LLC Yokohama R.P.Z. (YRPZ)
Production of tires for passenger cars
Total site area29ha
Number of employees717 persons (as of December 31, 2022)
LocationYOKOHAMA Plant, territory of SEZ PPT Lipetsk, Gryazy town, Gryazy District, Lipetsk Region, Russia, 398010
Contact for consultation and complaintsHR and Administration Dept.
TEL: +7 (4742) 727-800 FAX: +7 (4742) 727-900
Message from the President
Located approximately 450 kilometers south of the Russian capital of Moscow, LLC Yokohama R.P.Z. commenced its production activities in the Lipetsk Region in 2012.
In conducting our business, we aim to achieve the following:
・ We wish to create a high-quality and cleanly run factory from which our customers may experience peace-of-mind when they purchase our products.
・ We also wish to create an attractive company in which our employees can take pride.
・ We aim to contribute to the well-being of the local community.
It has been 11 years since we started production activities, and our most important requirements are safety (S), environment (E), quality (Q), delivery time (D), and cost (C), in that order. Of these, safety (S) is the most important requirement. We sincerely hope that all employees can finish their work every day and return home safely to their families.
We are continuously making improvements and promoting improvement activities with the participation of all employees by using our environmental management system as an axis on which to base activities.
In the future as well, we intend to push forward with our aim of becoming a business that can be trusted by our customers, by our employees and by regional society.
Organizational Governance
Compliance
We want to be a company that complies with all applicable Russian laws in our business activities.
Through our Legal, Compliance, and Internal Control departments, we regularly monitor Russian laws. As a result, any newly enacted or amended laws and regulations that come to our attention are promptly addressed by notifying both management and the relevant business units.
Since July 2016, we have operated an internal reporting system as a tool for anonymous whistleblowing, and we regularly encourage all employees, including new hires, to use the system.
Since August 2017 to date, YRPZ has been working to strengthen its compliance training. To this end, the legal department provides all employees with monthly compliance case studies.
Human Rights
There have been no instances of human rights violations in the Company's activities. In terms of recruitment and employment conditions, all employees are treated equally regardless of nationality, ethnicity, religion, gender, age, or physical appearance.
Labor Practices
The company has been conducting its activity in line with the following priorities which are of great importance to us: safety (S), environment (E), quality (Q), delivery (D), and cost (C).
Labor safety
Safety (S) is the highest-priority item. We are constantly striving, through the measures outlined below, to maintain and improve the safety standards on an ongoing basis.
- Safety education for employees
- Evaluations of safety awareness
- Internal inspections relating to occupational health, safety and the environment (conducted daily)
- Inspection patrols conducted by the internal safety committee (conducted weekly)
- Safety patrols conducted with the President acting as a leader (conducted monthly)
- Safety meetings (held monthly)
- Workplace environment evaluations of working conditions
- Provision of personal protective equipment (PPE)
YRPZ continued to review its near-miss reporting procedures in FY2022. During the year, 7,575 near-miss reports were submitted by employees. Corrective or preventive actions were initiated for 7,564 of these reports.
In 2022, there was a strong focus on ensuring the safety of work performed at height. In addition to the required personal protective equipment (PPE), employees who work at heights must receive special training to ensure they can perform their duties safely.
Disaster response safety measures
In 2022, the company conducted appropriate activities to enhance safety in relation to disaster prevention.
YRPZ continues to provide fire safety training for all employees and conducts regular fire drills.
In July 2022, an evacuation drill was held; employees (shift and office) from all divisions of YRPZ participated in the drill (250 employees).
Promoting health
Employee wellness plays an important role in ensuring safety. We conduct preventive monitoring by regularly checking the health of our employees and conducting health checkups at the time of hire and periodically thereafter. Records of medical examinations are kept in a medical facility on the premises of YRPZ.
Voluntary Medical Insurance (VMI) is not mandatory under Russian law, but YRPZ continues to offer it to all employees.
YRPZ's VMI program continues to be the best among industrial companies in Lipetsk Region in terms of coverage and content.
VMI allows employees to receive prompt, quality medical care and a better chance of recovery.
In FY2022, YRPZ took steps to further improve VMI, including continued support for YRPZ employees, expansion of coverage and clinic list, clinic audits, and employee satisfaction surveys and subsequent remediation measures.
- Even before the pandemic began, we provided disinfectant solutions to our employees in our workplaces
- We continued to provide safety face masks
- Regular temperature control was conducted at the plant entrance before the start of the workday and several times during the workday
- Increased the distance between employees and their desks for safety work
- Outsider access to the plant premises was limited to only those visits that were highly necessary for temperature control at the plant entrance
- Switched to online meetings whenever possible (e.g., recruiting, business, negotiations, etc.)
