Case Report Toyota manufacturing plant company is Singapore Standard, SS651:2019 certified. The company is due for re-certification in November 2022. The steps below outline the general steps involved in processing and manufacturing a typical synthetic rubber. The plant stores and uses hazardous chemicals and flammable materials (naphtha) during the manufacturing processes. Storage tankers are equipped with secondary containment to contain spillages or leakages that could occur through the whole manufacturing process. During several of the walk-through safety inspections, the following were pointed out: 1. A number of power-driven tools (grinders, hammer drills, chain saws) did not come with a Licensed Electrical Worker (LEW)'s inspection sticker. 2. Chemicals kept in containers were not labelled in accordance to the Global Harmonized System (GHS). Chemicals were transferred to plastic drinking bottles instead of appropriate secondary storage containers. 3. When a technician was interviewed, he highlighted that there was a "rotten egg" smell in the chemical storage area. 4. Safety Data Sheet (SDS) of certain chemicals were either found missing or dated more than 5 years. 5. One of the facility management technicians was performing maintenance on a process equipment and no barricades were installed to prevent any unauthorized access to the work-area. 6. One of the sub-contractors (who was engaged by the facilities management team) was observed to be standing on the top rung of an A-frame ladder with both of his hands on his work and he was not wearing any safety harness. 7. When a worker who performed Work-At-Height was interviewed, he said that he is trained and permitted to work at height. However, his actual work practices were unsafe and risky.

8. Self-contained breathing apparatus (SCBA) and chemical suits for Emergency Response Team (ERT) were faulty. 9. CPR pocket masks in the first aid boxes had expired. Used and opened triangular bandages were found. 10. Several of the lifting equipment (webbing sling, shackle and chain block) were expired and a few of them did not have any lifting tags. 11. Tools and materials were scattered on the floor in the maintenance room. Damaged T5 fluorescent light, metal piping and plastic casing were found in the waste scrap bin. When the facility supervisor was interviewed, he mentioned that scrap materials were consolidated and would be disposed when the waste bins were full. 12. A sample size inspection of the fire protection system revealed that three ABC type of fire extinguishers were not charged with enough pressure and two ABC fire extinguishers were found to be obstructed. Further inspection revealed that four hose reel casings were dented.

13. Liquid stains were found on the floor within the perimeter of the storage tankers where hazardous chemicals were stored. There were many lagging indicators that contributed to unsafe conditions or unsafe acts in the plant, such as: > Lack of control of the usage and storage of chemicals > Human factors such as the conduct of the supervisor, operators and sub-contractors > Inadequate training of the users on the chemicals > Insufficient preventive maintenance and inspection of critical equipment (emergency response kits and fire protection system) External audit by the certification body is due to commence in three months' time. To prepare for the SS651:2019 audit, the Toyota manufacturing plant management team had tasked you to lead a team of internal auditors to perform management system audit on the entire plant. Question 1 I am assigned to lead the audit team to conduct a two-day audit. Develop the schedule for the internal audit. Show the schedule in a table format and discuss the activities to be audited, members of the audit teams to be involved, etc.