iema ruk aug 2014 v2
TRANSCRIPT
SRM and Remanufacturing
IEMA - Waste to Resources
August 2014
Andy Whyle
Ricoh UK Products Ltd
Content
Ricoh’s Sustainability Strategy
Zero waste & Remanufacturing
Ricoh Global Manufacturing
■ Shanghai Ricoh Digital Equipment Co.,
Ltd.
■ Ricoh UK Products Ltd. (RPL) ■ Ricoh Industrie France S.A.S.
■ Ricoh Asia Industry (Shenzhen), Ltd. ■ Ricoh Manufacturing (Thailand), Ltd.
■ Ricoh Electronics, Inc
California & Georgia
U.S.A
UK
France
China
Thailand ■ Ricoh Components &
Products (Shenzhen) Co.,
Ltd.
■ Ricoh Japan
14 Production
Sites.
Ricoh Environmental Leadership
• “As the global environment is in critical condition,
business communities are expected to take a
leadership role in building a new social paradigm.”
(S. Kondo 2008)
• “We will continue working together with
stakeholders throughout the world, including our
customers, suppliers, shareholders and investors,
NGOs and NPOs, and the public, to realize a
sustainable society.” (S. Kondo 2010)
• “ ….. customer expectations of RICOH will evolve
into long lasting trust. They will realize that the
RICOH Group truly lives up to its "Harmonize with
the environment" value. In this way, the RICOH
brand will grow in society. “ (M Sakurai 2011)
“What makes Ricoh great is not only
our superior technology, but it is also
our culture of innovation”.
Zenji Miura (CEO, Ricoh Company Ltd)
The RICOH Way
Production System
Established in 1984
Based in Telford,
Shropshire
800 employees
£390 million sales
Supplying European
market place
Ricoh Telford - RPL
Product Range
Site
Entrance
RPL
3
RPL
2
RPL
1
Cartridge Recycling
Colour toner
+ Moulding
Remanufactured
Copiers
B&W Toner
Production
Production Printers
Building a Sustainable Society - Balance
1:Reducing the impact of our
environmental activities
• Energy Saving / Global Warming
Prevention
• Resource Conservation / Recycling
• Pollution Prevention
2: Preserve the eco-system
(Biodiversity)
• Increase the earth’s regenerative
capacity
• Maintain and enhance the eco-
systems
Ricoh Group's global environmental conservation: Keeping
environmental impact within the self-recovery capabilities of
the Earth
1
2
Sustainable Environmental Management
* Ref - www.ricoh.com/environment/management/picture.html* Ref - www.ricoh.com/environment/management/vision.html
Resource
Conservation create a resource
recirculating society
Energy
Conservation combat issues
associated with
climate change
Pollution
Preventionenvironmentally safer
manufacturing
Environmental management system, Environmental information system,
Environmental accounting, Environmental education, Produc lifecycle
assessment, Communications etc.
Biodiversity
Conservation improve the Earth’s
self-recovery
capabilities
2010 20502000 2013 2020 2030 2040
100%
80%
60%
40%
20%
0%
TECHNO-CENTRIC
Technical
innovation effect
Ricoh’s long-term goals for
environmental impact reduction
ECO-CENTRIC
Encouraging all employees
to participate in
environmental activities
1/8
TECHNO-CENTRIC
Technical
innovation effect
2013 Goal
25% reduction
2010 Goal
20% reduction
2030 Goal
30% Reduction
2050 Goal
87.5% Reduction
Sustainability
credentials
Cert no: FS 33325
ISO 9001:2008Cert no: EMS 61761
ISO 14001:2004Cert no: OHS 556746
BS OHSAS 18001:2007Cert no: IS 85241
ISO 27001:2005
Ricoh Telford
• Energy Efficiency Accreditation Scheme (Top 5 UK) 2004
• BQF UK Gold Medal for Sustained Excellence 2009
• Environment Agency: Best private sector Finalist 2010
• Business Commitment to the Environment Premier
Award 2011
• Benchmarking - being confident in sharing
validated environmental best practice
Benchmarking
Ricoh recognised as one of Top Global sustainable
corporations.
Strategic Summary
Concept: Long term strategic approach with staged
targets
Approach: Eco-centric culture change with Techno-
centric development, staged targets (Mid Term Plans)
working towards 2050,
Result: Not optional activity - Sustainability embedded
into management culture with performance targets
(organisational and individual).