- If an employee shows signs of illness or reports contact with a COVID-positive person, he/she is immediately isolated and tested for COVID-19 at company expense; COVID testing is also done when employees return from vacation (elsewhere in Russia or abroad) or from sick leave
- Disinfection of common areas is carried out on a regular basis
- Meeting rules: no longer than 15 minutes, distance between participants - 3 m
- To prevent outbreaks of COVID-19, an aggressive vaccination campaign (vaccination promotion, vaccination arrangements at the factory) was implemented, and the vaccination rate among employees reached almost 100%.
Education and training
In order to improve the professional skills and knowledge of our employees, we offer a variety of internal and external training programs.
Training conducted within the company is mainly related to occupational safety and health.
Training conducted externally is aimed at professionalizing and upgrading the know-how and skills of employees, and in many cases, with the cooperation of consulting companies, external instructors are used.
In addition, special allowances are provided to those who demonstrate a certain level of English proficiency.
Employment of people with disabilities
As of the end of December 2022, there are 5 persons with disabilities working at YRPZ as full-time employees.
Each of them can receive medical care without discrimination and has the same opportunities for self-development, promotion, and advancement as other employees.
Motivation and engagement
In order to improve the motivation and engagement level of employees, YRPZ implemented a number of tangible and intangible incentive measures and activities in FY2022, namely:
- YRPZ continued its tradition of birthday parties: in FY2022 every employee received a thermos bottle and a birthday card signed by the general director.
- All employees who have school-aged children received a set of school stationery at the beginning of the school year (September 2022).
- We held the Best Manager Contest again this year to motivate managers and improve their work efficiency.
- Employees who joined the company in 2012 (148 persons) celebrated their 10th anniversary and were presented with valuable gifts from the company.
- All employees and their children under 14 years old received seasonal NY gifts.
- All employees also got a special memorable gift - specially tailored branded zip-up hoodies, in commemoration of the 10th anniversary of YRPZ since its opening in 2012.
- On the day of Family, Love and Fidelity (traditionally celebrated in Russia on July 8) families and relatives working together at YRPZ got special gifts (branded mugs).
- Special allowance for coaching and mentoring was provided. Additional payments were made for mentoring and coaching subordinates and developing practical skills.
- Communication via internal Telegram channel contributed a lot to improving the internal climate of YRPZ.
The Environment
Environmental management
In addition to safety (S), the environment (E) is also an important issue, and YRPZ complies with all Russian laws and regulations related to the environment. Furthermore, we spare no effort to be an environmentally friendly company.
In our daily operations, we keep abreast of the country's environmental laws and regulations and strive to comply with any revisions.
In 2022, we renewed our ISO 14001:2015 certification. The certification is valid until December 26, 2025.
Environmental data
Move the screen to the left or right to see the table information
Category | FY 2018 | FY 2019 | FY 2020 | FY 2021 | FY 2022 | |
---|---|---|---|---|---|---|
Waste disposed (t) | 1,211 | 1,009 | 922 | 927 | 690 | |
Proportion sent to landfill (%) | 7.5 | 12.7 | 14.5 | 13.7 | 11.5 | |
Landfill waste (t) | 91.0 | 128.0 | 134.0 | 127.0 | 79.4 | |
Energy use (oil equivalent: kl) |
Electric power | 5,232 | 5,096 | 4,964 | 5,201 | 3,396 |
Fuel | 4,918 | 4,283 | 4,067 | 4,355 | 3,515 | |
Total | 9,865 | 9,379 | 9,031 | 9,556 | 6,911 | |
Greenhouse gas emissions (1,000t-CO2) | 18.2 | 16.7 | 16.1 | 8.7 | 8.9 | |
Water usage (1,000m3) | 50.1 | 46.2 | 44.1 | 48.5 | 36.0 |
- FY: January to December
- Greenhouse gas emissions from overseas business sites are calculated using the Greenhouse Gas Protocol Initiative and electricity emission factors of local businesses. It should be noted that 41% of the company’s gas emissions were used for the purposes of heating.
Measures for dealing with industrial waste
Disposal of industrial waste is strictly regulated by the Russian authorities. All waste generated by the YRPZ plant, of whatever type, is disposed of appropriately by certified waste disposal contractors. We are continuing our efforts to reduce the amount of industrial waste generated.
Total waste generated in FY2022 was 690 tons.
The amount of waste generated per tire produced was 0.13 kg/tire.
In FY2022 20,395 kg of paper and cardboard were sent to recycling.
Disposal of used tires
Under the provisions of Regulation dd 09.04.2016 No. 284 issued by the Government of the Russian Federation, which establishes the responsibility of manufacturers and importers for certain products, including automotive tires, as these are considered assets that leave the hands of the consumer (become used products) YPRZ is responsible for taking action to ensure that these are disposed of in accordance with the regulations.
