Hiratsuka Factory (HP)

Business activities

Design, basic research, development and evaluation of aircraft parts, sporting equipment, adhesives and sealants, conveyor belts, marine hoses, fenders and other industrial products

Total site area

285,794 m2 (including Adhesives and Sealants Plant)

Number of employees

2,360 (as of November 2018)

Location

2-1, Oiwake, Hiratsuka City, Kanagawa 254-8601, JAPAN

Contact for consultation and complaints

General Affairs Group, Hiratsuka Factory Tel: +81-463-35-9501 Fax: +81-463-35-9746

Message from the General Manager

Toru Nakamura

While continuing to serve as a “base for the dissemination of technologies and monozukuri manufacturing expertise throughout the Yokohama Rubber Group,” the Hiratsuka Factory is also aiming to be a “factory that maintains the affection and unwavering trust of both customers and the whole world,” in line with Yokohama Rubber’s CSR Vision. Within this strategic framework, in the environmental sphere the Hiratsuka Factory is focusing in particular on reducing leakage and noise pollution, which can have a pronounced negative impact on the local environment, to zero, while in regard to safety the Hiratsuka Factory will be striving to eliminate accidents that are serious enough to require employees to take time off work, by ensuring that everyone who works at the Hiratsuka Factory puts safety first; in addition, as a factory belonging to a company that plays a key role within the automotive industry, the Hiratsuka Factory will also be seeking to reduce road accidents in which people are injured to zero.

Furthermore, in every aspect of our business operations our actions will embody not only strict adherence to compliance-related regulations, but also an emphasis on enhancing disaster preparedness and on fostering a harmonious relationship with local communities and making a positive contribution to the region in which we are located.

Once again, in fiscal 2018, by holding the Think Eco Hiratsuka Event with its emphasis on protecting the environment, the Hiratsuka Factory was able to foster communication and exchange with local communities, while also providing support for the disaster prevention drills of local residents and schools. Our employees also volunteered to conduct planting and cleanup activities, with seedlings being donated to local communities; we also held a Regional Communication Meeting.

The Yokohama Forever Forest Project activity, which was launched in 2007 with the aim of helping to safeguard the local environment and fostering a mutually-beneficial relationship with local communities, reached its 12th year of implementation last year. The approximately 30,000 tree seedlings that were planted within the Hiratsuka Factory’s grounds have grown into an impressive forest. We are continuing to cultivate tree seedlings, which we donate free of charge for use in local tree-planting activities and other environmental events, etc. Furthermore, we have conducted biodiversity impact research on the trees that have been planted around the factory; this research has focused mainly on birdlife. Additionally, from fiscal 2013 we commenced promoting the biodiverse protection of the Kaname River system, whose groundwater we are able to use for our production activities. Besides continuing with this work, starting from 2016 we have also been implementing Satoyama (traditional community-managed forest) conservation activities focusing on Yatoda (areas of rice fields in small valleys created by erosion) within Hiratsuka City.

By continuing with such activities in the future, we want to strengthen awareness of the Hiratsuka Factory as a business located within Hiratsuka City which seeks to make a positive contribution to regional development.

Organizational Governance

Publicizing and sharing policies and issues

In that it represents a combined location, the Hiratsuka Factory hosts multiple business departments, production plants and R&D facilities. Close attention is thus paid to thoroughly publicizing policies and issues that involve the entire factory. We also strive to improve communication.
The publicizing of General Manager directives as well as safety and environment policies is done through factory-wide morning meetings. Meanwhile at factory meetings held each month, the General Manager personally shares factory issues and topics, etc. with all department managers.

Improved functionality through management systems

Concerning safety and environment issues involving the entire factory, both the Safety and Health Administration Office and the Environmental Management Administration Office coordinate with different factory units, and we are implementing effective operation of OSHMS and ISO 14001 management systems. Rather than relying solely on external audits, the Internal Audit Department executes our accounting audits, and we follow up on any stipulated exceptions or required improvements. Pursuing such actions can be linked to the strengthening of factory functionality.

Labor Practices

To achieve thorough statutory compliance, each month we decide on a theme such as forms of harassment or personal information management, etc., and then we conduct compliance education within each business unit. In addition to improving employee knowledge and consciousness of such topics, we are endeavoring to create a friendly workplace.
To realize suitable working hours, we have established a forum where both labour and management can check and discuss topics such as working hours, holidays and overseas business trips, etc. In much the same vein, discussions are held between labour and management to annually improve the work environment, with such improvements being promoted by us.
Through such responsiveness, we are taking care to create a working environment in which employees can feel peace of mind.

