英語版

For Technical Intern Trainees
ぎ のう じっしゅうせい む

技能実習生向けOne Step for TechnicalIntern Trainees to Conduct
Welding Operations Safelyぎ

のうじっ しゅう せい

あん

ぜん

おこな

よう

せつ

さ

ぎょう

だい

いっ

技能実習生が溶接作業をぽ安全に行うための第一歩

Contents

Introduction ����������������������������� 1

1
2
3
4
5
6

Three Common Types of Accidents in Welding Operations ��� 2
Operations with the Highest Incidence of Fatal Accidents���� 2
Accidents That Can Happen during Welding Operations and Questions�� 3
Know the Welding Situation in Japan ������������� 15
Four Points to Avoid Accidents ���������������� 16
Checklist Explanations �������������������� 17

Introduction

Welding is a skill used in products and structures in a wide range of fields,
including shipbuilding, automobiles, industrial machinery, and construction.
Related and peripheral work therefore encompasses a lot, and it can bedifficult to know how much information to include in technical training.
We ask technical intern trainees to read this safety and health operation
manual carefully to learn the techniques for staying safe and comfortable on
the job. This includes learning the proper way to wear protective equipment
and understanding where the dangers lie and what to be careful of in order toprotect oneself as a trainee in welding operations.
We hope that mastering the information in this manual will allow you to makeexcellent progress in your technical training by serving as a useful safety guide.

1

1

Three Common Types of Accidents in Welding Operations

The three most common types of accidents in the welding operations that you are involved inaccount for around 70 percent of all welding-related accidents.
(Based on an occupational accident survey conducted by JITCO in fiscal 2015.)

Eye damage from sparks and grinder shavings:

35％

Welding sparks and grinder shavings flying up and hitting
the eyes and face cause many injuries. Also, viewing
welding arc light can be harmful to the eyes and cause
them to hurt.

Pinching and entanglement:

23％

Gloves often get entangled in electric drills when workers
put a hand in to remove trash or material caught in amachine without turning the machine off. This sometimes
leads to serious injuries such as severed hands or
fingers, broken arms, or other injuries that leave workers
physically impaired.

Cuts and abrasions:

14％
Workers often cut their hands or legs with grinders andcut their fingers on materials such as steel plate.

2

Operations with the Highest Incidence of Fatal Accidents(1) Handling heavy loads 
Getting pinned between or under heavy loads can cause
serious injury. Never operate a crane, perform rigging, or
do other such work without a license.
When a licensed operator steps away, an assistant should
never do anything until the licensed operator returns. Wait
in a safe location.

(2) Handling processing machinery other than welding machines 
The scope of work that you can engage in as a welder
is defined. Just because someone might ask you to dosomething does not mean that you can engage in any typeof work.
You may not engage in work other than welding until after
you have received adequate safety and health training.

2

3

Accidents That Can Happen during Welding Operations and Questions

Checklist (Safety Glasses)
Item to Check1

Do you know what kinds of safety glasses there are?

2

Have you chosen a pair of safety glasses suited to the work
you do?

3

Are you using light-shielding protective eyewear?

4

Do you know the light-shielding number of the light-shielding
protective eyewear you are using?

5

Do the safety glasses fit your face?

6

Are you using safety glasses that have side protection?

7

Do you know why safety glasses that have side protection
are good?

8

Do the lenses of the safety glasses have a JIS mark?

9

Do you wear corrective prescription glasses?

10

Do you inspect the eyewear before use?

11

Do workers have their own safety glasses?

12

Are you taking care of the eyewear after use?

13

Are you storing the safety glasses properly?

14

Do you know when safety glasses should be replaced?

How much do you know?
Check your knowledge!
See the following pages for the answers.

3

Yes

No

Q1 Why does iron powder get in my eyes even though I wear safety
glasses?

