Yokohama Tire Manufacturing (Thailand) Co., Ltd. (YTMT)

Business activities

Production and sale of tires for trucks and buses, small trucks and passenger cars

Total site area

Total site area:418,029 m2 (plant), 1,690,000 m2 (test course)

Number of employees

2,030 (as of December 2018)

Location

7/216 Moo.6, Amata City Industrial Estate, Tambol Map Yang Porn, AmphurPluakdang, Rayong Province 21140, Thailand

Contact for consultation and complaints

Human Resources and Administration Dept.
Tel: +66-38-627-170 Fax: +66-38-627-199
Email : saksri_a@th.yokohamatire.com
    Jirinee_h@th.yokohamatire.com

Message from the President

Makoto Takagi

Yokohama Tire Manufacturing (Thailand) Co., Ltd. (YTMT) began operating in Thailand in 2004. In line with Yokohama Rubber’s Grand Design 2020 (GD2020) medium-term management plan, YTMT is being positioned as a major overseas production facility for general tire products (including TBS and PC/LT), and is aiming for further growth in the 2020s.
In 2009, to significantly strengthen the tire development and testing capacity of Yokohama Rubber, the Tire Test Center of Asia (TTCA), a tire proving ground, was built some 30 km from our plant. We expanded the WET and DRY handling courses in 2013. In 2017, development of the Geolandar G003M/T was undertaken at TTCA’s off-road evaluation course.
Commencing in Thailand, sometimes called the “Detroit of Asia”, and throughout the ASEAN Region, motorization has been developing with a tremendous vigor. For tires, which represent one important component of motor vehicles, both the degree of satisfaction with respect to required performance and the credibility issue with respect to quality have become increasingly important. At the same time, however, because being environmentally-considerate is also an important issue, a priority for us is to produce tires with minimum energy, using materials that place little burden on the environment from the stage of their being procured as raw materials, and through to the utilization of their properties. Based on this premise, we strive to achieve product development, marketing and production expansion.
Since obtaining ISO 14001 certification in 2007, by using our environmental management system as an axis on which to base activities, we have also addressed environmental preservation through participation by all employees. Each year, by establishing specific targets and working continuously to reduce environmental burdens, we see improvements in the various environment data categories. We moved to certification under the revised version of ISO14001 (ISO14001:2015) in September 2018.

In 2011, we were the first in Thailand to obtain ISO 50001 certification (for energy management systems), and on an ongoing basis, we continue to actively improve our savings in energy and electricity usage.
In June 2017, we commenced full-scale implementation of the Cogeneration Heat Plant (CHP) project, realizing a 14% reduction in CO2 emissions, equivalent to 5,642 t-CO2 (over the period from June to December, when the CHP system was in operation).
As part of our efforts to help safeguard the environment, for the purpose of reducing CO2 emissions and in order to communicate positively with local communities, tree-planting under the YOKOHAMA Forever Forest Project was launched in 2008. As of 2017, which was the final year of implementation of the Project, we had planted a cumulative total of 84,725 trees.
We realized a target achievement rate of 169%; the quantity of CO2 absorbed and sequestered by the trees planted in this Project amounted to 677,798 tons per year.
The seedlings used in these activities are sprouted from local acorns while the forest itself is created in accordance with the Miyawaki Method. Concurrent to employing this method ourselves, we have also taken steps to support its adoption by other companies and local schools. Furthermore, three years ago we became the first overseas location within the Yokohama Rubber Group to commence biodiversity protection activities. For the purpose of furthering our community integration, we have taken steps to introduce such actions to both government and the local people. In order to achieve ecological balance this financial year, we shall continue to monitor and improve the measures in which we are engaged.

Organizational Governance

Revising the organization and its structures

In aiming to create an organization that possesses a positive sense of unified team work, we employ organizational management practices.
Starting from FY2018, we have formulated new measures, so that safety activities can be conducted in a more focused manner. The manufacturing management department has been concentrating on employee safety activities such as risk reduction, etc.
We are working to improve and further develop both safety and quality through the verification of existing standard operating procedures (SOPs) and one-point lessons (OPLs), and through cause analysis, auditing, etc. We also install fool-proofing systems and verify safety and quality after making changes to machinery and after installing new machinery.

Labor Practices

Safety and health are the basis of all operations, and we aim to prevent labor accidents while creating more pleasant workplaces. We have engaged in various new safety and healthy activities up until now and continue to do so going forward.

Health and Safety Principles

Safety and health are the basis of every operation and we aim to prevent occupational accidents while building up comfortable workplaces.

