Onomichi Plant (OP)

Business activities

Production of tires for large construction vehicles, mining vehicles and industrial vehicles.

Total site area

193,000m2

Number of employees

415 (as of December 2018)

Location

20 Higashi-Onomichi, Onomichi City, Hiroshima 722-0051, JAPAN

Contact for consultation and complaints

Plant Control Section
Tel: +81-848-46-4580
Fax: +81-848-46-4579

Message from the General Manager

Masahiro Iida

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.

Organizational Governance

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.

Morning meeting

Outstanding QC Circle Activities Award Ceremony

Human Rights

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.

Labor Practices

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.

Responses in case of disaster

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.

Work-life balance

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

The Environment

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.

Environmental data

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.

  • The base year is defi¬ned 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 Coeff¬icients by Power Company (Ministry of the Environment).
  • ◆The Onomichi Plant changed the CO2 emissions coeff¬icient to the actual emissions coeffi¬cient in FY2009.
    Until FY2008, the Onomichi Plant used the targets of the Ministerial Order under the Act on Promotion of Global Warming Countermeasures.

Effective use of resources / Reduction of waste

Waste output

The Onomichi Plant has maintained a recycling rate of 100%.

Water usage

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
Average Maximum Minimum
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
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

Item NOx SOx
Amount of emission (t/year) 2.7
Facility Substance Regulatory values Voluntary standard values FY2018 result
Average Maximum Minimum
Onomichi Plant Boiler 1 NOx (ppm)
Soot and dust (g/m3N)
150
0.10
123 or less
0.011 or less
61.5
0.001
84
0.001
48
<0.001
Onomichi Plant Boiler 2 NOx (ppm)
Soot and dust (g/m3N)
150
0.10
120 or less
0.05 or less
94
0.002
100
0.003
85
<0.001
Soil contamination

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.

Consumer Issues

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.

The Dinosaur Park is open to the public

Participation in local activities

Cooperation in Onomichi Truck Festival (September)

Truck Festival

Volunteer participation in preparing and clearing up after the Onomichi Lantern Festival (October)

Onomichi Lantern Festival

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)

Fujii River no Yube – Evening event at Fujii riverside

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
Tel: +81-848-46-4580
A 30-minute walk from Higashi-Onomichi Station.