A１ Even though you wear safety glasses, debris can still get in your eyes throughgaps in the glasses if they do not fit your face, when blown in by a worker next
to you, or, in the case of goggles, when debris collected on the top of the goggles
falls into your eyes when you take them off.

◆ Use safety glasses suited to the type of work (cutting, shaving, grinding, etc.).

Spectacles (protect the eyesfrom flying objects)

HC-1

HA-1

HA-1

Spectacles with sideprotection (protect theeyes from flying objects)

Goggles (protect the eyes fromflying particles, air-borne dust,
and liquid spray, etc.)

Fitting safety glasses• Choose safety glasses that fit your face. Safety glasses
are for personal use. Do not share them with others.
• It is important to adjust the nose pads and temples sothat the safety glasses sit securely on your face.
• The glasses should be supported evenly at three points(your nose and both ears).

Fitting points

Inspection after use• Check to make sure there is nothing wrong, such as being
dirty, scratched, broken, or that the lenses, eyepiece, orframe are not deformed.
• After use, remove any dust or dirt by rinsing the glasses
in running water. Then store them in a soft pouch or case.
How to clean○
×○
How to put down safety glasses

×Place in a case or pouch
made for the glasses.

Do not put them in a
toolbox with the tools.

Storage4

Q2 People often get hurt doing grinding work. What should I be
careful of?

A２ A grinding wheel is easily damaged or broken by the application of force, so it

must be used correctly. You must also be careful of accidents caused by flying
shavings, accidents caused by touching or getting entangled in the wheel, andaccidents caused by inhaling dust. When performing grinding work, follow theproper procedures and wear appropriate protective equipment.

Example of how to properly use a disc grinder 
1. Work
Grinding soft steel sheet with a disc grinder (Fig. 1)
2. Materials and tools• Soft steel sheet (19mm × 80mm × 150mm)• Vise• Disc grinder, grinding wheel
3. Procedure(1) Prepare Set the work piece so that about 10 mm sticks up
above the jaws of the vise (Fig. 2).
(2) Grinda. Hold the grinder in both hands and turn it on.
Run it for at least three minutes, checking forabnormalities.
b. Holding the grinder at an angle of 15–30 degrees
to the grinding surface, gently push it back andforth to grind (Fig. 3).
(3) Cleana. Turn the grinder off. When the wheel has stopped
turning completely, place the grinder down next
to the vise with the wheel facing up. Unplug thegrinder from the electrical outlet.
b. Clean the grinding surface with a whisk broom.
Clean the grinder debris with a rag.

◆

Precautions◆(Fig. 1)
Work
piece

About
10 mm

(Fig. 2)15～30°(Fig. 3)

(1) Always wear safety glasses or a safety mask and dust mask when grinding.
(2) Never use a grinder with the safety cover removed.
(3) Never use a grinder with wet hands. Never wet the grinding wheel with water or oil.
(4) Use electrical outlets that have a ground-fault interrupter.
(5) Pushing too strongly on a grinder is dangerous, as it can cause the rotation to stopor break the grinding wheel.
(6) When a grinding wheel is new, the corner can cut into the grinding surface whenpushed forward. So, grind by pulling backwards.
(7) M ake sure to connect the ground wire. (Some grinders do not need to be
grounded.)(8) Special training is needed to change the grinding wheel.

5

Checklist (Dust Mask)
Item to Check1

Can you explain the types of dust created during the work
you are engaged in?

2

Besides dust, is there any oil mist?

3

Are there any places nearby where organic solvents are
used?

4

Do you know the type and capabilities of the dust mask you
are using?

5

Do you use disposable dust masks when doing work
involving highly hazardous dust?

6

Have you ever done a mask fit test?

7

Have you ever used a fit checker?

8

If you lightly cover the dust mask’s air inlets with the palmsof your hands, can you still breathe easily?

9

Do you know when to change the filter in a replaceable dust
mask?

10

Do you put the dust mask’s strap around your ears?

