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Introduction to Tokuyama Plant

  • Aerial view of the Tokuyama Plant Aerial view of the Tokuyama Plant

[Establishment]
1965

[Main functions and products]

  • Butadiene monomer
  • Synthetic rubbers
  • Synthetic latex
  • Polymerized toner
Most of our products are exported overseas, and we are expanding global activities as Zeon Corporation’s main synthetic rubber plant.


Plant Policy (from Plant Manager)

  • Tokuyama Plant Manager <br>Sachio Hayashi Tokuyama Plant Manager
    Sachio Hayashi

[Policy]
With production innovation as the pillar of factory reform, in order to realize a stable and safe plant, we cooperate with the two group companies (Zeon Yamaguchi Co., Ltd.) and (Zeon North Co., Ltd.) and operate as a plant rooted in the local community.
With the watchword “Greetings and 3Ss (seiri, seiton, and seisou, or sort, straighten, and scrub) are the Foundation of Everything We Do.” we are building a bright and lively plant through participation of all employees in production innovation.
We aim to be a plant that is trusted by society by making positive efforts to contribute to social challenges with every employee cooperating with the local community.

[Concrete efforts]

  • Collecting bottle caps and can tabs
  • Higashi River Cleanup volunteer activities


Safety Initiatives

[Policy]
Safety First! Every employee takes responsibility and acts to achieve zero accidents and disasters.

[Concrete efforts]

  • We promote the four integrated safety activities (risk prediction, risk assessment, nearmiss incidents, fool-proofing) and reduce work-related risks
  • We inspect past change management and prevent accidents before they occur

Efforts to Reduce Environmental Impact

[Policy]

  • Promotion of environmental impact reduction activities
  • Continuation of efforts for zero emissions from industrial waste
  • Steady reduction of CO2 emissions
[Concrete efforts]
1. Reducing toxic chemical emissions
We introduced exhaust gas purification facilities in fiscal 2011 and can now stably control the emissions of PRTR substances. We will continue to reduce PRTR substance emissions and aim for zero emissions*.

* Zero emissions
Creating systems with zero emissions to the natural world, or the basic idea of aiming to create such systems.


2. Reducing industrial waste
We have continuously sent zero waste to landfill since fiscal 2010.
We will aim to reduce industrial waste further following the 3Rs of Reduce, Reuse and Recycle.

3. Saving resources and energy
We created an Energy Conservation Working Group and Energy Conservation Promotion Committee at the plant, and promoted improvement by setting medium- and long-term planning for technical challenges such as equipment that uses a large amount of energy. In addition, through thorough promotion of daily management, we set the goal of achieving 90% of fiscal 1990 specific energy consumption and are making efforts by rallying the knowledge of all employees. Also, as the Energy Conservation Promotion Committee sponsored by the head office shares information on the status of initiatives in each plant, we are working day and night to continue to improve based on study from various angles, such as introducing ground-breaking technology.

4. Reducing air pollution
We started operation of a new boiler in fiscal 2014 and can now stably reduce emissions of SOx and CO2.

5. Reducing water pollution
We are reducing our COD and total nitrogen emissions year on year through improvement to our wastewater treatment equipment and processing methods.
We have passed environmental standards through our efforts up to now, and will make every effort to ensure stable maintenance in fiscal 2016 too.

6. Environmental Data
Tokuyama Plant FY2011 FY2012 FY2013 FY2014 FY2015
Toxic substances Butadiene consumption (tons) 186,784 181,275 206,710 170,327 195,538
Butadiene emissions (tons) 1.4 1.2 0.8 1.1 0.7
Acrylonitrile consumption (tons) 13,697 13,600 17,464 14,379 16,983
Acrylonitrile emissions (tons) 0.6 0.6 0.6 0.7 0.6
Substances subject to PRTR law Consumption (tons) 388,603 391,766 453,075 397,637 422,439
Amount emitted (tons) 3.1 2.7 2.0 2.7 2.1
Industrial waste Amount generated (before volume reduction) (tons) 18,718 16,939 19,201 24,063 23,163
Amount generated (after volume reduction) (tons) 3,762 3,505 3,377 4,674 4,737
Amount sent to landfill (tons) 0.0 0.0 0.0 0.0 0.0
Atmospheric emissions CO2 emissions (tons) 248,294 239,609 279,750 237,362 263,215
SOx emissions (tons) 502 322 471 507 622
NOx emissions (tons) 272 243 205 179.0 191
Soot emissions (tons) 7.7 6 4 2.2 11
Leakage of CFCs (tons of CO2) - - - - 3.9
Water resources (Industrial water + Ground water + Waterworks) consumption (1,000 m3) 9,482 8,788 8,927 8,393 8,812
Waste water Total waste water discharge (1,000 m3) 7,884 8,288 8,165 7,785 8,051
COD emissions (tons) 69 58 49 42 57
Total phosphorus discharge (tons) 0.6 0.6 0.7 0.6 0.8
Total nitrogen discharge (tons) 27 27 28 27 28
Energy Total consumption (crude oil equivalent, kL) 90,955 90,648 103,000 92,423 104,326
Unit consumption index (1990 = 100) 99% 102% 99% 106% 106%
Production of PDR equivalent (tons) 498,167 487,782 573,961 477,797 531,865

Quality Assurance Efforts

[Policy]
In line with Zeon's Mid-Term Management Plan, including the Enterprise Blueprint for 2020: “Zeon makes the future today through the Power of Chemistry,” the Tokuyama Plant continuously improves and innovates its production technologies to achieve a 100% yield rate* and build certifiable quality into all of its products. We aim to be a plant that consistently delivers high-quality products that satisfy our customers.

* Yield rate
The percentage of products rolling off the production line that pass quality inspections. A 100% yield rate means that no defective products were produced.


[Concrete efforts]
The most important thing when manufacturing quality to satisfy customers is to take a customer perspective. It is to always ask yourself “How would I think if I was the customer?” We always keep these words in mind when conducting quality improvement activities at the plant.

Relationship with Employees

[Aims of human resource development]
"Employees who can think through by themselves with high goals and keep improving"
 
[Basis of education]
“Bring out, develop and utilize each employee's ability.”
 
[Concrete efforts]
Operator basic education: Implement operator basic education for operators in their first three years of employment.
 

Living together with the local community

[Concrete efforts]
1.Zeon Waraku Odori Dance Festival
A festival organized by employees to deepen interaction with employee’s families and local people through the “Waraku dance.” It began in 1974 and now attracts over 2,000 people every year.
Employees hand out yakitori and oden and at the end everybody forms a circle and dances.
In addition to continuing to place importance on contact with local residents, the Tokuyama Plant will contribute to environmental protection and social welfare activities.

2. Public relations activities

Fiscal 2015 Results
  • 11th RC regional informational meeting and plant tour: Participation by the Chairman and Vice Chairman of five residents' associations adjacent to the factory.
  • Summer vacation parent and child classroom (organized by the Chamber of Commerce and Industry): Experimental classroom (making a super ball), plant bus tour

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