Download PDF - Honda of the UK Manufacturing Ltd

Safety and Environment Report 2010Honda of the UK Manufacturing Ltd, Highworth Road, South Marston,Swindon, Wiltshire SN3 4TZwww.hondamanufacturing.co.ukVERIFIEDENVIRONMENTALMANAGEMENTREG.NO. UK000109

2SE/D/G/15 - Nov 2011www.hondamanufacturing.co.uk

HONDA OF THE UK MANUFACTURING LTDSAFETY AND ENVIRONMENT REPORT 2010ContentsPage4 Foreword by HUM’s Managing Director5 1.0 Introduction5 1.1 HUM Profile5 1.2 Management Standards7 2.0 HUM Environmental Impacts and Controls7 2.1 Air and Odour9 2.2 Water Management10 2.3 Waste Management12 2.4 Energy Management14 2.5 Noise15 2.6 Traffic Management16 2.7 Visual Management17 2.8 Supplier Management18 2.9 Performance against Legal Requirements Summary 2010 - 201118 2.10 2011 Environmental Performance against Objectives and Targets19 2.11 Core Performance Indicators 201120 3.0 HUM Safety Risks and Controls20 3.1 Fire22 3.2 Plant and Equipment23 3.3 Vehicle Movements25 3.4 Associate Awareness26 3.5 Manual Handling and Ergonomics27 3.6 Performance against Legal Requirements Summary 201028 3.7 2010 Safety Performance against Objectives and Targets29 4.0 Safety and Environment Improvement Objectives 201129 4.1 Environment30 4.2 Safety31 5.0 Local Community Activity33 6.0 Glossary of Terms34 7.0 Verification StatementSE/D/G/15 - Nov 2011www.hondamanufacturing.co.uk3

FOREWORD BYHUM’S MANAGING DIRECTORThis is my first opportunity to introduce HUM’s EMAS report since joining as Managing Director in April 2011. However Ihave worked at HUM previously and have seen the Company grow and develop over some time.Our Company situation in financial year (FY) 2010/11 has improved with regard to production volumes, but only to thelevel of running single shifts in our car plants. The impact of shutting the whole factory for 4 months in 2009 did havenumerous concerns on our operations and, of course, makes year on year comparisons of our safety and environmentperformance misleading.We have continued to develop our management systems and work closely with the VCA, our external auditors, coveringOHSAS18001, ISO14001 and EMAS. I am pleased to report that on-going certification for all the standards has againbeen recommended, and we continue to aim for efficiencies and benefits from the auditing process. Being able to proveto external agencies and also to potential customers our safety and environmental credentials in this way is essential.On safety the actual number of accidents increased this financial year, but if we factor in the number of working monthsand again compared to the previous year there was a 6% reduction. Regardless, more attention is being given to bothaccident cause and robust countermeasures, supported with training from awareness to specific courses such as accidentinvestigation. I personally attend monthly safety tours to confirm actions following an accident where an Associate hassuffered a work related injury.Ergonomic improvements covering existing processes and factoring in New Model Planning has increased in importanceand will be a key Company business plan requirement in FY2011/12. Already we are seeing benefits withmuscular-skeletal related injuries at an all-time low – a trend that must continue to ensure our Associates are not injuredand enable them to complete a safe process that they have been trained on.On Environment, our report last year advised that we had set a target of zero waste to landfill by September 2010 – I ampleased to report this was achieved in August 2010, completing a 10 year project ahead of schedule, the original planbeing December 2010. This has been achieved in a sustainable way, with only the most difficult waste streams beingsent for incineration post August of last year. Only 83 tonnes of waste were landfilled in FY2010/11. Of the remainingincinerated waste HUM continues to strive for alternative solutions, with the ultimate objective of being a total recyclingcompany.CO 2emissions are now a key control item within our manufacturing operations and activities continued in FY2010/11 forboth data gathering and emissions reductions for many aspects within our business.The focus remains on direct energy consumption but we now include parts and product logistics, and for FY2011/12 willextend this work further - not only for this plant in Swindon, but for all of our EU factories and direct suppliers.Energy efficiency remains a top level control item – however although we control and improve energy use in the processand minimise out of hours, the extremely cold weather, measured in degree days over the last winter, significantlyincreased gas consumption for space heating. We will set extremely challenging targets in FY2011/12 for CO 2emissionswith an increased focus on energy base-load. Supporting our commitment for carbon reduction, we purchase electricityfrom our supplier utilising a low CO 2coefficient.We reported last year that our first renewable energy project would commence and a trial of two sets of photo-voltaicarrays was operational from August 2010. We had also hoped to receive planning permission for three wind turbineson our site, but the necessary decision was deferred – we will re-apply during this financial year and hope to completethis activity within calendar year 2013. With future plans for both on and off-site PV electricity, plus an on-site bio-massboiler partly using biomass fuel grown on-site also generating electricity, there is potential that 33% of HUM’s electricityrequirements can be from renewable sources.HUM’s coordination and legal compliance for materials usage continues and Honda globally has now joined theInternational Materials Data System (IMDS). Utilising supplier data and extracting information from IMDS into Honda’sown databases enables legal compliance confirmation, and also preparation for future changes which may restrict theuse of certain substances.Finally I would like to thank you for taking the time to read andunderstand HUM’s Safety and Environment performance.Soichiro TakizawaHUM Managing Director4SE/D/G/15 - Nov 2011www.hondamanufacturing.co.uk

INTRODUCTION1.0 INTRODUCTIONHonda’s operation in Swindon started in 1985 as a pre-delivery inspection facility and has grown into a carmanufacturer with the capacity to make 250,000 cars a year, currently employing over 3000 Associates.The decision to invest in Swindon was as a result of the development of Honda’s collaboration with the then RoverGroup, which started in 1979. The choice of Swindon itself was based on five key points: excellent people, excellentinfrastructure, good communications and work facilities and an available site for development.Since 1985 Honda has invested over £1.5 billion in the site and, since car manufacturing began in 1992, produced over2 million cars.1.1 HUM PROFILEEstablished - 1985Size of site - 376 acres (1.5 million square metres)Building area - 195,000 square metresNumber of Associates - 3200Annual capacity - 250,000 carsProducts - CR-V (Compact Recreational Vehicle), Civic 5-Door, Civic 3-Door, Civic Type-R, JazzMarkets - UK/Europe/Middle East/Africa/Australia/Russia1.2 MANAGEMENT STANDARDSHUM achieved certification to the international quality standard ISO 9002 in 1994, ISO 14001:2004 the equivalentenvironmental standard in 1998 and OHSAS 18001 (a nationally recognised safety standard) in June 2001. HUMupdated its Health and Safety Management system to comply with OHSAS 18001:2007 in 2008.ISO 14001 and OHSAS 18001 define formal systems of environmental, health and safety management. They are notintended to establish the absolute requirements for environmental, health and safety performance but to show acommitment to the safety and environmental policy, to comply with legislation and ensure continual improvement.Honda of the UK Manufacturing (HUM) published its first EMAS report covering both Safety and Environmentperformance on the 13th March 2002. The report has been fully revised and re-issued on 2 occasions and the mostrecent update has been confirmed by our external verifiers as compliant with the EMAS 3 standard.This 2010 report is a full revision as required by EMAS 3 and reports on HUM’s performance from April 2010 to the endMarch 2011.2010 has been challenging, with the focus on rebuilding the knowledge, experience and skills lost through the AssociateRelease programmes of 2008 and 2009. This is reflected in our performance and future objectives and targets.The Company Safety Policy was updated during 2009 and in 2010 the change was communicated to all Associatesthrough the monthly production meeting and Managers’ meetings, induction training, the notice board and theCompany and departments’ management systems. The Health and Safety Action Guidelines were not updated as it wasfelt that they still reflected the Company direction.The Company Environment Policy was reviewed and remains unchanged but the Company Environment ActionGuidelines have been updated to reflect the Company’s achievement of Zero waste to landfill in August 2010.Safety Policy StatementHUM will ensure a healthy and safe working environment by incorporating safety into the daily work processes andequipment, and by achieving relevant legal compliance.All Associates have a responsibility for their own health and safety and that of others, and must follow HUM’s safesystems of work.THERE CAN BE NO PRODUCTION WITHOUT SAFETYSE/D/G/15 - Nov 2011www.hondamanufacturing.co.uk5