Specifically, we offer two options to manufacturers and importers of such products They can either pay environmental fees according to a tariff set by the government, or they can make guaranteed arrangements for the disposal of their products, either on their own or by joining a union of waste disposal companies.
As a member of the Eco-Tyres Union (a union of tire manufacturers and importers who voluntarily act in accordance with the recycling standards set for tires and rubber products), YRPZ has contracts with recyclers for the joint recycling of used tires.
Tire marking
In compliance with the Russian law (Order of the Russian Government dd. 31.12.2019 No. 1958), which is intended to combat illegal tire production and distribution, YRPZ has been implementing obligatory tire marking by means of placing a sticker label bearing an individual DM-code (Data Matrix code) to every tire produced. Through the code it is possible to get the true information about place, date and time of tire production, which proves the tire had been produced legally.
Reducing water usage
YRPZ is constantly striving to reduce water usage through the implementation of a number of measures.
In 2022, total water consumption was 35,954 m3.
In 2022 in order to reduce water consumption we focused on prevention of water, steam and air leakage by timely replacement of equipment spacer plates, arms and hoses.
- Optimized the layout of pipelines supplying water to fire water storage tanks (water savings - 860 m3).
Managing wastewater discharge
Wastewater discharged from YRPZ's plant facilities is properly treated in a reliable manner prior to discharge into the sewage system.
In 2022 the following measures were implemented to prevent wastewater contamination.
- Grease discharge and cleaning of grease separators.
- Sampling to control chemical composition of wastewater: conducted monthly and quarterly.
Energy savings
We recognize the importance of energy efficiency, and we are continuing our concerted efforts to make our energy usage more efficient. In particular, in fiscal 2022 we implemented the following energy-saving measures:
- Lighting in the curing and MP-1 (except textile calender) processes was changed to LED lamps.
Biodiversity measures
In 2022 Green Wave activities were cancelled due to plant temporary shutdown period.
Fair Operating Practices
Internal controls
To prevent fraud, operations are carried out based on an internal approval system by management for contracts, purchases, and settlements. Furthermore, internal rules have been established, and the final decision is made by the final decision maker after checking by the management, legal, and accounting staff.
Selection of business partners
Concerning raw material procurement from new Russian domestic suppliers, we work to handle matters fairly while cooperating with the procurement department of Yokohama Rubber.
When selecting suppliers, we make sure to verify the compliance and reliability of potential suppliers, in order to avoid doing business with firms that are untrustworthy or which are engaged in illegal behavior. To this end, we implement documentary review and enterprise evaluation surveys in advance. As a result, in the period since the YRPZ plant began operation, there have been no instances of signing contracts with suppliers that turned out to be unreliable or engaged in illegal activity.
Consumer Issues
Quality management systems
In FY2022 we continued our efforts to improve our quality management.
In April 2022 YRPZ successfully passed the surveillance audits for IATF 16949:2016.
Strengthening communication with consumers
Based on cooperation with LLC Yokohama Russia which has direct contact with consumers as a sales company, we are working hard to gain evaluative information of products from the marketplace.
Community Involvement and Development
Internal activities
On an ongoing basis, the company shall continue to take care in fostering team spirit and a sense of loyalty among employees.
Team-building corporate events
The COVID-19 epidemic did not allow us to hold full-scale offline team-building activities. For that period we focused on building a community of employees through our internal Telegram channel. Motivational activities involving employees were carried out online on various occasions, such as the Men's and Women's Holidays, the Professional Celebration, and the Environmental Celebration.
Soccer team activities
YRPZ soccer team continues to attract and excite fans and spectators with outstanding performances.
In 2022, the team participated in the regional soccer league as well as in the Bekaert Soccer Cup Tournament on the occasion of Belgium Day.
External activities (Social contribution)
In 2022 YRPZ continued to participate in the Russian environmental and charity project "Dobrye Kryshechki" ("Kind caps").
In this project caps from plastic bottles are collected and recycled, and the money earned is donated to disabled children.
The project has two goals: to rid the world of plastic waste and to support children with disabilities.
In 2022 YRPZ participated in the Industrial Gymnastics Contest. Although YRPZ didn’t win the contest, we got into the finals.
In 2022 several employees of YRPZ took part in the 20-th regional contest of professional skills for the title “Best in profession”. Our employees showed high level of professional skills during the contest.
In August 2022 YRPZ provided charity support to the local educational center for children with special education needs – we gave them school stationery sets.
In 2022, YRPZ took part in the sports challenge arranged by SEZ “Lipetsk” managing company. Together with other residents’ employees we achieved the goal of the challenge – to participate in sports activities (running, cycling, working out in the gym, etc.) to cover the distance of 40,075 km to circle the globe at the equator.