Onomichi Plant (OP)
Production of tires for large construction vehicles, mining vehicles and industrial vehicles.Total site area
193,000m2Number of employees
415 (as of December 2018)Location
20 Higashi-Onomichi, Onomichi City, Hiroshima 722-0051, JAPANContact for consultation and complaints
Plant Control Section
Message from the General Manager
The Onomichi Plant is situated commanding a view of the Setouchi-Shimanami Kaido Expressway. It is a production plant that is dedicated exclusively to manufacturing tires for large construction vehicles, mining vehicles and industrial vehicles.
We conduct our activities with the aim of “becoming a company with world class technologies for protecting the environment,” the basic policy of the Yokohama Rubber GD2020 medium-term management plan, and based on “bright, happy and vigorous” activities and cherishing greetings and the “5S” activities. With regard to environmental matters, we have carried out the improvement of equipment, the reviewing of mechanisms, and repeated educational activities for the purpose of preventing a recurrence of any past environmental trouble. Such has also been carried out in order to realize a reduction of environmental risk, a reduction of greenhouse gas emissions and a reduction of industrial waste.
At the same time, as part of our contributions to local communities and communication activities, we have continued to carry out such projects as opening to the public a “Dinosaur Park” on the premises of the plant, receiving plant visits from children, students and guests, participating in regional cultural activities and events, and advancing the Yokohama Forever Forest project. Furthermore, we commenced a biodiversity protection survey in 2013, and we have been continued our measures to maintain and improve biodiversity, both here on the plant premises and in the neighboring watercourses.
In the future as well, the Yokohama Rubber Onomichi Plant will be considerate of the global environment, and as we aim to be a business that is both loved by our region and contributes to society, we will strive to become a company that is trusted by the region.
We have formulated plant safety, environment and quality policies, and we make use of regular morning meetings etc. to ensure that employees have a thorough understanding of these policies. In our day-to-day operations, by carrying out our work according to carefully documented standard operating procedures, we are able to implement a management system that prevents improper working methods, and we also undertake ongoing improvement. Managerial staff undergo compliance-related training on a monthly basis, and we are working to enhance awareness of compliance-related issues among all employees.
Respect for human rights
In order to create a pleasant workplace where employees can work cheerfully, happily and energetically, we conduct workplace education, covering a variety of areas including information management, workplace bullying and harassment prevention, etc., every month. The content of this training involves the management of information and other issues such as workplace bullying, etc. We also maintain close collaboration with the Corporate Compliance Department regarding compliance-related reports and consultations, and if a problem occurs, we will promptly respond to it.
Surveying of human rights among business partners
In order to determine whether or not business partners have issues such as human rights problems, etc., CSR and environmental surveys are conducted for confirmation purposes.
With respect to primary suppliers, child labor surveys have been conducted by the Raw Materials Procurement Department; the reports received have attested to the fact that no child labor issues exist.
Occupational safety and health measures
The plant has acquired Occupational Safety and Health Management System (OSHMS) certification and it continues certification activities. We took steps to revise the applicable work procedure manuals and to share such procedures horizontally with other sections. Moreover, by focused safety education activities, the revision of standard operating procedure (SOP) manuals through open work observations, individual education based on safe employee evaluation, the undertaking of one-on-one training between deputy work supervisors and workers, mutual advice, and daily “KYT” Hazard Prediction Training activities, we are working to heighten the consciousness of our employees with respect to safety.
We promote “safe employee” development as part of these activities, and award model employees with certification as “super safe employees”.
We have also begun implementing “safe employee” evaluation by process, to facilitate implementation of measures aimed at realizing improvements in relation to weaknesses at individual workplaces.
Education and training for employees.
- We conduct open work observations every month in accordance with the Standard Operating Procedure and abnormal Operating Procedure to make improvements by sorting out work risks.
- Contests are held to invigorate and improve KYT (Hazard Prediction Training). In addition, in order to enhance overall skill levels and help cultivate safety-oriented operatives, we have also been holding safety education courses, with instructors from the Labor Standards Association, for crane operators on the safe use of crane lifting slings (these courses are being held six times a year).