INTRODUCTION1.2 MANAGEMENT STANDARDS (Continued)Health and Safety Action GuidelinesHUM will ensure a healthy and safe working environment by incorporating safety into the daily work processes andequipment, and by achieving relevant legal compliance.All Associates have a responsibility for their own health and safety and that of others, and must follow HUM’s safesystems of work.1. Management - A policy of prevention by efficient planning, risk assessment and awareness is confirmed by regularsafety audits data collection and analysis. The achievement against safety objectives and targets is reviewed regularly.HUM will maintain an OHSAS 18001 compliant safety management system.2. Associates - Associates have a duty to work safely and not put others at risk. They should have a positive attitude tosafety, and support and promote safety improvements. Associates will maintain their workplace to a high standard.3. Equipment - HUM will ensure that all equipment is designed and installed for safe operation, achieves European andnational safety standards, is assessed prior to use and is maintained to ensure continued safe operation.4. Materials - HUM will assure Associates’ health and safety by effectively controlling materials based upon risk andsupported by health surveillance and monitoring.5. Production Process - HUM assesses the risk of all production processes and will apply robust control measures toensure Associates’ health and safety. HUM will strive to achieve a safe and healthy workplace.6. Fire Safety - To ensure protection for Associates and the business, HUM has installed systems and equipment for fireprevention, detection and fighting to a high standard. Training and practices for emergency situations are conducted.Environment Policy‘We will make every effort to protect the environment from the effects of our manufacturing operations and will achieve,by means of continual improvement, the expectation of society and our local community.’Environment Action GuidelinesThe following action guidelines have been developed to support the Environmental Policy and to provide the principles forenvironmental activities. HUM is committed to the understanding and achievement of all relevant environmental legislation.1. Manufacturing Environment - The environmental impact of HUM’s manufacturing operation will be minimisedby controlling all process emissions and using the appropriate technology to enable HUM to achieve the standards setby law as a minimum. Additionally, LCA (Life Cycle Analysis) techniques shall be developed to measure and reduce ourcarbon impact.2. Local Community - In line with Honda’s philosophy to be a company society wants to exist, the environmental impactof HUM’s operations to the local community will be minimised. Information concerning HUM’s activities will be madeavailable to Associates and the community.3. Waste Management - HUM will strive to become a total recycling factory by 2014. The management of waste shall beprioritised on the basis of:• Minimise waste at source• Re-use of materials• Re-cycle• Incineration with energy recovery where practicable4. Energy Management - HUM shall manage energy use within its manufacturing operations through the EnergyCommittee and Facility Services to:• Develop energy reduction plans, implement activities and confirm results data• Instigate countermeasures to maintain planned targets• Promote Associate awareness• Source sustainable energy where practicable5. Suppliers - HUM will encourage our suppliers to be aware of their environmental responsibilities and will promoteenvironmental management of their respective operations. First tier parts and production materials suppliers areencouraged to achieve certification to ISO14001 or equivalent standard.6SE/D/G/15 - Nov 2011www.hondamanufacturing.co.uk

HUM SIGNIFICANT ENVIRONMENTALIMPACTS AND CONTROLS2.0 HUM SIGNIFICANT ENVIRONMENTAL IMPACTS AND CONTROLS2.1 AIR AND ODOURHUM has emissions to air from a variety of processes around the site. These are:• Body and bumper painting – Volatile Organic Compounds (VOCs), Particulates and Isocyanates, Nitrogen Oxides andCarbon Monoxide from the abatement systems• Aluminium die casting - VOCs, Particulates, Fluorides, Chlorides and Metals• Petrol storage – VOCs• Use of Adhesives and Sealer – VOCs and ParticulatesAll of these processes are regulated by permits issued by Swindon Borough Council (SBC) under the EnvironmentalPermitting Regulations.How is the impact measured and controlled?The SBC permits set limits on specified emissions from stacks and require controls to be put into place to minimise theimpact on the environment from the process.Emissions from the painting processes are controlled through the following methods:• Calculate a monthly mass emission showing the grams of volatile organic compounds (VOC) released per squaremetre of vehicle surface area or per bumper• Annual stack testing to a pre-determined standard by an external company• Checks to ensure there is no offensive odour at the boundary or visible smoke from the stacks• The use of waterborne primer, surfacer, basecoat and a high solids clearcoat• The use of thermal oxidisers to reduce VOCs from the vehicle paint curing process• The use of high efficiency paint transfer systemsIn 2010 HUM has continued to make improvements to reduce emissions to air. In the body and bumper paintingprocesses this includes:• The upgrade of the solvent recovery system in Car Plant 2 to include stainless steel pipe work. This willenable more solvent to be recovered• Training of all the managers in the content and requirements of the body and bumper painting siteoperating permits• Introduction of formal weekly, monthly and annual documented checks on equipment function andmanagement controlsPaint Line 1 StacksIn 2011 the permit training will be revised and presented to maintenance Associates to improve their understanding ofthe permit conditions.SE/D/G/15 - Nov 2011www.hondamanufacturing.co.uk7

HUM SIGNIFICANT ENVIRONMENTALIMPACTS AND CONTROLS2.1 AIR AND ODOUR (Continued)Emissions from the Die Casting Process are controlled by:• Dust suppressors on all the furnaces to reduce the particulates being emitted to environment• A fume scrubbing system to minimise emissions from the sand moulding process• The use of low resin sand to minimise odour from the process• Daily visual inspections and continuous particulate monitoring• Regular odour checks at the boundaryImprovements in the die casting operation have focused on establishing the root cause of the odour complaintsreceived in 2009 and 2010. During the past year HUM has received 2 substantiated odour complaints from localresidents. A full review of the physical (equipment) and management systems was carried out and the followingconcerns and actions were determined.• Low pressure die casting dust filters were found to be damaged and split, and had contaminated the carbon filters.Dust filters were replaced and the Environmental Health Officer agreed that in the short term there was no need toreplace the carbon filters as they were considered ineffective• High pressure casting - manual damper used when drossing off was found to be broken in September and theprocedure for ensuring it was used was ineffective. The damper was repaired and the importance of using itreinforced with the Associates• Odour testing was updated to establish the main odour sources• Action plan developed to define and timetabled improvements for further investigationsEmissions from the petrol storage process are controlled by:• Use of vapour recovery systems to minimise vapour loss during petrol transfer• Documented control systemsEmissions from the adhesives and sealers process are controlled by:• Monitoring of VOC use using a mass balance approach• Minimisation of waste materials• Controlled application methods• Documented control systemsDie Cast Example of Operator Permit Awareness Training8SE/D/G/15 - Nov 2011www.hondamanufacturing.co.uk