11

Have you ever used a powered air-purifying respirator?

12

Does your workplace have a person responsible formanaging the wearing of protective equipment?

Yes

No

Do you know the answers this time?
Check these questions too!

6

Q3 Why must I wear a dust mask that makes it hard to breathe,even though I seem to have no bad symptoms?

A３ T h e s m o k e f r o m a r c
welding contains fine dust

particles called fumes. Whenbreathed in, this dust goes

Lung ofa healthy
personLung of apneumoconiosis
patient

deep into the lungs, where
it is deposited and neverexpelled from the body.
Dust breathed in today
is not going to make you
sick tomorrow. H owever,continued inhalation could
result in shortness of breath,a cough, and phlegm.
Further progression could(Photographs comparing the lungs of a healthy
person and a person with pneumoconiosis)

result in a scary disease called pneumoconiosis in which breathing becomesdifficult just by walking, you get heart palpitations, and you can no longer work.
It is important to observe the following points when performing arc welding and grinding
to avoid pneumoconiosis.

a. W hen you first become engaged in this work, get a medical exam forpneumoconiosis and then have regular pneumoconiosis exams thereafter toensure nothing is wrong.
b. Only start working after putting on a dusk mask that is suitable for the type ofwork.
c. Run local ventilation equipment.

What is a pneumoconiosis exam?
A pneumoconiosis exam is a test to check for a shadow
in the lungs caused by pneumoconiosis. It is performedby film radiography (direct radiography) using an X-ray
machine. Before starting dusty work, you must have thetest done to make sure nothing is wrong.
F lu o ro g ra p hy (a te c hni qu e in w hi c h X- rayphotographs are not directly taken) is used during
new employee health exams and regular healthcheckups, but it cannot detect pneumoconiosis.
Make sure you have direct radiography tests.
7

Proper way to wear a mask
Even if you go to the trouble of putting on a dust mask, dust can get in through any gaps.
Gently cover the mask’s air inlets with the palmsof your hands to make sure that air is blocked fromgoing through the filter, making it difficult to breathe.
If this does not make it difficult to breathe, there isa leak between your face and the mask. Move themask up or down, or adjust how tight the strap is to
fit the mask properly.

○×Types of dust masks
There are two types of dust masks(shown at left). Use a mask that has
been approved under national testing
standards.
Choose a replaceable dust mask if

Replaceable dust mask Disposable dust mask

Choose a replaceable dust mask whenworking with highly hazardous dust.

you conduct arc welding and grinding
frequently.

New filter

When to change the filters

Still usable filter

Filter that needs
to be changed* These photos are only examples. The color of filters that need to be changed differsfrom worksite to worksite.
 Check with the protective equipment manufacturer about the color of filters that need
to be changed at your worksite.
8Q4 Synthetic clothes are warm and rubber boots are convenienteven when footing is poor. Why can’t I wear them?

A４ Spatter and pieces of slag sometimes fly in all directions during welding. Wearflame-resistant work clothes and leg covers to protect your body from getting
burned.

◆Clothing and protective equipment for welding• Work clothes: Flame-resistant work clothes are preferable. Do not wear torn or
wet clothes.
• Apron: Leather is preferable.
• Hard hat: For protection from flying objects and falls• Safety glasses: Light-shielding spectacles or goggles• Dust mask: Replaceable or disposable• Safety boots: With a rubber sole
• Leg cover: Leather is preferable.
• Gloves: Dry leather. Do not use torn or wet gloves.
Hard hat

Safety glasses
Dust mask

Welding mask

Leather apron

Work clothes(ﬂame-resistantmaterial such as
55% cotton/45%
acrylic)
Arm covers
Leather gloves

Leg covers

Safety boots

Think about what other protective equipment besides the above is needed toprotect your body from accidents.
9Q5 I am told to use an automatic electric shock prevention device
when doing arc welding with an AC arc welder. What kind of
device is that?