- At the sensory training hall which enables for the experiencing of actual risk, all employees with less than three years of work experience undergo training once a year that is administered by the staff of the safety and health section.
- Concerning one-to-one education provided by managers to employees, for those with little work experience it is conducted once or more every three months, for veteran employees it is conducted once every six months.
- There is the opportunity to attend basic emergency first-aid seminars held by the fire department twice a year (40 to 50 persons annually choose to do so).
* As of the end of December 2018, 207 people have obtained basic emergency first-aid qualifications
Responses in case of disaster
- We have organized a disaster-prevention, self-protection force comprised of plant members. This force conducts both map-based drills and evacuation drills for all plant employees (including tsunami scenarios). Each type of drill is conducted once a year.
- Emergency contacts and emergency evacuation routes are posted at every process location of the plant, and they are thoroughly made known to all employees.
Promotion of employment of people with disabilities
Four disabled persons work at the plant. The tasks they undertake include both office work and light duties. We are continuing with activities for the purpose of newly-hiring disabled persons again in fiscal 2019.
In aiming to improve the work-life balance of our employees, policies have been instituted for the leaving of work at specified hours on Wednesdays and Fridays. We are also working to promote the refreshment of employee minds and bodies. Education and training for employees
Yokohama Rubber operates an environmental management system that is completely integrated throughout the entire company and makes efforts toward reducing risks by risk identification, countermeasures and improvements in areas exposed to environmental risks, through environmental risk management, implements its operations in compliance with relevant laws and ordinances, including the Pollution Control Agreement between the Onomichi Plant, Hiroshima Prefecture and Onomichi City, and looks to reduce risks by spreading awareness of nonconformities and small incidents at other Yokohama Rubber facilities. We are also implementing improvements to achieve ongoing enhancement of environmental performance, including a reduction of industrial waste and reduction of GHG emissions by promotion of energy savings. As a result of a plan to increase our internal audit staff according to corporate policy so as to further strengthen the ISO 14001 management system, we currently have 77 internal audit staff registered. We will further increase the number of staff according to our plan.
In addition, we have participated in the “Green Curtain Contest” held by Onomichi City as one of our environment activities.
Reductions in greenhouse gas emissions
The plant’s major energy sources are electricity and the city gas which is used as boiler fuel. Of the energy used in fiscal 2018, electricity accounted for 55.9%, city gas for 43.9% and other fuel sources 0.2%.
Greenhouse gas emissions
In order to reduce environmental loads, we have made efforts toward reducing GHG emissions by reduction targets for GHG emissions (total amount). In fiscal 2017, our energy-saving activities progressed as planned.
Effective use of resources / Reduction of waste
The Onomichi Plant has maintained a recycling rate of 100%.
The Onomichi Plant collects industrial water from the Numata River water system (river water) that flows in Hiroshima Prefecture.
Water is collected from the city waterworks of Onomichi City. We are working to reduce the amount of water use by circulating plant cooling water. Furthermore, we have implemented improvement measures by setting reduction targets.
Measures for discharge into water, air and soil
Data related to water contamination
Our plant mainly uses water from the Numata River water system in Hiroshima Prefecture.
We discharge rain water into a public body of water and life system water is discharged into the sewage system of Onomichi City. The water quality of discharges is managed by setting voluntary standard values.
Move the screen to the left or right to see the table information
|Item||Regulatory values||Voluntary standard values||FY2018 result|
|PH||More than 5–less than 9||5.4 or more–8.6 or less||7.5||7.7||7.2|
|BOD concentration (mg/l)||Less than 600||Less than 315||60.7||110||28|
|SS concentration (mg/l)||Less than 600||Less than 200||64.4||110||28|
|Oil concentration (mg/l) (mineral)||5 or less||Less than 2.0||Less than 1.0||Less than 1.0||Less than 1.0|
|Oil concentration (mg/l) (animal)||30 or less||Less than 24.0||6.5||12||3|
- Regulatory values are in compliance with the Onomichi City Sewage System Ordinance. Voluntary standard values were changed in September 2012.