2.2 WATER MANAGEMENTDescription of environmental impactThere are two types of water discharged from HUM; storm and foul water. Foul water is discharged through the publicsewers and contains effluent from HUM’s domestic facilities and waste water from HUM’s production operation. Stormwater is discharged from the roof drainage systems and car parking areas.How is the impact measured and controlled?Foul water discharge has to meet the discharge consent limits set by Thames Water as required by the Water IndustryAct and the Trade Effluents Prescribed Processes and Substances Regulations. The Environment Agency specify dischargelimits into South Marston Brook from the on-site storm water lagoon as required under the Water Resources Act.To ensure the trade effluent achieves the discharge consents, HUM operates an on-site Waste Water Treatment (WWT)facility. Waste water from the Paint, Bumper Paint and Engine processes are sent to WWT for additional treatment ina batch process. Sampling to confirm compliance to discharge consent takes place throughout the process, to achieveoptimum treatment and guarantee discharge levels.All storm water from the site is discharged through an on-site lagoon, which is a single point of discharge for the site.The lagoon is an engineered structure with a concrete interceptor at the discharge point to the off-site brook (SouthMarston Brook) which is designed to regulate the flow of water to prevent flooding down stream and prevent anypetroleum based contamination entering the brook. The quality of the water is checked monthly to ensure compliancewith the discharge consent.Activity and improvements in 2010In 2009 a trial within wastewater treatment to reduce the use of chemicals in the water treatment process wascompleted. The results were analysed during 2010. Although all of the contamination was removed the project was notviable as the quantity of filter cake that was produced was not significantly reduced.HUM received a domestic water saving audit from Thames water during 2010. There were a number of recommendationsthat HUM has now actioned. Water usage will form a key part of HUM’s future business planning process.Storm Water LagoonSE/D/G/15 - Nov 2011www.hondamanufacturing.co.uk9

2.3 WASTE MANAGEMENT (Continued)Returnable crates used to transport andstore parts between Japan and HUMCompacted polystyrene stored for collectionActivity and improvements in 2010Baled polythene and cardboard storedfor collectionIn the last year the following activities have been carried out to further reduce waste to landfill and, later, incineration.• The bag and tag reporting and collection system was reinforced in Engine plant and the canteen and rest areas. Theuse of a clear bag has enabled HUM to get a better understanding of the remaining waste to maximise recyclingopportunities and has led to some products with non recyclable packaging being removed from the canteens, forexample, drinks in plastic bottles rather than ‘tetra pack’• Food waste is collected from the canteens and rest areas for recycling at a food rendering plant, and changes inproducts offered in the canteen ensure they have recyclable packaging• The trial using a wormery for food waste has continued during the year• The paint phosphate sludge was diverted from landfill into the cement manufacturing processAlso during 2010 HUM in partnership with Hills Waste Solutions was recognised by the Chartered Institution of WastesManagement (CIWM) Awards for Environmental Excellence, for their good practice in sustainable waste and resourcemanagement leading to the achievement of zero waste to landfill.CIWM AwardSE/D/G/15 - Nov 2011www.hondamanufacturing.co.uk11

HUM SIGNIFICANT ENVIRONMENTALIMPACTS AND CONTROLS2.3 WASTE MANAGEMENT (Continued)2010 Waste To Landfill PerformanceWaste to landfillTarget(Tonnes)35.0030.0025.0020.0015.0010.005.000.00Apr-10May-10Jun-10Jul-10Aug-10Sep-10Oct-10Nov-10Dec-10Jan-11Feb-11Mar-112010 Incinerated Waste PerformanceIncinerated wasteTarget(Tonnes)40.0035.0030.0025.0020.0015.0010.005.000.00Apr-10May-10Jun-10Jul-10Aug-10Sep-10Oct-10Nov-10Dec-10Jan-11Feb-11Mar-112.4 ENERGY MANAGEMENTDescription of Environmental ImpactHUM supports the continuous drive for CO 2reduction by investigating every opportunity to reduce the consumptionof energy. Energy management at HUM includes gas, water and electricity use. The measurement of energy includesbase energy used to operate the buildings, such as heating and lighting, and process energy used to manufacturethe product.How is the impact managed/controlled?HUM manages energy based on the ‘user responsibility’ principle. Targets are set on an annual basis and action plansdeveloped by divisions to achieve their targets. In 2010 it was determined that a centralised energy management teamshould be established. It was agreed that the focus of the groups’ activities would be to optimise the use of equipment,replacing high-energy use equipment where possible and reduce the energy used outside of production hours. TheCompany Energy Committee will also be restarted in 2011 and include representatives from each of the divisions. It willsupport the management group’s activities. The Paint, Bumper Paint and Die Cast departments are required to meetClimate Change Agreement targets set by the government and agreed through our trade association, the Society ofMotor Manufacturers and Traders, to comply with the Climate Change Agreement (Eligible Facilities) Regulations. HUMalso falls within the scope of the EUETS scheme (part of the Greenhouse Gas Emissions Trading Scheme Regulations)and has demonstrated a year on year improvement against the target emissions set by DEFRA.The majority of electricity usage on site is metered and real time data can be accessed by divisions from the intranet.Renewable energyHUM is committed to reducing its carbon footprint as part of the Honda global target. This target will be formalisedin 2011.Part of this strategy will require HUM to generate its own energy. The overall aim for renewable energy is to meet thebaseload requirements of the site; that is, be able to generate enough energy to keep the site operational when there isno production, for example at weekends and overnight. The energy sources under consideration are biomass, solar andwind. Significant progress has been made over the past year in all areas.12SE/D/G/15 - Nov 2011www.hondamanufacturing.co.uk

2.4 ENERGY MANAGEMENT (Continued)SolarIn the past year HUM have been trialling two types of photovoltaic (PV) solar panels to determine which type will bethe most effective in the UK. The types of solar panel that are under test are Honda Soltec thin film panels which arecapable of producing 125W per panel and Schuco polycrystalline panels which can produce 165W each. Two test arrayshave been installed on the roof of the engine plant locker room (picture needed). Both test arrays were switched on inMay 2010.HUM will evaluate the trial and make a proposal for future strategy during 2011.Solar array on the engine locker room buildingWindWind power is a key part of HUM’s future renewable energy strategy. HUM is proposing to install 3 x 2.3MW turbineswith a generating capacity of 17.7GWh.Picture wind turbinesPlanning permission is required for the installation of these turbines, which has been progressing throughout 2010. Ifplanning permission is granted HUM will install the wind turbines during 2013.BiomassThe theory supporting biomass as an energy source involves the planting of a crop that absorbs CO 2from theatmosphere during the growing phase, which is then released during burning to generate energy. If this CO 2is thenabsorbed by the next biomass crop then the process becomes carbon neutral i.e. generates no net increase of CO 2.HUM has started the biomass process by planting miscanthus (description/picture) on an area of the site. Progresshas been encouraging so far. Year one allows the miscanthus to become established, whereas year two can result in acommercially sized crop although it is often better to wait until year three before harvesting.Planting miscanthus - HUM, April 2010 Miscanthus plot - HUM, November 2010Current HUM activity is focused on research and development surrounding the husbandry and handling of themiscanthus plantation. HUM is also developing a strategy for the use of the biomass material on-site.SE/D/G/15 - Nov 2011www.hondamanufacturing.co.uk13