A５ The voltage in the electrode holder is around 30 V when producing an arc

with an AC arc welder. When an arc is not made, the voltage increases rapidly,reaching around 70–80 V. So, were you totouch a connective part of the electrodeholder, you would receive an electric shock.
An automatic electric shock prevention
device automatically reduces the voltage
so much that there is no danger of electric

Exampleof external
automatic
electricshock
prevention
deviceshock during these times of no load. Some
automatic electric shock prevention devices
are internal and others are external.

(Nowadays most have an internal automaticelectric shock prevention device)

Danger of Electric ShockThe higher the current running through the body, the bigger the danger. Fifty mA(milliamperes) can be fatal.

Electric shock due to burnout ofelectrode holder

Electric shock due to exposure of secondaryside wiring of an arc welding machineElectric shock due to burnout of theflexible cable

The bigger the resistance, theharder it is for electric current toflow, and the smaller the resistance,
the easier it flows. Consequentially,
when you are sweating or wet fromrain, your skin resistance drops
considerably, so if you receive anelectric shock, more current would
flow through your body, which isdangerous. That is why you must be
especially careful in summertime.

An electric shock received by the electrode
touching the side of the body while building
a steel ramp

10

Q6 I used to use a crane to lift materials in my country by myself,
but I am not allowed to use cranes in Japan. Why?

A６ A crane is a powerful machine that can

Licenses for Rigging Work

lift and move heavy loads. This makes it

dangerous. If it is operated incorrectly, it cancause a big accident. The legal system inTechnical training

Completion certiﬁcate

Japan only allows people who have received
technical training and special training andLifting load
1 ton or more

who are licensed based on crane capacity tooperate cranes.
Also, rigging, such as wire ropes, fiberslings, and clamps and hooks are used tolift loads with a crane. Unless lifted correctly
for the type of rigging, the load could swing

Lifting loadLess than 1 ton

Special training

or drop. It is very dangerous. Rigging refers
to both the equipment and the method of attaching that equipment to lift loads.
Rigging is another type of work that requires a license in Japan.
List of technical training and special training for cranes, mobile cranes, and rigging
Type

Lifting load

Crane

Mobilecrane
Rigging

License, etc.

Floor-operated, 5 tons or more

Technical training in operation of flooroperated cranes

Less than 5 tons

Special training

1 ton or more, less than 5 tons

Small mobile crane technical training

Less than 1 ton

Special training

1 ton or more

Technical training for rigging

Less than 1 ton

Special training

Be careful

P OINT

11

Even when providing assistance for work not requiring a license, makesure to get special training and understand the dangers before engaging in
the work.

Q7 I got hurt due to my own fault when processing steel sheet.
Now I am not allowed to do press operations. Why?

A７ In order to engage in dangerous work, you must first receive sufficient safety

training and learn the dangers and the structure of the machines you will use as
well as the safe way to use them.
Also, the scope of work you can engage in is limited depending on the type ofskills you have acquired. Persons currently receiving technical training in welding
operations cannot perform press operations.

Work that technical intern trainees in welding
operations cannot do.

Examples of work that trainees in welding operations cannot do as a general rule
• Use a press machine to process components that will be welded, as a preparatory step
before welding• Use a spray gun to paint welded components, as a step after welding (excluding rustproofing)

Press

Painting
12Q8 The cleaning of machinery can be done more efficiently while

the machinery is running. Why must we stop machinery before
cleaning it?

A８ The severit y of accidents involving machinery is particularly high.
Entanglement of hands or other body parts caused by cleaning machinery thatis running can result in serious disabilities and even death. That is why Japanese
law requires machinery to be stopped before it is cleaned.

• Before cleaning, oiling, repairing, or adjusting machinery, turn off the machine, andmake sure that it is fully stopped. Only then proceed with the work.

• After turning off a machine, lock the starting system and put up a sign to prevent
others from turning on the machine.

