according to risks of their fields of work. Flu vaccine has been
made on 250 employ
ees in accordance with their request.


>> Risk Analysis


In 2012, occupational health and safety risk analyses made at previous years were updated,
after necessary evaluations were made, corrective and preventive actions were planned and
improvement studi
es were made.



>> Periodic Controls


In 2012, cranes, forklifts, elevators, air tanks, boilers, lightning rods and grounding lines used
at our factories were controlled by authorized persons. Necessary maintenance programs are
applied in order to enable
employees to use their equipment in safety.



>> Emergency Case Works


At Farplas, works are being carried out for the making of risk analysis, preparation of
emergency case plans, training of emergency case teams, emergency case drills in order to be
pre
pared for emergency situations that might take place due to natural disasters and for
emergency situations that may take place due to human actions.