HUM SIGNIFICANT ENVIRONMENTALIMPACTS AND CONTROLS2.5 NOISEDescription of Environmental ImpactNoise is generated from HUM from a number of processes (internal and external), for example the Press department,air conditioning systems and contractor operations. HUM is required to comply with the Environmental Protection(Statutory Nuisance andClean Air) Act.How is the impact managed/controlled?Internal noise is controlled through understanding of safety legislation and internal safety standards to ensure theprotection of our Associates. All excessive noise is engineered out of the process where practical at the design anddevelopment stage. Externally sited equipment is regularly maintained to minimise noise levels. Contractor work iscarried out with the aim of minimising the impact on the local community i.e., hours of operation are restricted.Noise modelling has been carried out across the site to confirm noise levels at the boundary and that HUM is incompliance with our planning consent. The noise model is updated for new developments where noise is likely tobe an issue.What is a noise model?A noise model is a pictorial representation of sound levels from a noise source, in this case HUM. Noise levels aremeasured at source and a computer program is used to determine sound levels at certain points. The calculation ofthese noise levels takes into account topography, physical noise barriers and prevailing weather conditions. The benefitof a noise model is that external noise sources, such as local roads, can be discounted from noise.Activities and improvements in 2010The site noise model was updated in 2009 to include the Engine plant and Press shop extensions and the new Paintpre-treatment process. No concerns were found about the limits set at the boundary. In 2010 there were two noisecomplaints. The first was overnight noise when Die Cast Associates were emptying cages with large pieces of aluminiuminto the external scrap skips. The drivers were told not to empty the cages between 10pm and 6am. The second wasdue to a faulty compressor blow off valve, which was repaired on the same day as the complaint.14SE/D/G/15 - Nov 2011www.hondamanufacturing.co.uk

2.6 TRAFFIC MANAGEMENTDescription of Environmental ImpactThere are three main causes of traffic into HUM:• Transporters taking cars to the ports or dealers• Parts deliveries• Associates driving to and from work.Each of these impacts has an impact on the local community, including air quality and noise.How is the impact managed/controlled?Transporters taking cars to the ports or dealers.HUM continues to use transporters to move new cars to the distribution points. In all cases the loads are maximised andthe distribution companies are requested to utilise the main road routes to minimise the impact on the local community.Parts DeliveriesThe majority of HUM’s parts suppliers deliver into warehouses operated by a Honda subsidiary, South MarstonDistribution Centre (SDC), or their own local warehouses. A large percentage of deliveries from the warehouses arecarried out via an internal road to minimise the impact on the local residents. To minimise deliveries that have to use themain routes, suppliers are required to use M and A roads wherever possible and ensure that vehicles are fully loaded.Working alongside HUM’s logistics service providers, HUM have further delivered improvements in the efficiency ofthe operation through improving the consolidation of loads and reducing the numbers of trips run throughout the UKand continental Europe. The vehicle fill on our UK fleet has further increased to exceed benchmark levels of over 73m 3which equates to 85% of the achievable fill of the trailers used. Fuel efficiency by driver training, installation of vehicletelemetrics and live de-brief at end of each route has also continued to add value and an average fuel efficiency level of8.4mpg has been achieved.Associates driving to and from workDuring 2010 the Site Green Transport Strategy was finalised and approved. The strategy includes details of the plannedimprovements to reduce HUM’s impact on the local community over the next three years.In addition to the approval of the strategy HUM also:• HUM regularly attend the local business green transport group (SWIFT) led by Swindon Borough Council (SBC) andhas used this group to promote a green travel road show on-site• SWIFT remapped the post codes of HUM’s Associates to reflect the reduced numbers and to enable HUM to have abetter understanding of transport options available to them. The site traffic survey was also updated to reflect thechanges in manpower and shift pattern. In 2011 the changes in the Associate demographic will be reflected in theCompany’s Green Transport Plan• During 2010, 47 Associates took up the offer of the “What If” discount cycle scheme. HUM hope to promote itagain in 2011. 9% of Associates cycle to and from work which is above the national average• HUM is currently working with SBC to establish a cycle path from Highworth Road directly on to site and improvingthe on-site cycle path. This activity will continue in 2011A section of the on-site cycle path leading fromEngine Plant to Car Plant 1SE/D/G/15 - Nov 2011www.hondamanufacturing.co.uk15

HUM SIGNIFICANT ENVIRONMENTALIMPACTS AND CONTROLS2.7 VISUAL IMPACTDescription of environmental impactVisual impact is a term used to describe the effect on the landscape caused by buildings and their associated facilities.The current site buildings cover an area of 195,000m 2 . In addition to the building area, HUM has extensive car parkingareas for product and Associate cars. HUM must ensure compliance with the Town and Country Planning Act.How is the impact managed/controlled?All buildings on-site are coloured and constructed with the principle of minimising space to reduce the visual impactand working to blend the construction in with the landscape. This also helps to maximise building efficiency.The site is surrounded by a series of tree belts incorporating English native species, such as english oak, beech andhawthorn that are regularly maintained in accordance with the site planning consent.Lighting in the car distribution areas of site is controlled by Vehicle Logistics. Lights are directional and are aimed awayfrom South Marston village. The lights are controlled to ensure that 2 out of 3 perimeter lights are off at night andtherefore the night light is substantially reduced, also resulting in energy savings. The Facilities Services department areresponsible for the management of the Associate car park lighting. Energy consumption is minimised through the useof timers and photocells.Activities and improvements in 2010An ecological maintenance plan is in place which includes the maintenance of the site trees, herbiniculums, grassedareas and lagoon. The site meadows were cut last year as part of the tri-annual cut to improve the meadow grass andhabitat for wildlife and wild flowers.In 2011 this plan will continue and in addition work will take place on the lagoon including thinning the bullrushes toencourage stronger growth of native plants.Meadow next to the vehicle test trackReptile herbiniculum16SE/D/G/15 - Nov 2011www.hondamanufacturing.co.uk

2.8 SUPPLIER MANAGEMENTDescription of environmental impactIn order to manufacture our product, HUM is reliant on the support of suppliers. HUM has over 200 parts and materialssuppliers based both in the EU and the rest of the world.How is the impact managed and controlled?HUM continues to encourage and promote suppliers to obtain certification to an Environmental Management System(EMS). Already 97% of first tier suppliers have achieved certification.The environmental performance of suppliers that do not have ISO14001 or equivalent standard is assessed on an annualbasis using the supplier environmental management survey which is issued by the HUM purchasing division. The surveyresults indicate that all remaining suppliers have no significant environmental risk.HUM’s policy is to utilise returnable packaging with regard to all component supply. The use of non returnablepackaging is not acceptable and cannot be supported through the supply chain. HUM also utilise a re-use and carry overpolicy on returnable packaging where possible from model to model.HUM’s activities include working with suppliers and logistics companies to monitor carbon foot prints and to improvethe utilisation of transport for parts deliveries by using a “milk round” system. The milk round system works bycollecting parts or returning packaging to a number of suppliers on one journey, thus ensuring the vehicle does not runempty which improves the overall logistics reducing both cost and carbon miles.These and all other significant environmental impacts are managed through the site environmentalmanagement system.Returnable Stillages/Cages used to Transport and Store Parts between Suppliers and HUMSE/D/G/15 - Nov 2011www.hondamanufacturing.co.uk17