• Never wear gloves when working with machines such as lathes, milling machines,
or drill presses, as this could result in a serious accident involving entanglement inrotating blades or machining chips.

• Just in case, practice stopping machinery using the emergency stop switch.

The following are not acceptable excuses!

Now cleaning.
DO NOT
TURN ON!

13Q9 When I was picking up some materials that had fallen on thefloor, a forklift that was backing up hit me and I got injured.
What should I have been careful of?

A９ Forklifts are a familiar sight, but they arealso powerful machines. The basic rule is to
not enter places where a collision is possible.
When that is not possible, a guide must be
assigned to the forklift to manage safety andensure there are no blind spots.

a. Keeping things tidy and in order is the basis of safety. There will be no collisions if
safety aisles and traveling lanes for forklifts are completely separate. Do not put things
in safety aisles. Do not put things that would be in the way in traveling lanes. That’s
how to avoid accidents.
b. There are spots that cannot be seen from the driver’s seat of a forklift. The load
obstructs the view when going forward. There are blind spots when backing up. Nevertake a shortcut or cut across an area.
The driver is not expecting this, and you could be in a blind spot. It is very dangerous.

Q10 What are 3S activities? Are they done every day?
A１
０ The 3Ss are the safety activities that include seiri, seiton, and seisou.
Ｓeiri

Sorting

ＳeitonSetting-in-Order

ＳeisouSweep/Shine

They are called the 3Ss (san-S) because
all three of these Japanese words startwith the letter S when written using thealphabet.

It is important to carry out the 3Ss every day to create a proper work
environment for everyone and to make dangerous areas clearly visible.

Seiri (sort)
Conduct safety inspections on
hand tools, make usable things
easy to use, and dispose of
unusable things.

Seiton (set in order)

Seisou (sweep/shine)

Properly put things back where

When the floor and aisles arethey belong so that they areclean, people do not slip or fall.

easy to use.
14

4Know the Welding Situation in Japan(1) Gas cylinder color: Differs by country. Check the colors used in Japan.

HydrogenCarbon dioxide

South Korea

Indonesia

South Korea

Indonesia

China

Japan

Argon

China

Japan

South Korea

Indonesia

China

Japan

OxygenAcetylene

South Korea

Indonesia

China

Japan

South Korea

Indonesia

China

Japan

(2) Power-supply voltage in Japan and Asia: Be careful handling electricity, as thefrequency and voltage differ by country.

a. Household voltage

Japan

Single-phase 100V

b. Industrial voltage

Japan

China

China

VietnamVietnamIndonesia
Philippines

Single-phase 220V

Indonesia

Three-phase 380V

Philippines

ThailandThailandSouth Korea

South Korea

15

Three-phase 200V

Three-phase 200/220/380V

5

Four Points to Avoid Accidents

 Lastly, we ask that technical intern trainees observe the following four points to avoid
accidents.

１ Fully understand the information necessary for work.

That is difficult unless you can understand the subtle differences of nuance inJapanese to a certain degree.
The quickest way to improve your Japanese is to use it in your everyday life.
Start by saying greetings in Japanese.

turn machinery off before conducting maintenance or２ Alwaysremoving accumulated dirt.
Machinery does not stop immediately when you press the stop button.
Do not touch the machinery until checking that it is perfectly still.
When working on a machine that is turned off, you need a sign such as,“Machine
Turned Off. DO NOT Touch the Switch!”

the habit of thinking for yourself about whether
３ Develop
something is dangerous.
It is important to think before doing something. Think first, then act, because
there are dangers all around.
It is very important to keep information up to date and to use your own
judgment.

４ Enjoy sports.

Although you move your body every day during work, that also causes stress.
Life is more than just work. You must also move your body in fun ways andenjoy yourself wholeheartedly.
Enjoy playing sports with your friends!

