S74 Small Remanufacturing Shop Design Level 1

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S74 Small Remanufacturing Shop Design Level 1

• World Expo 2003
• Las Vegas, Nevada
• Sunday, September 14, 2003

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Timing is everything

• Remanufacturing Printer Service is a couple
  decades smarter
• New Business / New Product Life Cycles
• Development 1986
• Growth 1995
• Expansion 1999
• Maturity Laser ??
• Saturation
• Decline

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Opportunity Placement

• Development stage, there are no cartridge sales
  at all. However manufacturing must support a
  development area and resources to insure a timely
  product launch.
• Growth stage, sales are slow and marketing costs
  are high often manufacturing resources need to
  be supplemented by frequent training sessions and
  manufacturing team building.
• Expansion stage, sales should grow more rapidly,
  and manufacturing teams are executing their well
  thought out plans to accommodate growth.
• Maturity stage, sales will plateau as most
  customers who want the product have quality
  sources for the product. Manufacturing teams have
  predicted this plateau and the production
  schedules will adjust for sales volume and
  inventory reduction.
• Saturation stage, every customer who wants the
  cartridge product has several competitive sources
  for acquisition, and there are few opportunities
  for increasing sales.
• Decline stage, cartridge sales fall and the
  product eventually becomes obsolete.
  Manufacturing teams have transitioned resources
  to new products and reduced raw materials and
  finished goods to reduce financial risk.

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Long Range Plan

• Data

• Home and Small Office Printing Group 1
• Education Group 2
• Professional Business Communication Group 3
• Business High Volume Group 4
• Business Presentation / Marketing Group 5
• Publishing / Proofing / Pre-press Group 6

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US Market (CAP Ventures) PRINTER Placements
Total Cartridge Market
OEM Portion
Remanufactured Cartridge Market
RM Portion
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Laser / Ink Jet CartridgeConsumables Market
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Value Chain Details

• Inbound Logistics
• Receiving / Inspection
• Production Scheduling
• Inventory Control
• Warehouse management (Position control)

• Operations
• Production
• Equipment Maintenance
• Rework
• Facilities
• Inventory
• H/R

• Outbound Logistics
• Order Acceptance
• Picking
• Inventory Adjust
• Cycle Count / Inventory Adjust
• Ship Confirm

• Service and Support
• Technical Training
• Production Process Development
• Testing
• Documentation
• Recruit / Hire

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Value Chain Details

• Sales and Marketing
• Sales Goals
• Product Management
• Advertisement
• Customer Identification and priority
• Forecasting

• Service and Support
• Training
• Sales Process Development
• Customer Support
• Documentation

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Product Success Metrics

• Image Performance
• Halftone reproduction
• Line art
• Yield
• Solid fill uniformity
• Printer maintenance reduced
• Fuser performance
• cleanliness
• Standards and industry uniformity
• Ultimately its Profit

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Objectives

• Consistency To provide your customers with
  functional products, insist on consistency from
  your vendors. The next shipment of a product has
  to be the same as the last acceptable shipment.
• Reliability A statistical sampling system
  enables you to ensure your vendors are reliable,
  with good product, in a timely manner, conforming
  to the specifications established during the
  development phase of product acquisition.
• Accuracy Incoming inspectors confirm the
  accuracy of incoming product. Confirming product
  identification, conformance to specification,
  packaging and labeling.

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Quality is People

• Every group, department, from the top
• down .. execute
• Process management measures results
• Results reaffirm the plan
• Constant improvement
• Lowers Cost

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Quality is people

• Process Development
• Consistent Product Service
• Understand limitations of the product Printer
  or Cartridge
• Specification and accuracy
• Corrective action
• Training . Training and more

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Electronic Printing Technology

• Large history of method standards for the copier
  industry
• Toner testing
• Photoconductor performance
• Customer satisfaction
• Remanufacturing a consumable
• Use Automotive parts industry as a model
• Customer quality assurance
• Purchasing guideline
• Core replacement
• Faceless and nameless ACCEPTED Quality

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Quality First and Foremost

• Objectives
• Consistency, Reliability, Accuracy.
• Raw Materials ( Purchases)
• Empties
• Incoming Inspection Quality Control Methods and
  Examples

• Allies Interactive Vendors, Customer feedback,
• Adversaries Variation, Unexpected Vendor
  modifications, Inappropriate process deviation
• Teamwork

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Test and Measurement

• Statistics 101
• List ALL areas where data can be gathered
• Accuracy
• Usable data
• Taking the data is the first step
• Leaders need time to work with the data to make
  process changes
• Acquisition and presentation

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Product or Service Feasibility

• Develop product model
• Printer placement and acceptance
• Cartridge mechanics and access
• Marketing info
• Printer Past history
• CPP Total cost of ownership
• Production Assumptions and Estimates
• Develop timeline
• Imagineer process and costing