HUM SIGNIFICANT ENVIRONMENTALIMPACTS AND CONTROLS2.9 PERFORMANCE AGAINST LEGAL REQUIREMENTS SUMMARY 2010Criteria 2008 2009 2010 Legal requirementAir and OdourBody paintingVOC mass emissions (g/m 2 ) 18 20 20 60VOC (mg/m 3 ) 8.61 4.51 7.63 50Particulates (mg/m 3 ) 0.5 0.7 1.1 5Nitrogen oxides (mg/m 3 ) 43 61 54 100Carbon Monoxide (mg/m 3 ) 26 39 37 100Isoyanates (mg/m 3 ) Not required until 2009 0.01 0.04 0.1Bumper paintingVOC (mg/m 3 ) 8.4 6.4 4.63 50Particulates (mg/m 3 ) 0.1 1.1 0.6 5Nitrogen oxides (mg/m 3 ) 49 39 50 100Carbon Monoxide (mg/m 3 ) 48 52 20 100Isoyanates (mg/m 3 ) 0.016 0.01 0.01 0.1Die castingParticulates (mg/m 3 ) 0.9 0.7 7.1 20Chloride (mg/m 3 ) 0.05 0.06 1.19 5VOC (mg/m 3 ) 9.1 5 2.3 30Water (note: annual averages)Metals waste water streamoil and grease (mg/l) 1.1

2.11 CORE PERFORMANCE INDICATORS 2010Media Indicator Measure Total Total / T of cars* CommentEnergyEfficiencyMaterialEfficiencyWaterWasteBiodiversityEmissionsTotal direct energy use(MWh)Total renewable energyuse (MWh)Annual mass flow ofdifferent materialsused (T)Total WaterConsumption (m 3 )Total Annual Generationof waste (T)Total AnnualGeneration ofhazardous waste (T)Build up area onsite (m 2 )Total annual emissionsof greenhouse gases(CO 2 , CH4, N2O, HFC,PFC, SF6) (T CO 2 )Total annual airemission (T)% of energyconsumption bythe organisationfrom renewablesources208,614 1.014540% 0To be agreed Not known Not known Development of measure anddata collection part of 2011business plan activity452,040 2.19838Landfill 83 0.00040Incineration 220 0.00107Treated 284 0.00138Recycled 13,374 0.06504607 0.00295697,000 3.38969Total 158,971 0.77312 Does not includemanaufacture of KD partsSO2 Not reported Not reported Not significant as solid fuelnot burnt on site and not asite permit condition.NOX 3.92 0.00002 Calculated from stackemssionsPM 7.48 0.00004 Calculated from stackemssionsVOC 249 0.00121 Based on mass emissionresults*Total Annual physical output measured as tonnes of cars produced in 2010 calculated by model -– 193365.7.SE/D/G/15 - Nov 2011www.hondamanufacturing.co.uk19

PLANT SAFETY HAZARDS3.0 PLANT SAFETY HAZARDS3.1 FIREDescription of Safety RiskThere are three areas at higher risk from fire within HUM. These are the Welding, Paint and Die Casting areas as eitherhot work is carried out or flammable material is being stored and used.How is the Risk managed/controlled?HUM’s fire policy focuses on the prevention of fire, ensuring effective and tested evacuation procedures are in place andfinally fire fighting but only if assessed as safe by trained and competent Associates.Fire PreventionThe most important part of managing fire is to prevent it occurring in the first place. This is achieved by both physicaland management controls including:• Fire Risk Assessments carried out for every building on site in accordance with Regulatory Reform (Fire Safety) Order2005 and action taken on all high priority items.• All new equipment is ATEX specified as required and checks carried out following installation on site.• A high standard of housekeeping is maintained.• Regular sweeps through higher fire risk areas to ensure combustibles are not in contact with sources of ignition.• Regular maintenance checks on all equipment.• The controlled storage and use of flammable substances, particularly petrol, solvents and gases.• The use of water based paint within the paint shops rather than solvent based paint• Responsibilities for fire prevention are clearly allocated and documented.• Designated smoking areas and a restricted site smoking policy.• A permanent security presence on site to the reduce risk of arson.• Permit to work system controls irregular hot work outside of designated hot work areas.• Regular inspections by related insurance companies.Fire Training at HUMFire EvacuationTo ensure effective, immediate and safe fire evacuation, detection systems are installed throughout. Fire managementsystems include:• Fire alarm sounders, break glasses, emergency lighting, fire exit signs and smoke detectors that are linked to a firemanagement computer system.• Fire procedures detail actions to be taken by Associates and emergency teams.• Emergency evacuations and roll calls tested regularly. There are two types of fire evacuation a soft evacuationwhich includes only the evacuation of people from their areas and a hard evacuation which confirm that allrequired equipment shuts down when the alarms are activated. Trained emergency teams to investigate and ensureevacuation.• Fire assembly points with radio communication to emergency teams.20SE/D/G/15 - Nov 2011www.hondamanufacturing.co.uk

3.1 FIRE (Continued)Fire FightingIf a fire were to take place at HUM the priority is to ensure safe evacuation.Stratton Fire Station is only 2 minutes away from the main site entrance and regular liaison is carried out to ensure allcrews are familiar with emergency arrangements and site layout. This enables the fire and emergency authorities toupdate tactical information, which is held at the main site entry point.Physical fire fighting controls are also in place. These include:• All areas except die casting have fire sprinklers.• Fire extinguishers in all areas including large trolley mounted extinguishers in higher risk areas and water hydrantring main around both plants.• Fire management computer system automatically shuts down high risk areas such as Paint and the petrol deliverysystem. It also opens security locked doors.• Specially designed solvent storage and mix rooms in Paint and Bumper Paint.• Emergency cabinets containing equipment and tools likely to be required in an emergency.• All fire equipment is regularly maintained.The effectiveness of these controls is reviewed in each department through the company safety audit system.Activities and Improvements in 2010Easy to Identify Fire ExtinguishersThere were a total of 12 minor fires during the last year details of the cause and countermeasure of these is detailed insection 3.6. Fire sweeps of each area hasve now been increased with the concern items from 2010 reflected into the firesweep check sheet.In addition in 2010 the following improvements were implemented:• All fire drills were completed according to schedule using the hard and soft fire drills method introduced in 2009.• A total of 158 people completed fire extinguisher training including 33 trained in the use of the Class D fireextinguisher for metal fires from the Die Cast area.• The site wide fire risk assessment was completed by an external company and while no major concerns werehighlighted a small number of minor issues were raised, which will be counter measured in the first part of 2011.SE/D/G/15 - Nov 2011www.hondamanufacturing.co.uk21

PLANT SAFETY HAZARDS3.2 PLANT AND EQUIPMENTDescription of Safety RiskEquipment is used to support every aspect of HUM’s manufacturing process. Equipment is defined as machinery,appliance, tool or assembly of parts. The typical equipment hazards at HUM are:• Mechanical hazards - trap or crush points; contact with moving parts; ejected or falling parts• Electric hazards such as shock or burns• High or low temperatures• Noise and vibration• Ergonomic• Chemical• Optical Radiation• BiologicalHow is the Risk managed/controlled?To minimise risk the priority is to eradicate any hazards during the design, manufacture and installation of newequipment. All new equipment is CE marked and purchased according to a strict Honda specification. Once theequipment is installed an equipment safety check sheet is completed to ensure that the equipment complies with theHUM specification.The company Engineering Committee is responsible for coordinating the review and upgrade of older equipment acrossthe site to ensure compliance to current legislation. This is an ongoing process of continuous improvement.Noise and vibration testing is carried out at the start of a new model, following a significant change in a process or ifa concern is highlighted through health surveillance. In 2010 noise monitoring in the Engine Plant has been completedand has been started in the Weld and Frame Assembly divisions.Activities and Improvements in 2010The Safety and Environment department have been closely involved in new projects over the last year working withthe project teams to ensure ergonomics, safety and environment are considered in the project phase and as part ofthe process design. The construction of the spot robot line in weld 1 which was completed in November 2010, is anexample where this has occurred.The planning stages of a new engine line started during 2010. Construction is planned to start in November 2011.22SE/D/G/15 - Nov 2011www.hondamanufacturing.co.uk