Promotion of gender equality

Free from gender bias, we are working to provide equal employment opportunities to both men and women, and we assign to them positions of responsibility in accordance with their abilities. Across the entire factory the percentage of female staff has tended to rise year-on-year as follows:

Ratio of female staff

Promotion of employment of people with disabilities

As of the end of December 2018, we have employed 68 disabled persons (this figure includes some double counting based on the severity of disability). The disabled employee ratio is 3.32%.
Centering on those who are mentally-disabled, as of December 2018, there were 26 disabled employees working in the factory. Their duties include cleaning tasks, collecting and distributing internal mail, and activities related to the greening business such as gardening and planting, etc.

Changes in the ratio of disabled persons employed

Occupational safety and health management

Since the Hiratsuka Factory acquired Occupational Safety and Health Management System (OSHMS) certification in July 2010, we have conducted OSHMS-based occupational safety and health management. This work has been mainly built around continuous risk assessment and KY (Hazard Prediction) activities, etc.
When new operational processes are introduced or changes are made to existing operations, we hold “open work observations,” which allow many employees to witness work practices and identify hidden risks. We do this so as to further work improvement that makes work practices even safer.
Furthermore, we comply with safety and health statutory requirements, and proactively promote both employees’ acquisition of qualifications and educational activities. We also work to develop human resources and prevent disasters.

Workplace accidents

Compared to the previous year, in fiscal 2018 the number of accidents fell by three from 13 to 10. Unfortunately, these included two accidents that required a work stoppage.
Besides continuing to promote Hazard Prediction Training (the KYT4R method) and activities that help to identify near misses, we are also working to improve the safety consciousness of each and every employee and striving to prevent accidents, in line with the Hiratsuka Factory guidelines advocating “Foresee hazards, spare no effort, and act in accordance with the rules.”

No. of accidents

Traffic accidents

In fiscal 2018, there were four accidents in which we were the blamed party; unfortunately, we are yet to achieve our objective of reducing the number of accidents to zero.
We provide traffic safety guidance to reduce the number of traffic accidents; for example, road safety seminars are conducted for all employees twice a year, and we also arrange practical skills training seminars for motorcycles and motor-scooters and seminars on traffic rules and road-user etiquette for bicycle riders, as well as implementing traffic safety education etc. in each workplace. Starting from fiscal 2019, we have designated one day each month at the beginning of the month as the Hiratsuka Plant’s “Traffic Safety Day,” on which efforts are made to enhance the traffic safety awareness of all employees, for example by the use of broadcasts on the Plant premises, etc. We are implementing measures to prevent traffic accidents based on heightened self-awareness of our responsibilities as a company that plays a role in the automotive sector.

No. of accidents involving injury

Seminar on traffic rules and road user etiquette for bicycle riders

Health management

40 employees were off work for periods of seven days or more in fiscal 2018. This figure represented a slight increase compared to 38 recorded in fiscal 2017.
53% of such long-term absences were related to mental health issues, and these accounted for 78% of total absentee days.
In response to this, concerning the eight counseling sessions (over two days) conducted monthly by professional counselors (commenced in fiscal 2010), as the number of people requesting counseling has been rising steadily every year, the number of counseling sessions has been increased to 12 counseling sessions (over three days) starting from fiscal 2017.
As part of the efforts by workplace managers and supervisors to promote mental health care, we hold “Seminars on How to Listen Effectively,” given by expert counselors.
Regarding the results of the stress checks implemented in fiscal 2018, of the 2,157 eligible employees, 93.2% participated in the stress check, up from 92.5% the previous year. As regards follow-up after the stress checks, those employees who were deemed to display high levels of stress were recommended to apply for face-to face counseling; this counseling was provided by an occupational health physician.

The Environment

Environmental management

The Hiratsuka Factory continues to operate environmental management based on ISO 14001 environmental management system certification, which was acquired in July 1999.
From fiscal 2012, it converted to an environmental management system integrating the entire company as one site of Yokohama Rubber. We will continue to deploy activities based on the company-wide environmental policy.
As the Hiratsuka Factory holds a wide range of business organizations, from MB related plants to the technical research and development department of the entire company, it divides them into 10 environmental blocks to advance daily environmental improvement activities under the Hiratsuka Factory Environmental Policy in compliance with the company-wide environmental policy.