Policy Towards Health and Safety
  1. Each worker must place their greatest emphasis on safety. Improved safety shall be obtained through active participation and cooperation between employees on one hand, and managers and supervisors on the other.
  2. We shall thoroughly observe all regulations and laws that pertain to issues ofhealth and safety.
  3. The importance of health and safety shall be conveyed to every member of the labor force, and all necessary training shall be carried out.
  4. To ensure the health and safety of every member of the labor force who engages in corporate activities, cooperation with the relevant partner businesses shall be strengthened.
  5. To eliminate the hidden risks associated with both devices and work tasks, a plan-check-do-act (PDCA) cycle based on the occupational safety and health management system (OSHMS) shall be utilized, and it shall undergo improvement on an ongoing basis.
  6. To preserve in good order the cleanliness that represents the basis of health and safety within the workplace, we shall thoroughly carry out 2S activities (seiri and seiton, or sorting and straightening).
  7. While actively supporting increased mental and physical health, we shall promote the creation of comfortable working environments.
  8. As a company that is involved in the automotive industry, we shall adopt measures for the purpose of preventing traffic accidents.

We continue to ensure safety and health as a top priority task. Based on the occupational safety and health management system, we promote activities in terms of both people (people and mechanisms) and equipment, including open work observation activities and inherent safety of equipment activities, etc.

OSHMS Certificate

TIS Certificate

Hazardous operations gap survey activity

Operations that are not specified in standard operating procedures (SOPs) can involve hidden risks. With this in mind, we implemented a hazardous operations gap survey activity in FY2017, and made improvements to all items. Checks on machinery and equipment gaps have been conducted by the related departments of Yokohama Rubber and YTMT from 2018 to confirm the safety of all machinery.
To facilitate the making of improvements to all machines and SOPs, we drew up a “Summary List of Risks Requiring Improvement,” based on the risk assessment inspection results. As of September 2018, improvements had been made with respect to 0 Level V risks, 126 Level IV-III risks (with a severity level of 8), 110 Level IV risks, and 492 Level III risks. Since then, we have continued to implement risk reduction activities and compile periodic activity reports, and our improvement efforts have been confirmed by the relevant departments at Yokohama Rubber.

Checking locations where entry is possible

Risk assessment in progress

Quality education activity

In fiscal 2018, some 30 teams engaged in quality improvement activities.
We implemented TPM (including QCC and OM activities) and follow-up training drills, as well as implementing related education through presentations and contests.

Such activities were not merely limited to what took place within the company; original equipment manufacturers (Toyota, Mitsubishi, Honda and Isuzu) also actively participated in those presentations that took place.

At Mitsubishi Motors

Within the company

Hands-on safety drills (Safety Dojo)

As a large number of accidents had been occurring, in 2018 the safety department revised the content of hands-on safety drills, with the aim of ascertaining the reasons for accidents. The method adopted involved the utilization of radar chart graphical displays to evaluate C-D rank. It was anticipated that by implementing hands-on safety drills using this method, it would be possible to enhance the safety awareness of managers and supervisors in all departments, as well as all operatives, including machine operators, electrical technicians, production technology specialists and IT technicians. A plan was formulated whereby personnel would undergo pre-testing and post-testing by March 2018; the aim was to ensure that even those personnel who only scored 30 points in the pre-test would be able to score 50 points (representing a 90% comprehension level) in the post-test. Those personnel that failed the test were required to undertake additional training until they could pass the test. As of March 2018, additional training at the Safety Dojo had been 100% completed.

Training flow

Training example

Hands-on safety drill in progress

Safety awareness meeting

safety awareness

From 2017, YTMT implemented various safety activities aimed at building a safety culture rooted in employees’ attitudes and awareness.
To help realize this goal, YTMT has provided a “Safety Awareness” training course, which enables employees to learn the basics of occupational health and safety, how different types of occupational accident are defined (for example, the distinction between minor accidents and serious accidents), and how to respond to the different types of incident. Trainees can also learn about the impact of the various types of loss that can affect us as a result of accidents (including direct loss and indirect loss). This type of training is very important for ensuring safe behavior by employees.
To enhance safety awareness in the workplace among all members of the organization, a training campaign has been implemented, and employees have been encouraged to participate.

The Yokohama Rubber Group engages in business on a global level, and communication is an important issue. YTMT offers a “working in English” training course so that employees who need to regularly communicate using English can improve their own language skills and correctly communicate in English with foreigners.