Resource Conservation
Zero Waste & Remanufacturing
Reducing Operational Impact
Ricoh Group's global
environmental conservation:
Keeping environmental impact
within the self-recovery
capabilities of the Earth
12
Ricoh Group Standard: Zero Waste to Landfill
All Ricoh Group Manufacturing sites since March 2002
Challenges and Problems
Adaptation of Corporate model
Management Commitment
Cultural issues
Employee involvement
Resources
Developing working methods
Maintenance and compliance
Zero Waste Launch 2000:
01/12/2014 16
Zero Waste Project
Steering
Group
Segregation
GroupCommercial
Parts
Engineering
Project launch included all
employees
Presentations were given by
senior managers/Director to
demonstrate support for project
Team working activities followed
presentations in respective work
areas
3R’s: Reduce-Reuse-Recycle
Zero Waste Launch
Manufacturing Environments
Segregation in, or adjacent to work
areas
RPL Office Environment
No personal bins
Central segregation
areas
Ricoh Telford waste streams
Zero Waste 2001: Waste-2-Product
Waste-2-ProductWood pallets
Plastic pallets
Steel
Ferrous metals
Aluminium
Paper
Cardboard
Plastics
Glass
Electronic equipment
General Waste
Haz waste
…. then prepared for the
contractor (customer)
Recycling Centre
Reuse: Packaging Re-use
• Martini Product Corner post packaging re-use
• Returnable post extension designed, enabling waste posts to be
used on finished products
• Waste reduced by 83 tonnes per year
• Reduction of waste for end user
• Horizontal deployment opportunities
• Returnable packaging opportunity
Zero Waste to Landfill: 2001
Approach:
Recognising “waste” as a resource
(Waste-2-Product)
Management commitment, targets
Ownership through people involvement and
use of knowledge
“Segregate at Source” approach included in
employees induction
Compliance with environmental legislation,
Result: waste recognised as a resource for
sale and cost saving, whilst reducing
environmental impacts.
Zero Waste : Cyclical Business model
Improve waste
segregation to create new
“Product”
Supply product
Reduce cost – Receive revenue
Market
saturation
Recycling Contractor
rejects low quality product
Decrease in operational
performance
Drives innovation
& process change (resource required)
Zero Waste is an ongoing continuous development
Resource Security - “Peakonomics”
Chris Martenson (Crash Course)
Jae Mather (Carbon Free Group)
Heed the warnings …….
Copper Ore Vein: 0.2%
• Earth movers capacity = 255 tonnes
• 0.2% = 0.5 tonnes of copper per load
IEMA – From Waste to Resources
Resources are the life blood of
manufacturing. Without a clear
view of supply risks and an active
and ambitious strategy to manage
those risks, businesses will be
increasingly vulnerable to price
volatility, supply chain
disruption and business
continuity risks.
Susanne Baker, AIEMA, EEF and Chair of
Materials Security Working Group Read
more about Susanne’s work at
www.iema.net/rm111
01/12/2014 27
The Circular Economy
COLLECTION
Extradition of
biochemical
feedstock2
Anaerobic
digestion
/composting
Biogas
Restoration
Biological
nutrients
Mining/materials
manufacturing
Technical nutrients
Farming
collection1
Biochemical
feedstock
COLLECTION
1. Hunting and fishing
2. Can take both post harvest & post consumer waste as an input
Source: Ellen MacArthur Foundation economy team
IEMA – From Waste to Resources report
01/12/2014 29
Ricoh Comet Circle
01/12/2014 30
20502000
100%
80%
60%
40%
20%
0%
Ricoh’s 2050 Plan
Impact reduction
Virgin Fossil and
Mineral materials
Reuse of products
and parts
50%of incoming
materials
from
Recycled
or Reused
Land use(factory construction/
landscaping).
Collection/ Recycling
Water Timber
Crude Oil
(fuel)
Natural
GasCoal
Zinc Ore
Nickel Ore
Copper Ore
Molybdenum
Platinum
Chromium Ore
Manganese Ore
Silver
Ore
Bauxite
Lead
OreTin Ore
Crude Oil
(raw Material)
Silver
Ore
Gold Ore
Titanium
C O
(carbon Monoxide)
NOx
(Nitrogen Oxide)
SOx
(Sulphur Oxide)
CO2
(Carbon Dioxide)
N20
(Nitrous
Oxide)
CxHy
(hydro
Carbons)
CH4
(Methane)Dust
NMVOC
(Non-methane
Hydrocarbons)
Slag
Unspecified Solid Waste
Sludge
BOD
(Biological Oxygen
Demand)
COD
(Chemical Oxygen
Demand)SS
(suspended Solids)
Logistics/ Marketing
Procurement of raw materials
Use/ Maintenance
Input Output
Design/ Manufacturing
Continuous INPUT of resources to create products and OUTPUT of chemical substances, a linear relationship between these two are to be the basis of increasing the negative environmental impact on the
Earth.
