s74 small scale remanufacturing shop design – level 1

S74S74 Small Scale Remanufacturing Small Scale Remanufacturing

Shop Design – Level 1Shop Design – Level 1

S74S74 Small Scale Remanufacturing Small Scale Remanufacturing

Shop Design – Level 1Shop Design – Level 1World Expo 2003World Expo 2003

Las Vegas, NevadaLas Vegas, Nevada

Sunday, September 14, 2003Sunday, September 14, 2003

Apr 12, 2023 Expo 2003 2

Long Range Plan 2003 Pages Printed by Group

Group 449%

Group 59%

Group 325%

Group 213%

Group 61%

Group 13%

Group 1

Group 2

Group 3

Group 4

Group 5

Group 6

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

Apr 12, 2023 Expo 2003 3

A Maturing Industry

Customer Needs

New and Current

Products/Service

Performance Priorities

and Requirements

Quality, Dependability, Service

Speed, Flexibility, and Price

Operations & Supplier Capabilities

Technology

PeopleSystems R&D Training Materials QualityDistributi

on

IT & Support Platforms

Financial ManagementHuman Resource

ManagementInformation Management

Enterprise Activities & Capabilities

Enterprise Planning Strategy

Apr 12, 2023 Expo 2003 4

Timing is everything

• Remanufacturing is a couple decades smarter

New Business / New Product Life Cycles• Development 1986• Growth 1995• Expansion 1999• Maturity

Laser ??• Saturation• Decline

Apr 12, 2023 Expo 2003 5

Laser / Ink Jet Cartridge

Consumables MarketConsumables / Revenue

$0.00 $2.00 $4.00 $6.00 $8.00

1997

2000

2001

2002

2003

Bill

ions

of U

S D

olla

rs Group 6

Group 5

Group 4

Group 3

Group 2

Group 1

Apr 12, 2023 Expo 2003 6

US Market (CAP Ventures)

TOTAL ANNUAL CARTRIDGE SALES

0.0

10.0

20.0

30.0

40.0

50.0

60.0

70.0

year

SALE

S IN

MIL

LIO

NS

OF

UN

ITS

rmfg

ttl. Mkt.

rmfg 11.1 12.6 13.0 14.2 15.0 16.0 16.9

ttl. Mkt. 35.1 44.0 47.9 52.8 56.4 58.4 60.8

1996 1997 1998 1999 2000 2001 2002

Total Cartridge Market

Remanufactured Cartridge Market

~27%

OEM Portion

RM Portion

Apr 12, 2023 Expo 2003 7

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.

Apr 12, 2023 Expo 2003 8

Carts/mo. #ofRM Cart Vol.$ Vol./

channel % GM Profitability Delta 1%

%of Total

50 250 12500 $396,875.00 32.00% $127,000 $3,969 0.65%

100 412 41200$1,308,100.0

0 28.00% $366,268 $13,081 1.86%

500 620 310000$9,842,500.0

0 28.00% $2,755,900 $98,425 14.00%

1000 576 576000$18,288,000.

00 26.40% $4,828,032 $182,880 24.52%

2000 342 684000$21,717,000.

00 24.50% $5,320,665 $217,170 27.02%

5000 64 320000$10,160,000.

00 22.60% $2,296,160 $101,600 11.66%

10000 25 250000$7,937,500.0

0 21.30% $1,690,688 $79,375 8.59%

20000 11 220000$6,985,000.0

0 18.45% $1,288,733 $69,850 6.55%

40000 5 200000$6,350,000.0

0 16.00% $1,016,000 $63,500 5.16%

Totals 2305 2,613,700 $82,984,975 24.14% $19,689,445 $829,850

Apr 12, 2023 Expo 2003 9

52X REMANUFACTURED CARTRIDGE SALES IN UNITS(BASIS '98 CAP)

0.0

1.0

2.0

3.0

4.0

5.0

6.0

7.0

8.0

HP

40

00

Sa

les

in M

illio

ns

of

Un

its

52X 0.0 0.0 0.1 0.5 1.0 1.6 1.7

Total carts 0.0 0.1 1.4 3.8 5.6 6.3 6.8

1996 1997 1998 1999 2000 2001 2002

US Market (CAP Ventures) HP4000 Life

Total HP4000 Cartridge

Remanufactured HP4000 Cartridge

Growth

2 years

Maturity

2 years.