Together with people with disabilities

The same number of employees with disabilities were working at YTMT in 2018 as 2017. These nine employees with disabilities continue to work at YTMT.

Management of a good working environment

In 2018, we continued with our efforts to develop good working environments through the employment of the following means:
We promise to eliminate unfairness and comply with regulations. YTMT has defined corporate responsibility policies related to a corruption prevention policy, a code of conduct for employees, and ethics escalation policy (whistleblowing policy).

Labor Relations and Welfare Award

YTMT participated in the Thai government’s Labor Relations and Welfare Award program.
On December 19, 2018, YTMT managers and labor union representatives attended the award ceremony in the Eastern Seaboard Industrial Estate in Rayong Province.
A total of 1,024 business enterprises from all over Thailand – including 178 large enterprises – received awards in various categories. Of these firms, 50 were based in Rayong Province.

Long vacation campaign

We are conducting a campaign that involves the distribution of sweets and flavored beverages, as well as the distribution of emergency contact details, in the hope that all employees will enjoy safe travel during long vacations.

Communication

Condolence visits to sick employees

We conduct condolence visits to sick employees in order to establish a good relationship between the company and employees.
We visited 20 employees during 2018. These activities encourage sick employees and lead to an early return to work.

Employee trip activities

The labor union and the company’s social welfare committee continued to jointly organize employee trip activities in 2018. These activities include team-building exercises, while in the afternoons employees are able to relax and enjoy sightseeing at beautiful tourist attractions.

Birthday parties

Since 2014, we have been holding birthday parties for employees, with the aim of strengthening employee motivation while at the same time contributing to the enhancement of production activities. In 2017, we continued to hold birthday parties for employees during the lunch break, while making some slight changes to the activity content. At these parties, managers eat alongside employees.
The participation rate in 2018 increased slightly by approximately 2 percentage points to 80%, and similar to FY2017, 99.76% of employees expressed satisfaction with the system.

The Environment

In 2018, the deployment of the environmental policy was revised through the addition of a scope for compliance with ISO14001:2015.
In order to comply with the environmental management system (ISO14001:2015), YTMT promises to apply it to work within the scope of the procurement of raw materials and the production of products and delivery of products to customers and to continue ongoing development and improvement in accordance with the principle of fair trade with society. We stress global-level strengths in technologies tosatisfy stakeholders, valueharmony with the environment, and protect the environment. The strategic policy for the environmental management system is as described below.

Environmental policy

We aim to develop environmentally-friendly technologies while adhering to the principles of dealing fairly with society and fostering harmony with the environment.

  1. Under the direction of top management, we will initiate environmentally friendly measures in all activities, and we will ensure that all of our products are environmentally friendly ones.
  2. We will endeavor to strengthen communication with stakeholders and to make a positive contribution to local communities and to society as a whole.
  3. We will implement ongoing environmental improvement measures, by strengthening our environmental management systems, alleviating the impact of our activities on the environment, preventing environmental pollution, and adopting a proactive approach towards reducing sensory nuisance.
  4. We will comply with relevant laws, regulations and agreements, and we will strive to implement activities that contribute towards environmental improvement on an ongoing basis.
  5. We will promote resource recycling aimed at helping to combat global warming, save energy, and foster the cyclical use of resources.
  6. We will strive to help safeguard biodiversity and to ensure that the organic resources utilized in our business activities are used in a sustainable manner.
  7. We will endeavor to build a harmonious, symbiotic relationship with the local community, and will aim to be an enterprise that is trusted by the local Community.

We will publicize this environmental policy and make sure that our employees are familiar with it.

Energy strategy
  1. We will introduce appropriate energy management systems as an integral part of company management, and revise these systems as appropriate; we will comply with energy-related laws and regulations.
  2. We will establish goals and provide platforms for ensuring adherence to our target energy profile and energy use methods; we will communicate with the employees to ensure that they all understand these goals and platforms and participate correctly in related activities.
  3. We will raise energy-saving awareness among employees at all levels; we will make it possible for all employees to participate proactively in energy-saving and energy management activities.
  4. We will provide the necessary resources, personnel, budgets and working hours to support the provision of platforms for ongoing energy improvement, including the provision of necessary training for all employees.
  5. We will implement improvements from an energy-saving perspective, while ensuring that this does not adversely affect the environment or productivity, and we will make energy efficiency a key requirement when purchasing buildings, products, machinery and equipment.
  6. We will publicize our energy management systems, and we will collaborate with local communities and organizations that have concerns regarding energy management systems.
  7. We will adjust our company’s management systems to improve energy efficiency on an ongoing basis.