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Process Design Details

• Cell .. To ...
• From past experience develop cell picture
• Solve material flow
• Breakdown training issues
• Document bill of materials (BoM)
• remember the long range plan (LRP)
• Managed Production
• Correct process
• Training
• Scale UP

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Prototype Process

• Draw pictures cut out the paper pieces
• Map the process from the Cell stage to Managed
  production
• Look at the facilities details
• Air .. Heat Power .. Lights Traffic
  Storage
• Pick your people resources share the ideas
• Set up a dummy cell . Dry run
• Check Raw materials flow
• Whos waiting
• Check your plan

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Corrective Action (plan for it)

• Process defects or procedural changes
• Review with all production teams you may have
  some ability to kill a problem before it starts
• Retain Visual samples of defects for training
• Preparation inspections prevent drone mistakes
  Awareness of the process is crucial
• End of shift positive reinforcement
• Announce data
• Show / Chart progress
• Training awards not material verbal praise in
  front of peers

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Team Leaders are people

• Groom with future goals in mind
• TRAINING is communicating your plan
• Clear concise and ATTAINABLE Goals
• POSITIVE Atmosphere
• Watch for diamonds in the rough

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Raw Materials Management

• Empties
• Source Cleaning Inspect . Waste Cost
• Cleaning Handling
• Storage Damage Control Assembly Staging
• Solvents Inspect .. Waste Time Cost
• Assembly
• Readiness Tools Inspection Time ..
  Cost
• Printer Parts and rebuilds.

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Process Foundry

• Build the REAL Cell
• Staff Cell
• Order protocol forecast
• TRAINING
• Flexibility
• Document changes and corrective action
• Statistics Process Measurement
• Raw material yields
• Flow issues
• Assembly rates
• Test performance

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Capital Equipment

• Primary Equipment requirements
• Time savings
• Quality enhancement
• Training required
• Human component
• Secondary requirements
• Maintenance
• Obsolescence
• Expansion

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Productivity

• Facility Layout
• Material flow
• Cleanliness
• Documented Procedures for simple tasks
• Simplifies training
• creates standard
• Training
• Cross training, and daily rotation
• Team Leaders Building Quality
• Sound Forecast
• Minimize... waste, storage,hassles
• Supply Chain Management

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Cell to Managed ProductionTransition

• Planned transition
• Pick the criteria early
• Set training goals early
• Quality is a job well thought out and well tooled
  
• Excellent training and complete task description
  fosters worker happiness
• Success is about people

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Planned new material, remove waste
Assemble
Inspect Stage
Empties.. Disassembly Cleaning Seal
Remove reject material
Test await packaging
Generic Cell
Empties
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Keep it Simple Stupid (KISS)

• Visual aids 75 of learning is facilitated by
  visual cognition. PICTURES not WORDS
• Constant positive reinforcement is Constant
  Improvement.
• Cross train similar job functions .. Remember
  social circles and peer pressure are your allies
• Disassembly ---- Assembly
• Evacuation ---- Component Prep
• Pre Test ---- Final Test

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Assess each work function

• Map mini process
• document
• training guidelines
• Timing
• Mini production for some work function
• Skill assessment
• Time
• Realistic training goals
• Critical for Quality Control
• No job is more important

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Safety Requirements

• FROM the TOP Down
• ALL quality management tools start from
  acceptance at the top Safety requirements and
  concerns are PRIMARY
• High visibility area for procedures and Training
• Monthly assessments

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Tracking
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Drums

• Visual Inspection All OPC Drums are inspected
  for surface defects. Visual contaminants or
  defects lead to further testing and/or rejection.
  Record and compare lot number identification on
  boxes. Store OPCs in a designated area, mark the
  area well. Data base lot data.
• Electrical Properties Electrical data provided
  by the vendor is compared to past data to confirm
  specification compliance. If a discrepancy
  appears or the data is inconsistent then contact
  the vendor for modification or specification
  change. Use print tests with your toner
  combination to determine the acceptability of the
  shipment.

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PCR Incoming Inspection checklist
Check For - Consistent Packaging- Product
Verification - Pin holes - Fish eyes - Coating
Defects and/or contaminates - Unclean Contacts -
Stains - Voids Rubber Gloves - required. Visual
Inspection Q.C. Sample --if needed-- Cartridge
fit and/or Print test
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RM Material Incoming Inspection method
Visual Inspection - Use a Sample or
Photocopy Sample Destructive testing ie Split
Seal 1. Strip backing from seal examine for
consistent glue. 2. Press seal on clean, flat
surface 3. Pull tab on seal. 4. Examine for
uniform removal of material. 5. --if needed--
Cartridge fit and/or UPS test.
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Summary

• More than 15 individual items may be purchase
  for high quality cartridges today.
• Less than 20 of remanufacturers have established
  quality processes for their products.
• More than 500 remanufacturers will fail in the
  next year. Because of quality.
• Less than 29 of the remanufactured cartridges
  sold last year met an OEM specification
• Lower Cost and higher profits will only be
  realized by executing a Total QMS system.