Introduction

2 years

Reman ~ 50% Threshold

Apr 12, 2023 Expo 2003 10

April 2002 Recharger Data

Cartridge Market by Engine

23.8%

5.9%

13.0%

8.7%

6.0%

0.9% 1.0%

10.0% 9.2%

5.9%

0.00%

5.00%

10.00%

15.00%

20.00%

25.00%

EX PX 4000 WX VX 8100 2100 AX SX NX

Engine

Man

ufac

ture

d Co

st

Market %

Apr 12, 2023 Expo 2003 11

Value Chain Details

Operations• Production• Equipment

Maintenance • Rework• Facilities• Inventory• H/R

Inbound Logistics

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

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

Apr 12, 2023 Expo 2003 12

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

Apr 12, 2023 Expo 2003 13

Cost Analysis • Feasibility Estimates

– Use existing production model

• Observe Market as the process is Developed– Target Cost per cartridge– Acceptable Cartridges / HOUR (First Pass Yield)

• Breakouts (QPA) – Materials– Labor– Handling .. Value added

Apr 12, 2023 Expo 2003 14


TRUE COST dpc >> $33.82 $33.86 $63.33 $55.59 $40.44 $85.50 $45.33 $41.41 $19.82 $33.25

Yr/Ave 23.80% 5.90% 13.00% 8.70% 6.00% 0.90% 1.00% 10.00% 9.20% 5.9%


2,618 649 1,430 957 660 99 110 1,100 1,012 649

$88,532 $21,978 $90,566 $53,204 $26,690 $8,465 $4,986 $45,549 $20,056 $21,582 $4,320,300

QPA(AVE) $580,648

OPC 0.95 $11.67 $12.45 $20.10 $18.06 $12.23 $22.90 $17.10 $12.10 $7.34 $8.20 $1.40

PCR 0.31 $7.01 $3.25 $3.20 $7.25 $3.20 $3.90 $2.80 $3.60 $3.20

Cblade 0.80 $3.19 $2.39 $3.10 $5.70 $2.29 $4.65 $3.25 $4.85 $1.85 $3.19

Sweeper 0.78 $0.26 $0.25 $0.32 $0.22 $0.25 $0.21 $0.25 $0.24 $0.36 $0.23

Dblade 0.42 $4.18 $2.65 $3.10 $4.67 $2.32 $5.32 $2.56 $2.65 $3.66

Toner 1.00 $7.29 $4.80 $12.50 $16.20 $5.69 $18.67 $5.30 $4.50 $4.54 $10.45

Seal 1.00 $0.79 $0.65 $0.90 $0.83 $0.80 $0.87 $0.87 $0.73 $0.34 $0.42

Mbush 0.38 $0.25 $0.49 $0.52 $0.25 $0.22 $0.22

Box 1.00 $0.55 $0.48 $0.60 $0.75 $0.52 $0.77 $0.63 $0.48 $0.67 $0.72

Bag 1.00 $0.15 $0.15 $0.15 $0.28 $0.15 $0.30 $0.15 $0.17 $0.15 $0.21

Rocker 1.00 $0.53 $0.52 $0.36 $0.89 $0.47 $0.90 $0.32 $0.55 $0.46 $0.64

Empty 1.00 $2.00 $6.20 $17.25 $4.50 $12.40 $27.00 $12.00 $11.90 $1.00 $1.55

Labor 1.00 $3.28 $3.43 $4.50 $4.20 $3.54 $4.40 $3.67 $3.76 $2.98 $3.77

Ship 1.00 $0.30 $0.25 $0.45 $0.45 $0.29 $0.45 $0.30 $0.25 $0.25 $0.29

QPA'd SUBTotal 43.7 $32.76 $32.54 $60.83 $54.38 $39.47 $82.64 $44.22 $40.23 $19.21 $31.18