We have actively adopted environmental and energy-saving management that we have incorporated into improvements at the company and its plants.
The company became the first company in Thailand to acquire energy management system ISO 50001 certification in August 2011 in recognition of improvements in energy performance.

ISO 14001 Certificate

ISO 50001 Certificate

Environmental data

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

Category FY 2014 FY 2015 FY 2016 FY 2017 FY 2018
Waste generated (t) 2,241 2,277 2,545 2,512 2,625
Proportion sent to landfill (%) 0.0 0.0 0.0 0.0 0.0
Energy use
(oil equivalent: kl)
Electric power 27,187 27,911 27,791 20,339 15,065
Fuel 11,402 9,986 10,088 15,065 12,324
Total 38,589 37,897 37,878 35,560 27,389
Greenhouse gas emissions (1,000t-CO2) 81.5 74.3 74.3 69.0 72.8
Water usage (1,000m3) 622 639 661 621 609

Chemical substance reporting

Limits on the special use of SVHC (substances of very high concern) spread to various countries around the world on November 18 (European REACH Regulations).
Yokohama Rubber plans to prohibit the use of SVHC on a global level in preparation for the extension of limits projected in the near future.
For this reason, we will investigate actual usage and consider eliminating the use of these substances.
The 10 SVHCs in the YTMT start target survey classified by YTMT are as follows.

  1. Chalk: Marking compound used in the mixture process
  2. GIP: Green tires were used in the BD process.
  3. Silicone bladder spray
  4. MP marking: Spray is used for the cap in the MP process.
  5. UF mark: Used for hot stamps on products in the FN process with the UF&DB machine.
  6. Blue paint: Used for products in the FN process.
  7. UF fluid: Used in the paint marker for products.

It was not a substance that is a SVHC component after completion of the check.

Environmental field management activities (Envi-SFM) were started in 2018 in response to a customer request (Toyota).
The topics for which chemical substances management is necessary for are as follows.

A self-evaluation was performed in December 2018 as the first step. An action plan for improving items that donot conform will beset as the second step.

Noise, vibration and odor

Responding to the concerns of local residents regarding odor issues, we have arranged for employees and security guards to carry out odor inspections in the vicinity of the plant, and we liaise with meetings local residents who are members of the local community association on a monthly basis. We have installed an odor prevention system that uses deodorizing wet scrubbing devices (scrubbers), and we undertake odor monitoring etc. in collaboration with the local community.
Employees made arrangements to conduct an investigation on the odor around the plant in response to concerns of local residents on the odor problem. A meeting is held with local residents who are members of the local community associations every month. In addition, automatic-recording precision meteorological instruments have been installed to monitor the following parameters.

Weather monitoring to obtain reliable odor information helps to prevent external complaints on the environment related to odors.

Minimizing the risk of environmental incidents

In 2018, we implemented the following measures at the Tire Test Center of Asia (TTCA), to ensure stable water quality in the wastewater treatment tanks.
Daily, weekly, and monthly continuous monitoring is strengthened to reduce the risk of problems occurring.

Biodiversity conservation activities in 2018

2From 2013 to 2017, we established biodiversity activity areas at offices, conducted ongoing monitoring on the status of habitats of all living creatures, and evaluated air and water quality.
At the end of 2017, biodiversity areas were opened during school visits, and we began to accept visits from the students of nearby schools. Learning activities were conducted a total of five times in 2018. These activities can provide students with knowledge of biological diversity.
Furthermore, an exhibition on safety and the environment was held for students around Amata City in cooperation with the Amata City Industrial Park and 20 other companies in Amata City. YTMT made it possible to learn the basics of biodiversity at one booth.
We will maintain and improve activities including biodiversity learning areas in the future.

Fair Operating Practices

In fiscal 2018, we visited 71 local suppliers to confirm the current status of their activities. The findings obtained from these visits showed that YTMT has succeeded in building a good relationship with its suppliers, and that YTMT and its suppliers are working together to build a fair operating environment.

Consumer Issues

In fiscal 2018, we continued to dedicate ourselves to the development and production of environmentally-friendly tire products.
YTMT released new BluEarth 707L tires for trucks and buses with new tread patterns.

Both the YTMT plant, which is our company’s tire testing facility, and the Tire Test Center of Asia (TTCA), receive many visits from distributors and sales companies, providing us with opportunities to share our tire know-how. A total of 31 groups of visitors were received in 2018.

