Transcript Y2k and Beyond .. Organic Photo Conductor and Toner

S74
Small Remanufacturing
Shop Design – Level 1
World Expo 2003
Las Vegas, Nevada
Sunday, September 14, 2003
Timing is everything
• Remanufacturing & Printer Service is a couple
decades smarter
New Business / New Product Life Cycles
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Development
1986
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Growth
1995
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Expansion
1999
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Maturity
Laser ??
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Saturation
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Decline
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Opportunity Placement
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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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L
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R
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2003 Pages Printed by Group
• Data
Group 5
9%
Group 6
1%
Group 1
3%
Group 2
13%
Group 1
Group 2
Group 3
Group 4
Group 5
Group 4
49%
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Group 3
25%
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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Group 6
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US Market (CAP Ventures) & PRINTER Placements
TOTAL ANNUAL CARTRIDGE SALES
70.0
SALES IN MILLIONS OF UNITS
60.0
50.0
Total Cartridge Market
40.0
rmfg
OEM Portion
ttl. Mkt.
30.0
20.0
Remanufactured Cartridge Market
10.0
RM Portion
0.0
rmfg
ttl. Mkt.
~27%
1996
1997
1998
1999
2000
2001
2002
11.1
35.1
12.6
44.0
13.0
47.9
14.2
52.8
15.0
56.4
16.0
58.4
16.9
60.8
year
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Laser / Ink Jet Cartridge
Consumables Market
Billions of US Dollars
Consumables / Revenue
2003
Group 6
2002
Group 5
Group 4
2001
Group 3
Group 2
2000
Group 1
1997
$0.00
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$2.00
$4.00
Expo 2003
$6.00
$8.00
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Value Chain Details
Inbound Logistics
Operations
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• Receiving / Inspection
• Production Scheduling
• Inventory Control
• Warehouse management
(Position control)
Production
Equipment Maintenance
Rework
Facilities
Inventory
H/R
Outbound Logistics
Service and Support
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Technical Training
Production Process Development
Testing
Documentation
Recruit / Hire
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• Order Acceptance
• Picking
• Inventory Adjust
• Cycle Count / Inventory
Adjust
• Ship Confirm
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Value Chain Details
Sales and Marketing
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Sales Goals
Product Management
Advertisement
Customer Identification
and priority
• Forecasting
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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 it’s 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
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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
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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
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• 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
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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
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Cell …………….. To ……………...
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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
– Who’s 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”
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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
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Raw material yields
Flow issues
Assembly rates
Test performance
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Capital Equipment
• Primary Equipment requirements
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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 Production
Transition
• 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
Inspect & Stage
Empties..
Disassembly &
Cleaning & Seal
Assemble
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
Print Performance Data
8000
Yield
SF.ID
1.60
20% HT
1.40
7500
7000
1.00
6500
0.80
0.60
6000
Image Density
Page Yield
1.20
0.40
5500
5000
9000
0.20
9100
9200
9300
0.00
9400
Lot #
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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
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Strip backing from seal examine for consistent glue.
Press seal on clean, flat surface
Pull tab on seal.
Examine for uniform removal of material.
--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.
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