Air pollutants (NOx, SOx, soot and dust)
Sooty smoke is measured twice a year by each individual boiler in order to monitor emissions and the density of pollutants. As a result of switching the fuel of boilers to city gas, emissions of Sulfur oxides into the air are now minimal. Thus, the Pollution Control Agreement was amended in March 2013. As a result of this development, the measurement of SOx is no longer necessary.
Move the screen to the left or right to see the table information
|Amount of emission (t/year)||2.7||―|
|Facility||Substance||Regulatory values||Voluntary standard values||FY2018 result|
|Onomichi Plant Boiler 1||NOx (ppm)
Soot and dust (g/m3N)
|123 or less
0.011 or less
|Onomichi Plant Boiler 2||NOx (ppm)
Soot and dust (g/m3N)
|120 or less
0.05 or less
- In compliance with the Pollution Control Agreement with Hiroshima Prefecture and the Pollution Control Agreement with Onomichi City.
In order to understand the status of contamination of soil by the specific hazardous substances, we autonomously measure the components of underground water once a year to monitor contamination.
Reporting on chemical substance management status (Pollutant Release and Transfer Register (PRTR) Law compliance)
The Onomichi Plant 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.
Biodiversity conservation activities
For the protection of biodiversity, local workshops were held in May 2018, and in June we participated in a regional event to conduct PR on our initiatives at the Onomichi Plant. In addition, we undertook conservation activities along the Fujii River. This water course runs near the plant before flowing into the Seto Inland Sea. In addition to our other conservation activities, on four occasions during the year we undertook the monitoring of insect and bird life on plant premises.
Fair Operating Practices
Communication with business partners
In collaboration with the Materials Procurement Department and Raw Materials Procurement Department, we collect opinions and requests from business partners and then respond to them sincerely. We also respond appropriately to questionnaires received from business partners.
At the seventh CSR study meeting held in 2018, we welcomed 27 participants from 27 business partners. Case studies involving recent corporate scandals and their responses were introduced to the meeting, along with our company’s compliance and consultation activities. Through this process we reconfirmed both legal compliance and risk management measures.
Furthermore, we are constantly hosting plant tours both by manufacturers who purchase our products and sales agents. These tours give the visitors an opportunity to inspect the production frontlines and to confirm the quality of our products.
Responses to complaints
If any information related to defects arises from the market, we collect both usage information onsite as well as the actual tires in question. We then conduct analysis to investigate the causes. The results of such analysis are reported to the customer via the department in charge. In fiscal 2018, we prepared reports for 48 cases. No complaints were made. Although many defects arise from usage factors, whereby the cause is either a manufacturing factor or a design factor, we will quickly carry out countermeasures to prevent any reoccurrence.
Community Involvement and Development
Relationship with local societies
As a place of recreation for people in the region, we open the Dinosaur Park to the public every day, from 9:00 a.m. to 4:30 p.m. We have also installed a restroom exclusively for visitors (which can also handle visitors in wheelchairs). This allows visitors to the park to enjoy a more comfortable time.
In fiscal 2018, a total of 1,589 persons visited the Dinosaur Park.
Participation in local activities
Cooperation in Onomichi Truck Festival (September)
Volunteer participation in preparing and clearing up after the Onomichi Lantern Festival (October)
Blood donation activities by employees (April, September) (Donors: 54 persons)
Beautification activities around the plant (once a month) (99 participants)
40th Fujii River no Yube (June)
Plant tour and workshop
We accept requests for plant tours from schools and companies from time to time.
Available days: Days when plant is in operation: from Monday to Friday
(Except for year end and New Year holidays, and consecutive holidays in May and August)
Hours: 9:00 a.m. to 3:00 p.m.
Contact: Onomichi Plant, Plant Control Section
A 30-minute walk from Higashi-Onomichi Station.