Ibaraki Plant (IP)

Business activities

Production of high-pressure hoses, sealing materials

Total site area

152,000m2

Number of employees

358 (as of the end of December 2018)

Location

1 Hatori-Nishi, Omitama City, Ibaraki 319-0198, JAPAN

Contact for consultation and complaints

Tadashi Kamimura, Plant Management Division
Tel: +81-299-46-1111
Fax: +81-299-46-0235
E-mail: tadashi.kamimura@y-yokohama.com

Message from the General Manager

Morimichi Honkai

The Ibaraki Plant started its operations in 1973 as an exclusive plant of high pressure hoses, one of the largest in Japan, and in 1997 it started plant operations for building sealing materials and has continued production until today.

While working on measures in accordance with Yokohama Rubber’s GD2020 Basic Policy so we become “a company having world-class strengths in technologies for protecting the environment”, in that we also aim to achieve harmony, fusion and coexistence with the abundant and beautiful nature of Ibaraki, the plant is promoting numerous regional and social contribution activities in addition to its environmental policies. With respect to reducing industrial waste, we have achieved results by strengthening team-improvement activities under the themes of reducing process nonconformities and improving materials and equipment management. As regards energy saving activities, all employees actively promote renewal of machinery and equipment by replacement with energy-saving models, increased energy saving awareness and paperless processes. The plant has been maintaining the highest AAA rank of the eco office registration system established by the prefecture.

Furthermore, although we have completed the tree plantings plan within the plant, we continue to grow seedlings. We donate these seedlings to both locally-held planting events and planting activities held within the disaster impacted areas.

In 2013, we also commenced biodiversity activities and we conducted a survey of aquatic life from the Sonobe River down to Kasumigaura. Through such activities, we are striving to improve our communication with local communities.

Additionally, our biodiversity activities have been recognized, in that in 2018 we were given an opportunity to present the details of what has been done to the World Lake Conference. When at the event, we were also given the opportunity to come into contact with neighboring organizations. We hope to develop those contacts into further interactions going forward.

Through such means we further strengthen our environmental management systems at the Ibaraki Plant, and push forward with the total-employee participation model, both with regard to those activities that make an environmental contribution, and with regard to the prevention of environmental trouble.

Organizational Governance

Decision-making processes and structures

The following three items have been established with respect to the structuring of the plant’s safety culture:

  1. The taking of initiative when conducting the 3S’s
    (seiri–organizing, seiton – arranging, seiso – cleaning)
  2. The delivery of safety “greetings” in a loud voice
  3. Putting pointing and calling into practice at the workplace

With respect to the plant’s safety, environment and quality policies, such are established in accordance with corporate policy. Concerning their orientation, such is decided through the meetings system.

Human Rights

Consideration of human rights by suppliers

In February 2018, the seventh CSR study meeting was conducted, and suppliers participated. On this occasion, explanations were given with regard to the following topics:

Complaint resolution

There were no reports submitted to the Corporate Compliance Department in 2018, and no consultations requested.

Labor Practices

Creating a safe and healthy workplace environment

Based on the recognition that the basis of corporate activity is assuring the safety and health of both our employees and those of cooperating companies, Occupational Safety and Health Management System (OSHMS) certification in accordance with Japan Industrial Safety & Health Association (JISHA) standards was obtained, and safety and health management has been implemented. This was done as a means by which to realize a safe, comfortable, and healthy workplace.
Safety management at each workplace is followed up at the Safety and Health Committee monthly. This year, efforts have focused on the parallel deployment of safety measures, particularly for achieving fundamental safety in plants, and results have been achieved.
In addition, we have also focused on traffic safety education because the majority of employees commute to work by car, and we have worked to develop safe drivers and prevent accidents through means such as inviting external instructor to hold courses on traffic manners in an effort to improve driving manners.

Circle activities

Circle improvement activities are being conducted to allow employees to make their own workplaces more comfortable and easier to work at. We are working to vitalize these activities through the holding of events including regular announcements on the results of improvements and bulletin board contests.

Human resources development and training

Work training is undertaken by our assignment of more senior workers to instruct both new hires and fixed-term employees. This one-on-one training increases individual skill levels because training results can be reviewed and revisited.

Promotion of employment of people with disabilities

As part of our promotion of the employment of disabled people, we currently have two disabled employees working actively in the plant.
We will continue to implement improvements to create a barrier-free workplace, so as to foster the employment of disabled people.

Work-life balance

Two days a week, Wednesdays and Fridays, have been established as days with specified hours for leaving work.

The Environment

Environmental data

Reductions in greenhouse gas emissions

Greenhouse gas emissions

Greenhouse gas emissions have been gradually decreasing since fiscal 2010.

  • The base year is de¬fined 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 Coeffi¬cients by Power Company (Ministry of the Environment).
  • As the closing of accounts period was April to December in FY2011, the calendar year of January to December was calculated by the duplication of data for the period January to March.

Effective use of resources / Reduction of waste

Waste generated

From fiscal 2006, we have continued complete zero emissions.

Waste landfill

In fiscal 2007, we achieved a recycling rate of 100% and we have maintained that rate since.

Water usage

The plant uses 400,000 tons of water a year.
Sources consist of underground water of about 90% and city waterworks of 10%.

Measures for discharge into water, air and soil

Data related to water contamination

The plant discharges about 430,000 tons of wastewater a year into the Sonobe River.

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 5.8–8.6 6.7–8.2 7.7 8.2 7.3
BOD concentration (mg/l) 10 5.5 2.1 6.4 1.0
COD concentration (mg/l) 10 5.5 2.1 6.2 1.0
SS concentration (mg/l) 15 5.0 1.0 1.6 1.0
Oil concentration (mg/l) 3 0.8 0.5 0.7 0.5
Soil contamination

We conduct groundwater analysis (shallow well) once a year and confirmed that the standard values were within the laws and the ordinances of Omitama City.