Environmental data

Reduction of greenhouse gas emissions

Greenhouse gas emissions
Hiratsuka Factory
  • The base year is defined as 1990 except for HFC, PFC and SFF6, where the base year is 1995 as per the Kyoto Protocol.
  • Method of calculation of greenhouse gases (GHG): this is in compliance with the “Calculation and Reporting Manual for Greenhouse Gas Emissions” issued by the Ministry of the Environment and the Ministry of Economy, Trade and Industry.
    Note that GHG emissions associated with purchased power in FY2009 were calculated using the Table of Emission Coefficients by Power Company (Ministry of the Environment).
Adhesives and Sealants Plant
  • The base year is defined as 1990 except for HFC, PFC and SF6, where the base year is 1995 as per the Kyoto Protocol.
  • Method of calculation of greenhouse gases (GHG): this is in compliance with the “Calculation and Reporting Manual for Greenhouse Gas Emissions” issued by the Ministry of the Environment and the Ministry of Economy, Trade and Industry.
    Note that GHG emissions associated with purchased power in FY2009 were calculated using the Table of Emission Coefficients by Power Company (Ministry of the Environment).

Effective use of resources / Reduction of waste

Waste output
Hiratsuka Factory
Adhesives and Sealants Plant
Water Usage
Hiratsuka Factory (including the Adhesives and Sealants Plant)

Measures for discharges into water, air and soil

Data related to water contamination

Move the screen to the left or right to see the table information

Drain Item Regulatory values Voluntary standard values FY2018 results
Average Maximum Minimum
Hiratsuka Factory PH 5.0~9.0 7.6〜8.6 7.8 8.4 5.1
BOD concentration (mg/l) 600 70 73 360 21
SS concentration (mg/l) 600 77 42 80 11
Animal and plant oil concentration (mg/l) 30 15.0 3 15 1
Mineral oil concentration (mg/l) 5 2.5 1 1 1
Adhesives and Sealants Plant PH 5.0~9.0 7.0~8.92 8.1 8.4 7.4
BOD concentration (mg/l) 600 97.6 35 93 12
SS concentration (mg/l) 600 71.8 28 61 13
Animal and plant oil concentration (mg/l) 30 15.0 3 7 1
Mineral oil concentration (mg/l) 5 2.5 1 1 1
Air pollutants (NOx, SOx)

Move the screen to the left or right to see the table information

Substance NOx emissions (t/year) SOx emissions (t/year)
Hiratsuka Factory 3
Adhesives and Sealants Plant 1
Facility Substance Regulatory values Voluntary standard values FY2018 results
Average Maximum Minimum
Hiratsuka Factory
Boilers 1-2
Nox (ppm)
Soot and dust (g/h)
150
371
91.0
4.2
Removed
Hiratsuka Factory
Boilers 5-6
Nox (ppm)
Soot and dust (g/h)
150
463
48.5
6.2
Hiratsuka Factory
New Boiler 1
Nox (ppm)
Soot and dust (g/h)
150
635.4
25.3
231.5
23
5.0
23
5.2
21
4.8
Hiratsuka Factory
New Boiler 2
Nox (ppm)
Soot and dust (g/h)
150
635.4
24.2
231.5
23
5.0
23
5.0
22
4.9
Hiratsuka Factory
New Boiler 3
Nox (ppm)
Soot and dust (g/h)
150
635.4
27.3
231.5
24
5.0
24
5.0
23
5.0
Hiratsuka Factory
New Boiler 4
Nox (ppm)
Soot and dust (g/h)
150
635.4
120
370.4
21
5.2
21
5.3
21
5.0
Hiratsuka Factory
New Boiler 5
Nox (ppm)
Soot and dust (g/h)
150
635.4
120
370.0
22
4.9
22
4.9
22
4.8
Hiratsuka Factory
New Boiler 6
Nox (ppm)
Soot and dust (g/h)
150
635.4
120
370.0
22
5.0
22
5.1
22
4.8
Adhesives and Sealants Plant
Boiler 1
Nox (ppm)
Soot and dust (g/h)
150
180
29.6
90.1
26
1.3
27
1.5
24
1.1
Adhesives and Sealants Plant
Boiler 2
Nox (ppm)
Soot and dust (g/h)
150
180
31.2
90.1
23
1.5
24
1.6
21
1.4
Adhesives and Sealants Plant
Boiler 3
Nox (ppm)
Soot and dust (g/h)
150
180
36.3
136.1
24
0.7
25
0.88
18
0.56

Reporting on chemical substance management status (Pollutant Release and Transfer Register (PRTR) Law compliance)

The Hiratsuka Factory verifies whether secondary materials and auxiliary materials contain chemical substances subject to Safety Data Sheet (SDS)requirements, and in the case of substances where the amounts handled exceed the thresholds specified by the PRTR Law, annual reports are submitted to the national (or prefectural) authorities and safety impact assessment is performed.
Regarding the handling of substances pursuant to the PRTR Law, please refer to the Safety Evaluation Table of Domestic Production Bases.

