FY2016 CSR Website CSR > Site Reports > Worksites > Tokuyama Plan

Tokuyama Plant

Introduction to Tokuyama Plant[Establishment]
1965[Main functions and products]
・Butadiene monomer
・Synthetic rubbers
・Synthetic latex

Aerial view of the Tokuyama Plant

・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)[Policy]With production innovation as the pillar of factory reform, in order to realize a stable andsafe 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, andscrub) 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 tosocial challenges with every employee cooperating with the local community.

Tokuyama Plant Manager
Sachio Hayashi[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-1-FY2016 CSR Website CSR > Site Reports > Worksites > Tokuyama Plan

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, andpromoted improvement by setting medium- and long-term planning for technical challenges such as equipment that uses alarge amount of energy. In addition, through thorough promotion of daily management, we set the goal of achieving 90% offiscal 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 CO 2.
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
Toxic

Butadiene consumption (tons)

substances

Butadiene emissions (tons)
Acrylonitrile consumption

FY2011FY2012FY2013

FY2014FY2015

186,784

181,275

206,710

170,327

195,538

1.4

1.2

0.8

1.1

0.7

13,697

13,60017,464

14,37916,983(tons)
Acrylonitrile emissions (tons)
Substances

Consumption (tons)

subject toAmount emitted (tons)

0.6

0.6

0.6

0.7

0.6

388,603391,766

453,075

397,637

422,439

3.1

2.7

2.0

2.7

2.1

PRTR law-2-FY2016 CSR Website CSR > Site Reports > Worksites > Tokuyama Plan

Industrial

Amount generated (beforewaste

volume reduction) (tons)
Amount generated (after

18,71816,93919,201

24,06323,163

3,762

3,505

3,377

4,674

4,737

0.0

0.0

0.0

0.0

0.0

volume reduction) (tons)
Amount sent to landfill (tons)
Atmospheric

CO2 emissions (tons)

248,294

239,609279,750

237,362

263,215

emissions

SOx emissions (tons)

502

322

471

507

622

NOx emissions (tons)

272

243

205

179

191

Soot emissions (tons)

7.7

5.7

3.5

2.2

10.9

Leakage of CFCs (tons of CO2)

－－－

－

3.9

9,482

8,788

8,927

8,393

8,812

7,884

8,288

8,165

7,785

8,051

COD emissions (tons)

69

58

49

42

57

Total phosphorus discharge

0.6

0.6

0.7

0.6

0.8

Water resources (Industrial water + Ground3water + Waterworks) consumption (1,000 m )Waste water

Total waste water discharge
3(1,000 m )(tons)
Total nitrogen discharge (tons)
EnergyTotal consumption (crude oil27

27

28

27

28

90,95590,648103,000

92,423

104,326

99%

102%

99%

106%

106%

498,167

487,782

573,961

477,797

531,865

equivalent, kL)
Unit consumption index (1990= 100)
Production of PDR equivalent (tons)

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 toachieve 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"-3-

FY2016 CSR Website CSR > Site Reports > Worksites > Tokuyama Plan

[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-4-