In the future, if natural resources are to be depleted the we won’t be able to continue our normal business activities. We wonder if there is
a way to avoid running out of resources as opposed to such linear activities.
Extracted Resources for the business activities
such as
•Energy resource
•Mineral resource
•Renewable Resources
Substances that discharge in the
process of business activities.
Resource Security
Manufacturing Today
The sustainable ideal is a balanced 3Ps
approach
Most of today’s product tends towards 1st life/
single use (profit centric)
Sustainable design is increasing, but not yet
the mainstream (Manufacture assembly,
disassembly and end of life - MADE BS8887
part2)
Ricoh reacts to the market conflict of “1st Life
vs. Sustainable Customer Demand” through
Developing robust reverse logistics
Life cycle (Comet Circle) drive towards
retention of assets
Ricoh’s role is to learn, and move towards
resource conservation.
Planet
People ProfitProfit
Eco-Line products
UK Remanufactured
Products
TELFORD FACTORY
Ricoh Remanufcturing
Green centre
Firmware upgrades
Technical modifications
PRODUCTION LINE
COMPONENTS
Eco Line - Remanufacturing Process
Remanufactured machines (BS-MADE
8887-2)
Striped to chassis
All mortality parts replaced /All panels
sprayed
All firmware / software modifications fitted
Completely Re-branded and sold as new
line
Quality Control: inspected and assured the
same as new products
Extending the life cycle, reducing
environmental impact
Life Cycle Analysis
Raw material Manufacture Customer usageRecycle
& disposal
Remanufacturing = 38% Environmental impact reduction
Life Cycle: Comet Circle deployment
Customer
Operating
Company
Product
Manf.
Parts
Manf.
Materials
Manf.
Materials
Supplier
MaintenanceParts
Recovery
Materials
Recovery
Material
Separation
Raw material
recovery
Incineration with
Energy Recovery
Final
Disposal
Recovery
Secondary User of
Materials
Recycling
Centre
Green
Centre
Remanufacturing Zero Waste
SRM Summary
Strategy: to develop our business to maintain materials for productivity
Long term approach (2050 Plan)
Zero Waste underpins Sustainable Resource Management
Increasing Supply Chain awareness of Reverse Logistics
Life Cycle - Comet Circle deployment
Diversification of operation (remanufacturing)
Result:
Manufacturers and Customers now beginning to grasp Resource
Conservation as a strategic issue.
Reduced environmental impact of operation, extended life cycle of
materials, resulting in an increased ability to maintain future business
continuity (Sustainability).
The Ricoh Way – Responsible Business Growth
RPL’s expertise is used
to assist Ricoh Sales
and to show customers
The Ricoh Way
Ricoh Telford’s Energy
Reduction exceeds
Ricoh’s CO2 targets and
also saves £0.5 Million
per year.
The Waste -2-Product
program increases the
life cycle of materials
whilst increasing
profitability
Remanufacturing
Eco Line and Supplies
Recycling increase the
sustainability of raw
materials and our
manufacturing process
Waste and CO2 generation is now decoupled from growth (turnover
increased by 325% since 2003) in line with Zero Impact Growth philosophy
Waste-2-Product
The RICOH Way
Production System
RPL Energy Emissions (CO2)
RPL Telford Electricity (MWh)
5,000
7,000
9,000
11,000
13,000
15,000
17,000
19,000
2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013
MWh
Electricity MWh
Corporate Biodiversity
actively repairs damage
and engages
employees and
stakeholders.
RPL Telford Turnover (£M)
0
50
100
150
200
250
300
350
400
450
2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013
£ M
Turnover (£M)
Impact vs £ Turnover
Greater understanding of your business
Knowledge
Share
Continuous Innovation & Improvements
Site Visits
Best
Practice
Technology
Assessment
Strategy
Development
Tailored
Training
Ricoh: sustainable
business services
Ben Curtis
Account Manager
Key Commercial
www.ricoh.co.uk