Pollution prevention

We have established self-administered values that are even stricter than regulated targets so as to strictly observe all environmental laws and ordinances concerning air pollution, water contamination and noise, etc. We take steps to monitor and measure these values.
Furthermore, to ensure that no sensory discomfort resulting from noise, vibrations and odors, etc. is caused to neighborhood residents, we have established monitoring points outside the factory grounds and are working to prevent such issues.
With respect to PCB waste within the factory, it is suitably handled in accordance with the relevant laws and regulations.

Use of sustainable resources

We are taking steps to reduce overall volumes year-on-year by placing a top priority on the goals and targets of the ISO 14001 management system with respect to reductions in industrial waste, organic solvents, greenhouse gas emissions and water usage.

Alleviating and adapting to climate change

In the “Energy-Saving Month” of February and the “Environment Month” of June, in addition to establishing important measures relating to core business areas and reporting on the energy-saving results achieved, environmental patrols are conducted by the business unit managers of each block within the factory, and through the thorough implementation of measures such as twice-weekly mandatory times for leaving work, we are working to reduce CO2 emissions.

Environmental protection, recovery of natural habitats

Activities were commenced in fiscal 2013 to protect the biodiversity of the Kaname River’s water resources.
Factory employees have been participating, on an “experiential” basis, in the environmental monitoring of the Kaname River river system. In fiscal 2018, an additional 19 employees participated in this activity, giving a cumulative total of 333 employees that had participated in the activity since it was first launched.
Up until this point, the monitoring activities have resulted in 10 or more bird species being identified, with the status of birdlife along the river being judged healthy.
Furthermore, gobies (a species of fish), mitten crabs and river shrimp, etc., were also recorded. This indicated that the area’s water-life was also healthy. At the same time, the high degree of clearness of the water pointed to a state of eutrophication. We are also now proceeding with an evaluation of water quality based on a scoring of the caddis-fly, dragonfly and mayfly larvae numbers found along the river.
A further point is that, concerning the flora found along the river, exuberant growth was noted of introduced species such as ragweed and burr cucumber. It was also confirmed that indigenous species have been in retreat. After obtaining the agreement and collaboration of local government authorities and local organizations, starting from fiscal 2014 we have been implementing, on an ongoing basis, an activity to eradicate introduced plant species from specific sections of the river, and to monitor the changes in the flora found along the river.
Starting from fiscal 2015, with the aim of helping to conserve the Kaname River’s water resources and restore the local satoyama (traditional community-managed forest) landscape to its original condition, we undertook conservation activities, in collaboration with members of local environmental organizations and with local university researchers, that included leasing an area of land (which had formerly been under cultivation but had been allowed to become overgrown) within the boundaries of Hiratsuka City, clearing the brush etc. that had grown up on the land, and creating a biotope habitat by hand, as well as monitoring the subsequent changes in the ecosystem.
Starting from fiscal 2017, a dragonfly pond was created within the grounds of the Hiratsuka Factory, to create an environmental activity location that is closer to home; observation is undertaken of the way the dragonflies and other creatures living in the pond interact with each other.
In recognition of these biodiversity conservation activities, as well as on the basis of the carbon capture surveys etc. conducted in relation to the growth of the Yokohama Forever Forest tree plantings undertaken in the vicinity of the Hiratsuka Factory since 2007, in March 2017 the Hiratsuka Factory was certified as an Association for Business Innovation in Harmony with Nature and Community (ABINC) biodiversity-friendly factory.

Biodiversity activity: Kaname River monitoring

Weeding activity to remove invasive species

Satoyama landscape preservation activity

ABINC logo mark

Fair Operating Practices

Impartial and fair selection of business partners

We have switched over to using a system for ensuring the fair selection of business partners, with surveys conducted when choosing new suppliers to verify whether any private interest exists between the company in question and our own employees.
In addition, during our supplier study meetings, we used case studies to show business partners how to handle inappropriate behavior in relation to compliance that occurs in the course of ordinary business transactions.