3.3 VEHICLE MOVEMENTSDescription of Safety RiskVehicle movements on site include:• Associates coming to work• The delivery and movement of parts around site.• The movement and testing of new vehicles.• Associates business driving on public roads.• Visitors and contractors.All of these activities present different risks to our Associates, visitors and other road users and need specific controls tobe appropriately managed.How is the Risk managed/controlled?Car MovementsCar movements include the movement of new vehicles to loading areas, Associates driving on and off site and thedelivery of parts and materials on site. Where possible pedestrians and vehicles are kept separate. A site speed limit of15mph outside the building and 10mph inside the building is imposed. Vehicle speed checks are carried out to increaseAssociate and driver awareness and enforce the speed limits.Forklifts and TowtrucksForklifts and tow trucks are used to move parts and consumables around the factory.Examples of process controls to minimise the risk includes:• All drivers are selected, trained and hold an HUM licence which gives them the authorisation to drive.• All trucks undergo regular maintenance and daily checks are carried out before they are used by the driver.• Only gas and electric trucks can be used on site and they are speed limited.• Dock lock systems are used for all loading and unloading activities in lorry bays.• Barriers are used in front of doorways and gangways painted green to protect pedestrians.• Seat Belts worn on all counterbalance forklifts.• Clear warning signage to alert pedestrians to the vehicle movement hazards.All drivers moving cars on site or driving for company business are required to undergo defensive driver training andsign the company driving procedures to confirm they will comply with the company rules.Cycle routesAssociates and visitors that wish to cycle to HUM are provided with bike shelters and safe and clear routes ofaccess/egress. Drying facilities are available for damp/wet clothing.In the last 5 years extensive reviews and maintenance has taken place on all site roadways, cycle paths and car parks toensure clarity of demarcation and signage.Vehicle Pedestrian SegregationIn 2010 this work focused on improving the routes for pedestrian between the two car plants.Improvements included:• Upgrading the barriers to discourage Associates from going under them or round them• Widening of the pedestrian crossings to incorporate the walkway from the picnic area.• Hatched area prior to crossing to discourage HGV’s from stopping or waiting in front of the pedestrian crossing.• Fencing erected in front of the locker room building and around the picnic area to encourage Associates to use thepedestrian crossing.• The Associates understanding of the requirements to use the correct routes was confirmed by observing the area atbusy times.SE/D/G/15 - Nov 2011www.hondamanufacturing.co.uk23

PLANT SAFETY HAZARDS3.3 VEHICLE MOVEMENTS (Continued)Improvements to the Pedestrian and Vehicle Segregationbetween Car Plant Line 1 and 2Workplace transport risk assessments were carried out in the external areas including the car parks by an outsideconsultant. Signage and road marking improvements were recommended and these will be completed during 2011.Example of Planned Road Marking andSignage Improvements24SE/D/G/15 - Nov 2011www.hondamanufacturing.co.uk

3.4 ASSOCIATE AWARENESSDescription of Safety RiskGood Associate safety involvement is critical to ensure that safe working practices are followed and accidents arereduced. Unsafe behaviour or a poor safety culture can lead to an increase in all types of accidents.How is the Risk managed/controlled?A strong safety culture and good Associate safety awareness is maintained at HUM through some of thefollowing methods.• Training of all levels of Associates through induction, specialist Safety and Environment courses and jobspecific training.• Safety and environmental care points are stated within department procedures and operation standards.• All departments have safety and environment notice boards in place that include details of the company polices anddepartment specific activities.• Managers hazard spotting tours and specific themed safety tours carried out in all production areas.• Elected or nominated Safety and Environment representatives in each area with specified duties.Divisional Safety and Environment Notice-boardFirst Aid Board in Engine PlantIn 2010 the focus has been on reinvigorating the divisional safety and environment committees by ensuring the electedor nominated representatives can carryout their duties and regularly attend their committee meetings. As part of thisactivity a working group was established to review the Personal Protective Equipment (PPE) requirements for HUM. Itsmain activity was to conduct a PPE survey with the support of the Safety representatives and respond to any concernsor actions resulting. The overall objective was to reduce accidents related to PPE by 10%. The survey highlighted anumber of required improvements including uncomfortable and ineffective safety glasses, unsuitable gloves in someareas of Engine plant. These issues have been addressed and trials into alterative more comfortable and suitable PPE willcontinue into 2011.In 2010 accident, incident and near miss reporting and investigation procedures and accident investigation trainingwere improved with the objective of ensuring root causes are established following accidents to reduce the potential forreoccurrence. This activity will continue in 2011.SE/D/G/15 - Nov 2011www.hondamanufacturing.co.uk25

PLANT SAFETY HAZARDS3.5 MANUAL HANDLING AND ERGONOMICSThe Use of Manual Handling Assist DevicesManual handling assists, conveyors and other mechanical aids are used when the manual handling risk can not bedesigned out of the process. Forklift trucks and trolleys may be used to move heavier irregular objects and parts aredelivered to the production line in purpose built stillages to where they are needed to reduce the amount of space online used by the parts but also to minimise the amount of manual handling.ErgonomicsHUM has a dedicated team of Associates in place to manage the ergonomic risks of building cars and engines. Theprimary role of the team is to carryout assessments of the production line processes in order to identify the ergonomicrisks and the establish countermeasure activities. The design and application of countermeasures is a complex task andinvolves consultation with engineering, quality and process functions as well as the Associates performing the task inorder to come up with the right solution.HUM has established an ergonomics policy as well as a detailed risk assessment system which is communicated to allthrough the Health and Safety manual. A monthly report is generated to keep Associates and managers appraised ofany developments regarding ergonomics as well as the progress against objectives and targets.Old Process Connecting CouplersNew Process Fitting CouplersIn 2010 there have been many improvements regarding ergonomics.• Key Associates involved in the development of new models have received basic ergonomics training. This will helpwith the design of processes and car components in order to minimise ergonomic risks.• An activity plan covering the next 3 years has been developed that includes all aspects of ergonomics managementfrom new model introduction to plant layout issues, policy development, Associate recruitment and rehabilitation.• The ergonomic risk assessment method has been revised to ensure that HUM focuses on the most significantergonomic risks by introducing an enhanced rating system. This rating system has been developed with the help ofthe onsite physio provider, Rehab Works, who have provided information on the types and severity of injury. Thenew system also allows the effect of process rotation to be accurately determined.• All of the ergonomic guidelines that HUM uses to set up processes have been reviewed and updated to reflect thestature of European Associates.HUM is an active member of the Motor Industry Ergonomic Group (MIEG) which is a body made up of ergonomicexperts from UK motor manufacturers. This MIEG meets 3 times a year to share information on ergonomic concerns,issues and innovative solutions.26SE/D/G/15 - Nov 2011www.hondamanufacturing.co.uk