Inventory(6turns) $0.943 $1.252 $2.356 $1.127 $0.915 $2.638 $0.674 $1.146 $0.602 $2.046

Rework/cart $0.12 $0.08 $0.15 $0.08 $0.05 $0.22 $0.43 $0.04 $0.01 $0.02

Rework % 10.45% 12.00% 7.50% 11.00% 6.70% 5.00% 17.00% 39.00% 3.20% 1.00% 2.10%

No. RW 314 49 157 64 33 17 43 35 10 14 736

CostEng/mo. $309.13 $50.09 $212.36 $80.79 $35.05 $22.22 $47.23 $39.71 $9.05 $15.41 $821.03

0.14%

Approx. True Cost Production Model

Apr 12, 2023 Expo 2003 15

Production Mode 1000/mo.

19-Feb-99 EX PX 4000 WX VX 8100 2100 AX SX NX

TRUE COST dpc >> $33.82 $33.86 $63.33 $55.59 $40.44 $85.50 $45.33 $41.41 $19.82 $33.25

updated 2/00 Yr/Ave 23.80% 5.90% 13.00% 8.70% 6.00% 0.90% 1.00% 10.00% 9.20% 5.9%

Customer Model Cart/ Mo. EX PX 4000 WX VX 8100 2100 AX SX NX CANON

Laser Bob 1000 238 59 130 87 60 9 10 100 92 59 844

$8,048 $1,998 $8,233 $4,837 $2,426 $770 $453 $4,141 $1,823 $1,962 $392,755 Proj. Cost/mo.

QPA(AVE) $83,421 GM = 12% Ave

OPC 0.95 $11.67 $12.45 $20.10 $18.06 $12.23 $22.90 $17.10 $12.10 $7.34 $8.20 $1.40 CarryCost/cart AVE>

PCR 0.31 $7.01 $3.25 $3.20 $7.25 $3.20 $3.90 $2.80 $3.60 $3.20

Cblade 0.80 $3.19 $2.39 $3.10 $5.70 $2.29 $4.65 $3.25 $4.85 $1.85 $3.19

Sweeper 0.78 $0.26 $0.25 $0.32 $0.22 $0.25 $0.21 $0.25 $0.24 $0.36 $0.23

Dblade 0.42 $4.18 $2.65 $3.10 $4.67 $2.32 $5.32 $2.56 $2.65 $3.66

Toner 1.00 $7.29 $4.80 $12.50 $16.20 $5.69 $18.67 $5.30 $4.50 $4.54 $10.45

Seal 1.00 $0.79 $0.65 $0.90 $0.83 $0.80 $0.87 $0.87 $0.73 $0.34 $0.42

Mbush 0.38 $0.25 $0.49 $0.52 $0.25 $0.22 $0.22

Box 1.00 $0.55 $0.48 $0.60 $0.75 $0.52 $0.77 $0.63 $0.48 $0.67 $0.72

Bag 1.00 $0.15 $0.15 $0.15 $0.28 $0.15 $0.30 $0.15 $0.17 $0.15 $0.21

Rocker 1.00 $0.53 $0.52 $0.36 $0.89 $0.47 $0.90 $0.32 $0.55 $0.46 $0.64

Empty 1.00 $2.00 $6.20 $17.25 $4.50 $12.40 $27.00 $12.00 $11.90 $1.00 $1.55

Labor 1.00 $3.28 $3.43 $4.50 $4.20 $3.54 $4.40 $3.67 $3.76 $2.98 $3.77

Ship 1.00 $0.30 $0.25 $0.45 $0.45 $0.29 $0.45 $0.30 $0.25 $0.25 $0.29

QPA'd SUBTotal 43.7 $32.76 $32.54 $60.83 $54.38 $39.47 $82.64 $44.22 $40.23 $19.21 $31.18

Inventory(6turns) $0.943 $1.252 $2.356 $1.127 $0.915 $2.638 $0.674 $1.146 $0.602 $2.046