We hope that you will take the initiative on these four points, develop your skills, returnhome happy and healthy, and play an active role there.
c. Frequency

South Korea
Philippines

Japan

China

60Hz

Vietnam
60Hz

50Hz

50Hz

Indonesia

166

Checklist Explanations

Safety Glasses

1

Safety glasses exist to protect the eyes from different kinds of dangers, including
the intense light and harmful rays in welding and cutting operations, substancesthat irritate the eyes such as dust, and flying objects such as machining chips,
flying particles, and mist.

2

There are a variety of types of safety glasses for different purposes to protect
the eyes from flying objects, flying dust, airborne dust, liquid spray, etc. Use
safety glasses that are suited to the task.

3

Choose light-shielding protective eyewear suited to the work environment toprotect your eyes from harmful light produced during arc welding and thermal
cutting. Light-shielding protective eyewear can be either safety glasses or asafety mask.

4

The degree of hazard of harmful rays differs depending on the kind of weldingor thermal cutting and the conditions. When using safety glasses, choose andcorrectly use lenses and safety mask plates with a light-shielding number suited
to the work environment.

5

Choose glasses that fit your face.

6

The majority of injuries to the eyes occur from foreign objects entering throughgaps on the side. Use safety glasses that have side protection.

7

Injuries occur not only from flying objects such as metal but also the spray ofchemicals such as paints and harmful rays produced during welding (ultraviolet
rays, infrared rays, etc.) entering from the side.

8

If the lenses are bad they could break or get scratched and end up hurting your
eyes.

9

You must wear goggles or fit-over glasses over your prescription glasses.

10

a. Check for abnormalities such as dirt, cracks, breaks, or deformation. If there
are any, change the glasses.
b. If the glasses are loose or rattling, tighten the screws appropriately.

11

If several people use the same pair of glasses, they can start to feel
uncomfortable, like they do not fit, leading to an accident.

12

Following the user manual, clean your glasses after use to remove dust and dirt.

13

a. When putting safety glasses down, do not put the lens/eyepiece-side facing
down. That could make them dirty or scratched.
b. Store the glasses in a soft bag or case so that the lenses/eyepieces do notdirectly touch other objects.

14

Replace the glasses if there are abnormalities such as dirt that doesn’t come off
when washed, scratches, breaks, or deformation.

17

Dust Masks
1

You cannot choose an appropriate dust mask if you do not know the different
types of dust.

2

Masks for dry conditions do not perform well when there is oil mist. In this case,choose a mask designed for oil mist.

3

Choose a gas mask with an anti-dust feature equipped with a chemical cartridge
respirator.

4

It is necessary to know whether or not a mask is suitable for the work to be
carried out.

5

Use a replaceable mask when doing work involving highly hazardous dust.

6

It is important for a mask to fit your face. If contact with your face is not
maintained, you will inhale dust. Do a fit test to make sure your mask fits.

7

Nowadays, there are masks that have a built-in fit checker. Use the fit checker,
as it is an easy way to make sure a mask fits every time you wear it.

8

If you can breathe easily when you cover the mask’s air inlets with the palms ofyour hands, then there is a gap and the mask does not fit. Most of the time it ispossible to get the mask to fit properly by moving it up or down or adjusting thestrap.

9

The time to change the filter is determined by the color of the filter.

10

The strap must not be put around the ears as is done with a gauze mask. Put thestrap directly around the back of the head.

11

This makes it easy to breathe even when wearing the mask.

12

Do not manage masks by yourself. The person responsible for their management
must check them.

Mask with a built-in
ﬁt checker
If you have a mask with abuilt-in fit checker, you caneasily perform a fit test
after you have put themask on. This is a very
effective way of making a
habit of checking that yourmask contacts your face
fully.

○
Put the strap directly aroundthe back of your head.

×

Put it over your ears and helmet.

18

Commissioned by the Ministry of Health, Labour and Welfare. Printed March 2017