Building Emergency Procedures |
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Assuring continuous service of DISCO machines at all times |
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DISCO is establishing a system in case of a natural disaster, such as an earthquake, so that customers can continue to use DISCO equipment and tools with security of supply and support. The following will explain the policy and the latest situation regarding this system.
Japan, the location of DISCO headquarters and manufacturing factories, is a country that has many earthquakes. DISCO is firstly preparing for a disaster based on a large earthquake that will ensure customers can continue to use DISCO products with security. In an emergency situation, the items that should be clarified are stated below and they focus on management resources for recovery measures.
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Ensure the safety of employees |
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Contribute to the local community |
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Maintain the supply of consumable products |
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Maintain equipment servicing and maintain the supply of parts |
DISCO is developing a Business Continuity Plan (BCP) to
establish a system that will "maintain the supply of necessary products and
services to sustain customer's current manufacturing volume" for when a major
earthquake occurs. The policy will also develop systems for other threats in addition
to earthquakes.
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Establishing an earthquake-proof manufacturing base |
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Humans cannot prevent an earthquake from occurring. However, advanced preparation can greatly reduce the extent of damage. DISCO is pursuing preventative measures to minimize earthquake damage, assuming an earthquake the size of the Kobe (1995) or Kanto (1923) earthquakes.
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| Built-in seismic isolators in the new Kure Plant building |
Seismic isolation structure |
The dicing blade manufacturing is carried out at two separate locations in Hiroshima- the Kure Plant and the Kuwabata Plant. Both plants are gradually replacing their current buildings; the new buildings use seismic isolation structures to prevent earthquake damage to the furthest extent possible. The seismic isolation structure reduces earthquake vibration, as illustrated, and is an extremely effective method to protect the manufacturing facilities from being critically damaged.　The Kure Plant, which is the main factory, is increasing the safety levels by moving the manufacturing lines one by one to the new building with seismic isolation structure, completed in November 2007. Meanwhile, the current building, with earthquake resistant structure, that houses the grinding wheel manufacturing lines, has been assessed by a company specializing in earthquake risk evaluation, and has implemented facility reinforcement and other safety measures as advised. At the same time, DISCO is securing the procurement of raw materials by ensuring secondary sources. In addition, 6-months worth of specific critical raw materials are stocked in the automatic warehouse in the new seismic isolated building in the Kure Plant, to be prepared for unforeseeable circumstances.
While focusing on damage prevention on the one hand, we are also establishing a system to ensure product supply in the remote chance that one of the factories is seriously damaged by an earthquake. In such a case, the other factory will take up the required manufacturing output and continue to supply consumable products to our customers. Further, we are considering our affiliate company DAIICHI COMPONENTS' Chino Plant to manufacture major Precision Processing Tools products to allow for distributed manufacturing. Chino Plant is in Nagano prefecture, 545 km away from the current Kure and Kuwabata plants, therefore, establishing an alternative manufacturing base in such a distance will further ensure a stable supply.
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| Reserve information system in Kure Plant |
A particular focus is on the digitization and duplication of information data that is essential for the supply of products to customers. DISCO has established a backup information system to increase information security by completely duplicating the system, not just the data. Major computer systems are installed at both the Tokyo R&D center and the Kure Plant in Hiroshima for duplication, with equivalent functions. Normally, the system in Tokyo is used, which is installed in a building with strong earthquake resistant structure. The severs are placed on a seismic isolator, and the room is equipped with an emergency power generator and fire extinguishing facilities; however, in case it becomes difficult to the run the system in Tokyo, we have a backup system to immediately start up the system in Hiroshima, and to switch operation. Data is constantly backed up and saved at both Hiroshima and Tokyo to prevent loss of information. To further ensure safety, we periodically perform switching tests and training for these computer systems.
The facilities are not the only important factor in earthquake-proofing the manufacturing bases. It is equally important to cultivate a "disaster-proof culture", by encouraging each individual to think about disaster and to raise their disaster awareness. In 2005, an original novella "The day DISCO quaked" was published in-house. It was a big hit. In response, all employees raised ideas for a faster recovery and to further reduce damage, many of which were implemented. The company decided that for a second earthquake novella, an internal competition would be held. Many employees entered the contest, and the best one was selected. This event has greatly contributed to raising disaster awareness by enabling employees to visualize an emergency situation, in a creative way.
In 2008, the Tokyo R&D center will have a new building on an adjoining site, with seismic isolation structure. The current computer system will be moved to the new building, to further improve earthquake resistance. Also, this new building will house a dormitory for single employees, so it will be possible for employees to be there within minutes in case of an emergency. This is to ensure adequate levels of staffing in case of a disaster, in addition to making the buildings earthquake resistant.
Meanwhile, DISCO is improving the earthquake resistance of sales and branch offices to protect the human resources that support customers. Sendai branch office and Shinshu regional office have been moved to locations which have been adequately earthquake-proofed in August 2006 and April 2007, respectively.
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Customer support system in an emergency |
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DISCO Japan is located in Tokyo and Hiroshima, which are far apart. Using this advantage, if Tokyo, which is the center of customer support, suffers a disaster, the Hiroshima office is prepared to perform this function instead of Tokyo. Also, if a services center or sales office within Japan suffers a disaster, the Tokyo office can directly support customers as a temporary replacement. DISCO would adopt a system that would give priority to the emergency repair of customers·equipment in the disaster area by redeploying all of the country's service engineers. DISCO headquarters would also directly support Taiwan and the Asian region which have a high possibility of an earthquake disaster like Japan.
There is concern about misinformation in an emergency like an earthquake. DISCO considers it important to promptly convey accurate information to customers and continually provide the latest damage situation to both customers and stake holders using the DISCO website and other means. DISCO is publishing in advance the contact people in case of an emergency and is make preparations to minimize the effects on customers.
DISCO disaster emergency contact people by region
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Preparing people for a disaster |
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In addition to earthquake-resistant buildings, it is important to have employees who are trained to respond in a disaster. In an emergency situation such as a large earthquake, people cannot instantly think and act rationally.
For this reason, DISCO thinks training that involves actual experience is important. "Earthquake! Get out!!" project, started in 2007, aimed to drill employees with emergency evacuation techniques. This was not just routine escape training. The project team thoroughly researched the ideal escape procedure utilizing the Earthquake Early Warning system, and performed tests with an earthquake simulator to create a tailored escape procedure, and repeated a thorough drill where all employees participated. As a result, the escape time reduced by 61.3 %, a remarkable achievement. Through these drills, employees have experienced the escape procedures as well as their importance. DISCO considers that making these drills part of our corporate culture is also important as mental preparation to a disaster.
The 240 disaster response personnel, who are to take immediate action in case of an earthquake, are continuing with further trainings. To be able to confidently take initiative in the initial operation, they are going through 18 curriculums consisting of classroom lectures and hands-on trainings, including emergency first aid and CPR training by qualified employees. The Disaster Response Task Force conducts an annual comprehensive disaster simulation to evaluate the training results, and to further improve them.
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| "Earthquake! Get out!!" training |
Escape test using earthquake simulator |
Comprehensive simulation training |
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Preparations for a large earthquake can never be perfect. Therefore it is necessary to make continuous improvements. DISCO, led by the BCM committee, which consists of company directors, is trying to continually improve our readiness while using the "Business Continuity Guidelines," which were announced by the Japanese Government in 2005, as our assessment guideline.
Based on this, DISCO is aiming for a "disaster-proof corporate culture" so customers can use DISCO equipment and tools with greater security of supply and support.
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