Some of our visitors:

VIP quests from the Thai Industrial Standards Institute (TSI) of the Thai government visited our test course on August 8, 2018. A test method demo was conducted with the new UN/ ECE R117 pass-bynoise regulations related to the standards of the Automotive and Tyre Testing, Research and Innovation Centre (ATTRIC).
On November 20, 2018, Yokohama Rubber invited a total of 28 people from distributors in ASEAN countries to test ride event for ADVAN dB V552 and BluEarth ES32. The drive menu included confirmation of operability and wet performance.
On March 20, 2018, a group of approximately 14 people from distributors in the Middle East and Africa visited YTMT.
On November 29, 2018, approximately 29 logistics association members visited YTMT.
Besides visits from sales companies and distributors, we also welcome visits from university groups wishing to deepen their knowledge of tires.
In 2018, YTMT was visited by four university groups.

A consumer-oriented approach

In 2018, we focused on implementing activities aimed at meeting our customers’ needs and reducing internal quality-related incidents to zero. To realize these goals, we carried out two main activities relating to requests from the Yokohama Rubber Group and from a major customer.

1. Safety activity in collaboration with the Yokohama Rubber Group as a whole

After participating in the Yokohama Rubber Group’s Safety Master project, we started molding process model activities (kikenyochi (KY: hazard detection)) and near-miss incident and minor stoppage prevention activities in 2017. In FY2018, we expanded these activities to all processes and made ongoing improvements (KY4Round activities).
Small groups were created and plans and an evaluation by the leader group were set. These activities are followed up by an administrator every month.
We refer to near-miss incident and minor stoppage prevention activities as “Daily communication activities”. The understanding of employees can be confirmed through this evaluation. The supervisor summarizes risk point data and corrective action (temporary and permanent prompt action within one day), and then sets plans for interviews with employees in the working area. The employees who participated in these activities were impressed because the progress of activities was according to plans and work to discover which activities overall would result in a reduction in accidents and not cause absences or a fatal accident.
To verify that these activities were being implemented on an ongoing basis, a group of auditors from Yokohama Rubber visited YTMT, and followed up on Yokohama Rubber Group’s Safety Master project in September. Following this audit, YTMT has continued to implement activities aimed at maintaining safe production, focusing on employees’ hazard awareness.

2.Safety activity in collaboration with a customer

This is an extremely important for us. We have set safety plans covering the entire range of relevant activities. In 2018, we focused on factory management safety mechanisms, fundamental rules for responding to problems with machinery, machine safety risk assessment, non-routine work by contractors (such as working at height and electric machinery), improvements in work instructions (non-routine operations), and fire-prevention systems. As a result, we were able to enhance safety awareness, improve the management of chemical substance storage, and realize improvements to workplace activities. An audit by the customer in question was completed in January 2019.
We will continue implementing all activities following this audit.

Response to complaints

Information received from stakeholders regarding odors is quickly confirmed, an investigation is conducted to confirm whether the odor notified is an odor from YTMT, and the results are provided as feedback for confirmation by the community.
In 2018, YTMT received no complaints from stakeholders.

Community Involvement and Development

Community relationships

In 2018, we implemented 50 activities.

Environmental response activity

YTMT was one of 19 firms chosen out of 88 firms with factories in industrial parks to receive the highest level Platinum Award (Outstanding Performance Award) for waste management from the Industrial Estate Authority of Thailand.

YOKOHAMA Forever Forest Project activities

YTMT achieved the Grand Design 100 (GD100) target for tree planting activities over ten years in September 2017.
In 2018, YTMT expanded the total area by300m3 to plant 2,600 tree seedlings including tree planting by YTMT employees and students participating in biodiversity activities while continuing to maintain the 10th tree planting activity area.
There were plans to plant 5,250 trees in the general track area of approximately 470 m2 to the west of TTCA, and ultimately 5,775 trees were planted.

Work experience

As part of our education support activities, YTMT provides students with opportunities to acquire knowledge that will be useful to them in the Future.
In 2018, a total of 16students from 8universities took part in this training.

Recycling waste beverage containers

In 2018, YTMT employees donated a total of 120kg of waste beverage containers. After recycling and processing, the recycled material was used to construct roofs and walls for social housing built for low-income households. This recycling initiative also helped to reduce waste processing costs.

Social contribution activities

In December 2018, YTMT cooperated with CSR volunteer activities in Amata City (a safety and environment learning rally), and YTMT provided knowledge on biodiversity to 168 students from three schools near Amata City.
TTCA made donations to the regional government organization Tasit, KhaoNoi Temple, Rawerng School, and other government organizations 13 times in FY2018.