3.6 PERFORMANCE AGAINST LEGAL REQUIREMENTS SUMMARY 2008 – 2010Injuries as defined in The Reporting of Injuries, Diseases and Dangerous Occurrences Regulations 1995 (RIDDOR)occurring to HUM employees.*per 100,000 employees as defined in HSE publication Successful Health and Safety Management (HSG65)Description of Major InjuriesThere were 8 serious accidents during 2010.1. Associate was repairing an engine with the wrong drill bit which shattered and went into his eye. The Associate wasnot wearing safety glasses and was using the incorrect drill type. Increased signage and training in the area wascarried out.2. Associate was unloading parts at his work station when the cylinder head he was moving slipped out of his righthand and transferred the full weight through his left hand resulting in a dislocated shoulder. Permanent slide tableintroduced3. Associate had been recently transferred to the area and was picking up a parts box and struck his elbow on a girderresulting in a fractured elbow. The layout was improved to allow easier access to parts.4. Associate was pushing a stack of boxes. As she turned away she felt pain in her back and legs. The Associate was inhospital for several days. The subs assembly area layout was changed to remove the need for boxes being pushed.5. Associate broke a bone in his hand as a result of forcing the parts into place. Associate was using incorrect fitmenttechnique. Correct technique confirmed with other Associates. Additional PPE made available.6. Associate cracked a rib when he fell into a shallow pit he was cleaning during production downtime. As he steppedinto the pit he slipped on some spilt brake fluid. Risk assessment and visual aids created.7. Associate tripped on broom stand or parts boxes and fell, resulting in a broken elbow. The Associate was in theproduction area before shift and lighting levels were lower than usual. Broom stand moved and 5S improved.8. Associate broke a bone in his hand as a result of forcing a part into place. Incorrect technique used. Improvedcorrection technique information to be added to operation standard and supported with additional on thejob training.Improvements in accident reporting and investigation procedures have been implemented (see section 3.4).Description of firesThere were 12 minor fires during 2010.Measure 2008 2009 2010Fatal accidents 0 0 0Major injuries 1 6 8Dangerous occurances 0 0 03 day reportable accident rate * 816 1049 734Reportable disease 0 0 0First aid accident and ill health rate * 6560 8813 10277HSE enforcement notices 0 0 0Convictions of HSE offences 0 0 09. Weld Metal Inert Gas (MIG) unit caught fire. MIG gun sent for analysis but root cause not fully understood.10. Smoke from the conveyor due to incorrect cable tension which led to a short circuit. New cable fitted with thecorrect tension11. Aluminium leak from DC due to the core not being correctly closed due to sand build up. Associates reminded tomaintain 5S and operation standards updated12. In the Engine control centre a spark from grinding and welding ignited the dust and debris under the floor support.The area is now damped down prior to any welding or grinding and the importance of a fire watch reconfirmed.13. A box for purging weld sealer caught fire on hood line. Box removed and replaced with lidded metal container.Container emptied on a daily basis.14. Rectifier fire on Paint equipment. Equipment sent for analysis but cause unknown.15. In the repair area an Associate was MIG welding under the car and the interior melt sheet, harness and carpetcaught fire. Associate training improved and fire watch put in place for similar processes.16. Small fire in Weld Spot Robot line 2nd station due to sealer build up. Rear Right (RR) wheel arch area robotsre-taught to minimise sealer waste.17. Fire on side panel mezzanine due to sealer dripping onto sheeting. More regular changing of plastic sheeting tominimise sealer build up.18. Electrical panel fire in the impregnation area in Engine plant due to fan overheating. Panel isolated and fanremoved. Fan overload de-rated. Fed forward to other departments.19. Robot cables caught fire due to material contamination. Deep clean schedule in place.20. Fire on flexi truck in Engine Plant. Truck in question removed from service and repaired. Other flexi –trucks areunder review.All of these fire incidents have been investigated and root causes established (see section 3.1)SE/D/G/15 - Nov 2011www.hondamanufacturing.co.uk27

PLANT SAFETY HAZARDS3.7 2010 SAFETY PERFORMANCE AGAINST OBJECTIVES AND TARGETSMedia Objective Planned activities Result CommentReduce accidentrate and accidentseverityMSD incidentmanagementimprovementMinimise risk offire at HUMImplement safety cultureimprovement throughtraining, competence,audits and tours tosupport Associate releaseto perform the safetyrep roleFocus on theimplementation of robustcounter measures toaccidentsReduce risks from trafficon siteManage and reduce siteergonomic risksEnhance fire riskmanagementIncrease knowledge andcompetenceImplement safety campaignsthrough the genba meeting,supporting divisional campaignsEstablish and implementdepartment manager practicalHS&E inspectionsReview and improve site widePPE provision, performance andusage through the PPE workinggroupImplement COSHH cabinet andlabels through COSHH workinggroupStrengthen and empower safetycommittees through S&Etraining, performancemeasurement and S&Edepartment involvementIntroduce new accident formand upgrade accident databaseComplete assessment of allinternal traffic routes,determine countermeasures anddevelop implementation planComplete assessment of allexternal traffic routes,determine countermeasures anddevelop implementation planSupport HUM linesideimprovement projectComplete Jazz ergo assessmentsIssue new ergonomic policyFocus on new modelintroduction, especially toinclude S&E issues at newmodel evaluationsDevelop and deliver ergonomictraining for new modelAssociatesStrengthen link to AS, OH andRW to improve restrictionmanagementComplete all required hard andsoft fire evacuation drills andcountermeasure concernsReview and update fire riskassessmentsDevelop and implement firetraining9 presentations madeInspections started toplanPPE survey completed.Trials of improved PPEongoingCabinet standard in place.Labelling standard indraftS&E attend departmentaland divisional safetycommittees.Formal feedback standarddevelopednew form in place andbeing usedSurvey completed andreviewedAssessment notcompletedSupport given as requiredAssessments completedUpdate policy issuedS&E attend new modelmeetings and on site newmodel buildsTraining completed toscheduleSupport in completionof longAll fire drills completedup to dateFire risk assessmentscompletedFire manager trainingdeveloped and deliveredContinue withinspections to scheduleOngoing targetedimprovement activitiesset by the PPE groupContinue with COSHHworking groupComplete Associatesurvey when back at fullproduction rateAccident databaseimprovements ongoingImplementimprovementsAssessment formatresearchedWeld direct deliveryarea is much improvedAttend off site buildeventsComplete actions fromfire risk assessments28SE/D/G/15 - Nov 2011www.hondamanufacturing.co.uk

HUM SIGNIFICANT ENVIRONMENTALIMPACTS AND CONTROLS4.0 2011 SAFETY AND ENVIRONMENT IMPROVEMENT ACTIVITIES - KEY THEMESHUM safety and environmental objectives are set on annual basis from the company business plan with specific actionfor achievement documented and monitored on the department business plans. The main objective for 2011 is:‘A safe and environmentally focused workplace with highly efficient utilisation of energy.’Environmental Management programmes are also in place within departments to encourageenvironmental improvement.4.1 PLANNED IMPROVEMENTSNew modelMediaPlanned activitiesDevelop and implement detailed ergonomic (and S&E) action plans for each new modelHS&E risk evaluation of each current/new modelAttend build events and raise concerns as required (Support genba divisions in CRF development)Total recyclingfactoryDevelop textile recycling route to support zero waste to incineration planImprove management of drum waste to support zero waste to incineration planDevelop measure of consumable materials in vs waste outInvestigate development of green technology and create long term vision for waste (and environmentalimpact) reductionTraining anddevelopmentDefine S&E training requirements for each job function and level within HUM and deliverappropriate trainingEnhance Administrator capability through S&E mentoring process to improve accident reportingand investigationDevelop and deliver C3 managers trainingEnhance the capability of lineside reps through mentoring programme todeliver tool box talksPlant LayoutS&E to identify current risks on AF1 and feed forward possible countermeasures to taikai teamS&E to identify current risks on Engine and feed forward possible countermeasures Engine Diesel line teamContinue to implement Green travel plan improvements including cycle pathManagementsystemsReview, rationalise and upgrade HS&E management system to deliver clear, precise and detailedinformation to all stakeholdersSE/D/G/15 - Nov 2011www.hondamanufacturing.co.uk29