Rework/cart $0.12 $0.08 $0.15 $0.08 $0.05 $0.22 $0.43 $0.04 $0.01 $0.02

Rework % 10.45% 12.00% 7.50% 11.00% 6.70% 5.00% 17.00% 39.00% 3.20% 1.00% 2.10%

No. RW 29 4 14 6 3 2 4 3 1 1 67

CostEng/mo. $28.10 $4.55 $19.31 $7.34 $3.19 $2.02 $4.29 $3.61 $0.82 $1.40 $74.64

0.09% of GM

Apr 12, 2023 Expo 2003 16

Process Developments for Planned Improvement

• IM&P Inventory Management & Planning– Reducing raw materials as well as product inventory creates cash flow.– Forecasting purchases helps lower prices and insures availability

• Understand market and your cost• Monthly assessments of executing your plan

Apr 12, 2023 Expo 2003 17

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 $$$$$$$$$$$$$$$$$$$$$

Apr 12, 2023 Expo 2003 18

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.

Apr 12, 2023 Expo 2003 19

Success is People

• Every group, department, from the top down …….. execute

• Process management measures results• Results reaffirm the plan• Constant improvement• Lowers Cost

Apr 12, 2023 Expo 2003 20

Success is people

Process Development

Consistent Product Understand limitations of the product Specification and accuracy Corrective action Training …. Training …… and more

Apr 12, 2023 Expo 2003 21

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

Apr 12, 2023 Expo 2003 22

Target Areas for Standardization

• Raw Materials• Replacement Componentry• Finished Assemblies• Performance and

Comparison• Materials acquisition • A/P and A/R• Forecasting• Shipping

Apr 12, 2023 Expo 2003 23

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

Apr 12, 2023 Expo 2003 24

Imaging Competition

• Consumables– OEM Benchmark– Cost– Reliability

• Remanufacturing– Expectations from consumables– Cost per page .02-.04/or replacement cost

– Media independence – Value (perceived)

Apr 12, 2023 Expo 2003 25

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

Apr 12, 2023 Expo 2003 26

Product Feasibility• Develop product model

– Printer placement and acceptance– Cartridge mechanics and access– Marketing info– Past history

• Production Assumptions and Estimates – Develop timeline– Imagineer process and costing

Apr 12, 2023 Expo 2003 27

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

Apr 12, 2023 Expo 2003 28

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

Apr 12, 2023 Expo 2003 29

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

Apr 12, 2023 Expo 2003 30

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”

Apr 12, 2023 Expo 2003 31

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

Apr 12, 2023 Expo 2003 32

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

Apr 12, 2023 Expo 2003 33

Capital Equipment

• Primary Equipment requirements– Time savings– Quality enhancement– Training required– Human component

• Secondary requirements– Maintenance– Obsolescence– Expansion

Apr 12, 2023 Expo 2003 34

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

Apr 12, 2023 Expo 2003 35

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 people

Apr 12, 2023 Expo 2003 36

Generic CellEmpties

Empties.. Disassembly & Cleaning & Seal

Test & await packaging

Remove reject material

AssembleInspect & Stage

Planned new material, remove waste

Apr 12, 2023 Expo 2003 37

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

Apr 12, 2023 Expo 2003 38

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

Apr 12, 2023 Expo 2003 39

Production Layouts

• Layout 2– Assumes products total ~250 carts a day (3-6 products)

monthly target is 10000– Setup is for one line “teams” and a “specialty cell”– Product switchovers are scheduled on daily intervals

Apr 12, 2023 Expo 2003 402000 square feet

Materials cart

Tear-down / Evacuation

Final Test Printing Area

Component Cleaning and Prep area

Sto

rag

e A

rea

Empties Prep Area / Recycling / Sorting

Inco

min

g D

ock A

rea

OPC PCR Corona

Box Tape & Sort

Production REWORK

Hopper Split & Prep

Labeling / Bagging / Packaging Area

Disassem.

Waste Bin Clean.

Waste Bin Assm..