Air pollutants (NOx, SOx)

Measurements are conducted twice a year, and we have confirmed that the results are within the standards set out in all laws and in Omitama City Ordinances.

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

Substance NOx SOx
Amount of emission (t/year) 2.7 0.4
Facility Item Regulatory values Voluntary standard values FY2018 result
Average Maximum Minimum
Ibaraki Plant Boiler SOx emissions (K-value)
NOx (ppm)
Soot and dusts (g/m3N)
17.5
260
0.3
10 or less
125
0.1
0.30
71
0.0025
0.67
87
0.004
0.13
57
0.001

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

The Ibaraki 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.

Noise reduction

Noises are measured at 15 places on the border of the plant premises once a month. We can confirm that the results are within the standards set out in Omitama City Ordinances (below 55db).

Preventing pollution

So as to prevent risks to the environment, once a year we conduct drills and tests in response to predicted emergency scenarios (such scenarios include oil leaks occurring from heavy oil storage tanks and solvent cans being upset during transportation, etc.).

Steps to reduce industrial waste

On the issue of reducing industrial waste, through our waste-reduction (MD) activities, we are revising the methods used to segregate waste within the plant and also promoting a paperless culture. Concerning auxiliary materials that are incidental to our products, we have obtained the EU ELV and RoHS Statement of Non-Inclusion Directives. Furthermore, goods that we purchase do not contain those substances that are subject to these provisions.

Alleviating and responding to climate change

As energy-saving activities, we have introduced LED lighting, and adopted the use of high-efficiency air conditioners and motors, along with promoting the application of heat-resistant and heat-retaining materials.
“Energy-saving Month” activities were implemented in February and August, with all employees participating in energy-saving promotion activities; a number of suggestions were put forward for reducing unnecessary energy wastage, and improvements were made.

Environmental protection, and recovery of natural habitats

Concerning the Sonobe River into which discharges from this plant flow, biodiversity protection surveys have been conducted at a frequency of three times a year. During these surveys, we have monitored water quality, aquatic life, plants and birdlife, etc. We have also taken steps to eliminate certain species of introduced plant and aquatic life. In the future, we will continue with our elimination of introduced species and our monitoring of the environment at a frequency of three times a year. Additionally, we were given the opportunity to report on our activities at the 17th World Lake Conference (Lake Kasumigaura, Ibaraki, 2018) that was held in October.

Biodiversity conservation activities

Fair Operating Practices

Thorough statutory compliance

The managers mainly responsible for placing orders with subcontractors have participated in seminars dealing with the improvement of subcontracting transactions. In addition, all personnel acting as subcontractor contact persons attended the subcontractor study sessions organized by the Indirect Materials Procurement Department that were held at the plant, reinforcing their understanding of legal requirements.

Consideration of supplier labor, safety and workplaces

Business dealings are conducted that are fair, transparent, openly competitive and suitable.

Thorough compliance

At the 7th CSR study meeting, presentations were given to suppliers on the topics of “Report on the Company’s CSR Measures”, “Procurement Guidelines,” “Lessons from Recent (Compliance-related) Corporate Scandals,” and “CSR Measures at the Ibaraki Plant.”
As education within the company, we hold compliance seminars at a frequency of once a month.

Consumer Issues

Responses to complaints

If any complaints are raised about products, we quickly collect the actual item and investigate the causes and prepare reports to make a response satisfactory to the customer.

Promotion of universal design

Concerning the brand logo mark that is printed on our products, we are continuing activities to consolidate on the new type that is identical to the one used on tires. We are doing so in order that consumers are not confused.

Community Involvement and Development

Coexistence and shared prosperity with the local community

In April, we held a presentation on biodiversity for local residents, with 21 local residents and eight plant personnel participating.

Employment creation

In fiscal 2018, two new employees were recruited from local high schools. As part of our efforts to promote the employment of older people in the local community, the plant is currently employing five people introduced by the local Senior Human Resources Center.

Regional contributions

We donated 500 seedlings for the Fureai Plaza in Hatori district, with six employees volunteering to assist with the seedlings. We exhibited at the Omitama Environment Festival that was held on July 21, where, in addition to putting on show a MIRAI car, a vehicle that runs on a hydrogen fuel cell, we set up displays of hydrogen hoses and information panels that introduced our CSR activities, and donated approximately 500 free seedlings to the event. Additionally, we set up a stall at the Omitama City Fureai Festival and distributed 1,440 free seedlings to members of the public.
To help contribute to the restoration of the Tohoku region and to forest regeneration in the region, we donated 389 seedlings to the Iwate Prefecture Otsuchicho Tree Planting Day, with two volunteers to assist with this activity.

Hatori Fureai Plaza

Provision of seedlings at the Fureai Festival in Omitama City

Omitama Environment Festival

Presentation for local residents regarding our activities to help safeguard biodiversity

In April we held a meeting with local residents to explain our biodiversity protection activities. Through tours of the plant, we were able to make Yokohama Rubber and the Ibaraki Plant more familiar for local residents and to deepen their understanding of both our environmental activities and the steps that we are taking to protect biodiversity.

Relationship with local societies

As part of our efforts to foster close communication with local government authorities and local corporations, we attend the regular meetings of the local corporation association to exchange views and share information with the Mayor, local councilors and the managers of other local corporations. (The annual meeting of the Omitama City Business Association was held on February 1, with 14 representatives of 11 companies attending)

Plant tours

Plant tours were held for local high schools and 30 people participated in August.
Through such activities communication with neighboring areas is being promoted.