Establishment of a “Procurement Code of Conduct” and its thorough implementation

We prepared the “Procurement Ethics (Rules for Procurement Staff)”. These guidelines indicate matters to be noted by procurement staff when conducting fair and impartial transactions in accordance with the “Basic Procurement Policy”. They also specify unethical practices that must not be engaged in. These ethics were combined with the “Basic Procurement Policy” to become the “Procurement Code of Conduct”.
We are working to ensure comprehensive awareness of compliance issues through workplace-based classes, which are held on a regular basis.

Deployment of CSR activities for business partners

In 2018, we continued to hold “CSR supplier study meetings,” focusing on the topic of working to prevent global warming, which is addressed in Yokohama Rubber’s CSR Report, and explaining the need, in relation to greenhouse gases, to identify and reduce CO2 emissions throughout the entire supply chain in the future. There were also explanations of the sustainable natural rubber procurement policy that Yokohama Rubber has adopted; in addition, suppliers were requested to implement workplace safety measures tailored to their own circumstances.
58 representatives of 58 companies took part in the workshops held in the Hiratsuka Factory.

Consumer Issues

When purchasing stationery items that are to be used in our plants, we focus on buying products that are eco-certified and listed in the Green Purchasing Network (GPN) database.
We continue to purchase 90% of our requirements through such means, buying sustainable products that place little burden on the environment.

Community Involvement and Development

Regional activities

We participate on an ongoing basis in volunteering activities – such as tree-planting and river clean-up, etc. – organized by local groups. Many of our employees participate in these activities together with their family members, working hard and having an enjoyable and rewarding experience together with local residents.

Tree-planting at Shonan International Village

Hanamizu River embankments clean-up activity

Disaster-prevention activities

Three teams from the Hiratsuka Factory participated in the firefighting competition sponsored by the Hiratsuka City Hazards and Safety Committee. Our teams won first prize in the small pump operation competition, and in the indoor fire hydrant operation competition.
Participating in this competition helped to foster more extensive communication among younger employees, who also benefited from the experience of participating in rigorous training and from acquiring the skills needed for first-response fire-extinguishing in the event of a fire breaking out.
We also participated in a disaster readiness drill in collaboration with the Hiratsuka School for the Visually Impaired, which is located adjacent to the Hiratsuka Factory and with which we have signed a disaster response collaboration agreement. Besides providing support for evacuation to evacuation assembly areas, in fiscal 2018 we also provided support for training School staff in the use of fire-extinguishing equipment.

Firefighting Competition

Support for disaster prevention training at Hiratsuka School for the Visually Impaired

Participation in local events

Hiratsuka Environment Fair

We participated in the “Hiratsuka Environment Fair” which is held by the city each year. Besides presenting displays that showcased Yokohama Rubber’s environmentally-friendly products, we also gave a poster presentation introducing the activities that we have been implementing to help safeguard biodiversity.

Regional contributions

Regional exchanges

In fiscal 2018, we held the “Think Eco Hiratsuka 2018” environmental event, marking the tenth time that this event has been held. On the day of the event, which was blessed with good weather, an impressively large total of around 3,400 people (including local residents and plant employees and their family members) attended, thanks to active collaboration from local universities and civic groups. A total of 905,754 yen – including 651,000 yen in proceeds from the event, and 254,754 yen in donations received from the Yokohama Rubber Safety Association (as of June 30), the members of which consist of partner companies of the Hiratsuka Plant, which sponsored the event – has been donated to Ishinomaki City via Hiratsuka City, which has signed a disaster relief agreement with Ishinomaki City, as a contribution to the Great East Japan Earthquake Relief Fund. The cumulative total of donations that have been made over the years has now reached 3,520,000 yen.

Think Eco Hiratsuka 2018

Donation presentation

Results of a questionnaire survey about our local communication events

How many times have you participated?
Factory summary/Initiatives
Facility tour course
Satisfaction with the overall program
The most interesting content

List of FY2018 Regional Contributions / Community Activities

Volunteer activities

Provision of Yokohama Forever Forest seedlings (Total: 4,046 seedlings)

Number of seedlings provided by the Hiratsuka Factory for the Yokohama Forever Forest project

Support for education

Work experience activity

Local event support, donations, and participation

Disaster-prevention activities