HUM SIGNIFICANT ENVIRONMENTALIMPACTS AND CONTROLS4.2 SAFETYNew modelMediaPlanned activitiesDevelop and implement detailed ergonomic (and S&E) action plans for each new modelHS&E risk evaluation of each current/new modelAttend build events and raise concerns as required (Support genba divisions in CRF development)Training anddevelopmentDefine S&E training requirements for each job function and level within HUM and deliverappropriate trainingEnhance Administrator capability through S&E mentoring process to improve accident reportingand investigationDevelop and deliver C3 managers trainingEnhance the capability of lineside reps through mentoring programme to deliver tool box talksDevelop and deliver stress management trainingDeliver and enhance ergo trainingDevelop and deliver enhanced manual handling trainingPlant LayoutS&E to identify current risks on AF1 and feed forward possible countermeasures to taikai teamS&E to identify current risks on Engine and feed forward possible countermeasures Engine Diesel line teamManagementsystemsComprehensive understanding of all risks Associated with all processes through enhanced Riskassessment processRevise and maintain ergo quality standardsReview, rationalise and upgrade HS&E management system to deliver clear, precise and detailed informationto all stakeholdersRisk reductionComplete internal workplace transport risk assessment and implement planned countermeasuresto concernsComplete noise testing for Jazz and 2KC CivicImplement finding from PPE working group to reduce PPE related accidentsDevelop DSEAR assessment and implement planned countermeasures to concerns30SE/D/G/15 - Nov 2011www.hondamanufacturing.co.uk

LOCAL COMMUNITY ACTIVITY5.0 LOCAL COMMUNITY ACTIVITYThe HUM’s charity policy focuses charitable work to within a 15mile radius of the factory where 85% of Associateslive. The work ranges from small scale raffle prizes on request to larger annual financial and resource commitments.Examples of these commitments are shown below.The Swindon AcademyIn 2006 Honda Motor Europe invested £1m over a 5 year period (2006 to 2011) to support the development of theacademy in Swindon.• HUM support his activity by working directly with the School, local authorities and the United Learning Trust (ULT)initially in the building of the school and more recently in day to day activities.• HUM represent Honda on the Board of Governors and support Academy with curriculum activities including mostrecently the Mock interview day were students were invited on site to receive interview advise and support andattended an interview with an experienced member of HUM staff.• ULT Challenge ‘do something innovative campaign’. Hum supported the judging activity in the school.• Official school opening took place in 2010 and HUM provided technical support and event management.Safe Drive – Stay AliveSince 2005, HUM has committed £100,000 to this programme where it is the single sponsor to support the position ofa principle Education Officer within the Wiltshire Fire Brigade. His role is to make key stage 4 (16-17 year olds) aware ofthe dangers of driving with or under the influence of alcohol or drugs and the impact of family and friends followingan accident.This Officer coordinates all aspects Associated with the delivery of the programme into the local Community.We aim to reduce the number of young peoplekilled or injured on Wiltshire & Swindon’s roadsJunior Good Citizen AwardSince 1992, HUM has committed £30,000 to this programme where it financially supports with the set-up and essentialadministration aspects of the programme.The Junior Good Citizen Scheme was designed to engage young people from Year 6 (10-11 year olds) in a fun learningenvironment. The aim is to equip them with life skills as they make their transition from Primary to Secondary education.Schools, Emergency Services and Local Authorities work together in partnership to promote the safety of young people.SE/D/G/15 - Nov 2011www.hondamanufacturing.co.uk31

LOCAL COMMUNITY ACTIVITY5.0 LOCAL COMMUNITY ACTIVITY (Continued)The Wiltshire and Swindon Community Foundation (WSCF)HUM has been a major sponsor of the WSCF for over 10 years. The WSCF is a charity that aims to help those most inneed in Wiltshire and Swindon, by managing and distributing funds on behalf of individuals, companies and charitabletrusts. To date, HUM has given out a total of £35,000 to over 26 different local charities. In addition, through a WSCFsponsored initiative, called “Seeing is Believing”, HUM Associates are invited to visit those Charities which HUMhas supported.In the last year HUM has maintained its commitment to local charities despite the financial situation.32SE/D/G/15 - Nov 2011www.hondamanufacturing.co.uk

GLOSSARY OF TERMS6.0 GLOSSARY OF TERMSAF Assembly Frame departmentATEX The term ‘ATEX’ is derived from the French Atmospheres Explosive.Associate Employee of Honda of the UK Manufacturing LtdCCL Climate Change LevyCRF Change Request Form – used to formally request changes in the design of a part.CR-V Compact Recreational VehicleCE The letters “CE” are the abbreviation of French phrase “Conformité Européene” which literally means“European Conformity”.CO2 Carbon DioxideDCM Die Cast Machining departmentEET Engine Effluent Treatment plantEL Employers Liability insuranceEMAS Eco-Management and Audit SchemeEU European UnionEUETS European Union Emission Trading SchemeFoul Water Process or sewage water discharged to an off site sewage treatment plant.HME Honda Motor EuropeHSC Health and Safety CommissionHSE Health and Safety ExecutiveHSL Health and Safety LaboratoriesHUM Honda of the UK Manufacturing LtdMSD Musculo Skeletal DisorderODP Ozone Depletion PotentialOEM Original Equipment ManufacturerPA Paint shopPPC Pollution, Prevention and ControlPO Plastic OperationsREACH Registration, Evaluation and Authorisation and restriction of ChemicalsRIDDOR Reporting of Injuries, Diseases and Dangerous Occurrences RegulationsRTO Regenerative Thermal OxidiserSBC Swindon Borough CouncilSDC South Marston Distribution CentreSMMT Society of Motor Manufacturers and TradersS&E Safety and Environment departmentStorm Water Water that runs off the car parks and discharges directly into controlled watersVOC Volatile Organic CompoundsVQ Vehicle Quality departmentWWT Waste Water TreatmentSE/D/G/15 - Nov 2011www.hondamanufacturing.co.uk33

VERIFICATION STATEMENT7.0 VERIFICATION STATEMENTEnvironmentThe information and data contained within Section 2, 4.1 and 5 has been verified as representing an accuratestatement of fact and this statement has been validated as meeting the requirements of the ‘Eco-Management andAudit Scheme (EMAS 3) (Regulation (EC) number: 1221/2009).’Signed:Date:VCA Accredited Verifier for EMAS 3 (UKAS Registration No. 028)Verifier Number: UK-V-0014.Vehicle Certification Agency1 Eastgate Office CentreEastgate RoadBristolBS5 6XX0044 (0) 117 9524133SafetyThe information and data contained within section 3, 4.2 and 5 has been verified as representing an accuratestatement of fact and the safety statement has been validated as meeting the requirements of the document ‘Healthand Safety in Annual Reports: Guidance from the Heath & Safety Commission.’Signed:Date:Andrew CrossClient Manager for OHSAS 18001 (Occupational Health and Safety Assessment Series Specification)Vehicle Certification Agency1 Eastgate Office CentreEastgate RoadBristolBS5 6XX0044 (0) 117 9524133www.vca.gov.uk34SE/D/G/15 - Nov 2011www.hondamanufacturing.co.uk

SE/D/G/15 - Nov 2011www.hondamanufacturing.co.uk35