Hopper Clean

Sealing Filling

Hopper Reassemble

FINAL

Assemb.

Specialty Reman Cell

Sh

ip D

ock A

rea

Apr 12, 2023 Expo 2003 41

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

Apr 12, 2023 Expo 2003 42

Toner• Toner Inspection: Vendors conduct laboratory testing

and print testing on all incoming lots of toner, and retains a sample for future reference. Track the data !!!

• Physical Testing: Laboratory testing is conducted to determine the average particle size, percentage fines (small particles - less than 5 mm), percentage grit (large particles - greater than 12 or 16 mm depending upon the toner), and Tribocharge (charge generated from contact with a blade or roller).

On Site• Print Testing: In your print room the sample toner is

run for a screen test, with prints being sampled for Black Image Density and Background at the beginning of the cycle, at 100 pages and 500 pages. (ASTM 1856 …. others)

• Acceptance

Apr 12, 2023 Expo 2003 43

Canon Cartridge Reman Eff

300

320

340

360

380

400

420

440

460

1 2/ 21 / 98 2/ 9/ 99 3/ 31 / 99 5/ 20/ 99 7/ 9/ 99 8/ 28/ 99 1 0/ 1 7/ 99 1 2/ 6/ 99 1 / 25/ 00 3/ 1 5/ 00 5/ 4/ 00

Date

Car

ts Per Day

Apr 12, 2023 Expo 2003 44

Cartridges Produced (per man per hour)

2.50

2.70

2.90

3.10

3.30

3.50

3.70

12/21/98 2/9/99 3/31/99 5/20/99 7/9/99 8/28/99 10/17/99 12/6/99 1/25/00 3/15/00 5/4/00

Date

Car

t/M

an/h

r

Per/LW

Production SPC

Apr 12, 2023 Expo 2003 45

Production SPC

2/23/00 132 60 32 20 19 6 7 58 22 15 371 2.912/24/00 127 70 46 35 15 8 5 58 14 27 406 3.18

Line workers 2/25/00 125 61 46 38 18 8 5 54 14 29 396 3.1115 2/28/00 137 63 51 23 13 6 7 37 40 17 393 3.09

2/29/00 138 67 43 32 12 6 7 58 41 35 439 3.443/1/00 128 66 36 26 26 11 7 18 22 26 366 2.873/2/00 136 64 50 26 22 4 6 46 28 20 400 3.143/3/00 126 70 34 22 21 6 9 27 36 27 379 2.973/6/00 127 65 38 30 20 7 5 42 44 25 402 3.16

Totals Days EX PX 4000 WX VX 8100 2100 AX SX NX Grand Rate

291 38468 18436 12128 7657 6535 1892 1898 10930 9486 7106 114534 3.08

Hours 2474Ave/hr $6.75Fringe $1.53

Payroll/Line $307,292Overhead $120,000Utilities $4,500

Apr 12, 2023 Expo 2003 46

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.

Apr 12, 2023 Expo 2003 47

Check For:- Consistent Packaging- Product Verification- Sufficient gear attachment- Uniform glue pattern- even removal of coating on the margins- Consistent color and texture- Lightsafe packaging attached- Look for tape residue from packaging- Handle with care

Generic OPC Incoming Inspection checklist

Apr 12, 2023 Expo 2003 48

Check For:- Consistent Packaging- Product Verification- Pin holes- Fish eyes- Coating Defects and/or contaminates- Unclean Contacts- Stains- Voids

Rubber Gloves - required. Visual InspectionQ.C. Sample--if needed-- Cartridge fit and/or Print test

PCR Incoming Inspection checklist

Apr 12, 2023 Expo 2003 49

Visual Inspection - Use Q.C. Sample or Photocopy

Sample Destructive testing: ie: Split Seal

1. Strip backing from seal examine for consistent glue. 2. Press seal on clean, flat surface3. Pull tab on seal.4. Examine for uniform removal of material.5. --if needed-- Cartridge fit and/or UPS test.

RM Material Incoming Inspection method

Apr 12, 2023 Expo 2003 50

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.