ricoh (rpl) sustainability oct 2016
TRANSCRIPT
Sustainability at Ricoh UK Products Ltd
Oct 2016 Andy WhyleEnvironment & Sustainability SpecialistMark Anderson Maintenance Manager
Ricoh Corporate Data
Founded in 1936 Headquarters in Tokyo, Japan 229 Consolidates companies worldwide 109,950 employees worldwide
Ricoh Global Manufacturing
Ricoh Electronics, California Ricoh Industrie France S.A.Ricoh Dianzhuang (Shenzhen)
Electronics Co., Ltd.
Ricoh R&D Centre
Ricoh Electronics, Georgia
Ricoh Thermal Media ( Wuxi ) Co.ltd.
BOZ, The Netherlands Ricoh UK Products Ltd. Shanghai Ricoh Facsimile Co., Ltd.
RPL Multi-Site Operations
REPCEstablished 2014
Business lines:• MFP light Assembly
Employees: 6 + DHL staff
RPLW (Wellingborough)Acquired 1996
Business lines:• Machines forward and reverse logistics• Service parts logistics (ESPC)• Machines recycling• Customer data cleansing (sanitization)
Employees: 66 (includes associates)
Total employees: 992
RPLS (Stirling)Acquired 2014
Business lines: • Digital Duplicator inks and
masters
Employees: 30
Business lines:• Toner production• Production Print machine production• PP Customer Experience Centre• Ink Jet Solutions Centre• Rapid Fab AM Services• Recycled products & R&D• Solutions products & services• Consultancy Services (R2R)Employees: 890 (includes associates)
RPLT (Telford HQ)Opened 1985
Ricoh Industry France
Technology Development
Elimination of customer information ( Sanitisation)
③トレーサビリティ情報の保存
②ハードウェアの情報消去①コントローラの情報消去
3rd PartyのHDD情報消去サービス
リサイクルマシン
情報消去サービス
J AM紙、原稿の取扱
ドラム上の電子潜像
外装カバーのラベル
その他のメモリ
SDカードHDD
③トレーサビリティ情報の保存
②ハードウェアの情報消去①コントローラの情報消去
3rd PartyのHDD情報消去サービス
リサイクルマシン
情報消去サービス
J AM紙、原稿の取扱
ドラム上の電子潜像
外装カバーのラベル
その他のメモリ
SDカードHDD
Recycle products
RFIDCap
Poron Seal
Holder Gear (Taurus)Agitator (Taurus)
Shutter
Reuse(Assembly condition)
Reuse
Mandatory Parts
Reuse(Assembly condition)
Bottle Assy
Cap Assy
Vacuum form tray
Reuse
Sponge seal
Bottle (Taurus)
RFIDCap
Poron Seal
Holder Gear (Taurus)Agitator (Taurus)
Shutter
Reuse(Assembly condition)
Reuse
Mandatory Parts
Reuse(Assembly condition)
Bottle Assy
Cap Assy
Vacuum form tray
Reuse
Sponge seal
Bottle (Taurus) Solution products
Media qualificationEMQC
Automation tools for Configuration
750750
+
Plug & Play
Software development
“More Than Just a Factory”
Factory Show Case& Consultancy service
Concept of IMS
Annex SLCMS
ISO 27001
ISO 9001
OHSAS18001 RGS
IMS
ISO14001
1993 - ISO 9001 Quality Standard
1996 - ISO 14001 Environmental Standard
2006 - OHSAS 18001 Health & Safety
2006 - ISO 27001 Information Security
Structure of The RICOH Way Production System
In 1946, Kiyoshi Ichimuradefined the RICOHGroup’s founding principles, which instruct us how to do business, encouraging us to constantly improveand contribute tothe well-being of our families, customers, and society.
RICOHRICOHFoundingPrinciples
Spirit of 3 Loves
R&
D
R&
D R
S
VICE
ER
S
VICE
ED
ES
GN
I
DES
GN
I
AS
L
SE
AS
L
SE
The RICOHRICOH WayMission, Vision, Values
Essential Principles: S, E, Q, C, DEssential Principles: S, E, Q, C, D
12 Key Fundamentals12 Key Fundamentals
RP
O
TC
ION
DU
RP
O
TC
ION
DU
The RICOHRICOH Way Production Statement:Become the world’s No. 1 manufacturing
company that delivers best-in-class products and services
The RICOH Way Production Statement is the ultimate goal in our production operations.We reach that goal by
focusing on fiveEssential Principles:
SEQCD.We use 12 Key
Fundamentalsto improve
performancein the areas
of SEQCD.
12 Key Fundamentals
1. Think Safety; Act Safely
2. Embrace 5S
3. Foster Employee Development
4. Be Environmentally Responsible
5. Model Corporate Social Responsibility
6. Deliver Quality
7. Breathe Fact-Based Decision-Making
8. Show Visual Management
9. Deploy Standardization
10. Live KAIZEN
11. Pursue Super Low Cost
12. Implement Synchronization
S
E
Q
C
D
Fundamental Behaviours
The Ricoh Way - Fundamentals
“What makes Ricoh great is not only our superior technology, but it is also our culture of innovation”. Zenji Miura (CEO, Ricoh Company Ltd)
Landfill
Green ProcurementSuppliers
environmental management
systems
BiodiversityConservation on and off site
Recycling of ProductsRecycled machines, parts and cartridges
Energy & Water ReductionManagement of CO2/Water
Resource Conservation
Minimisation & Zero Waste to Landfill
(Waste-2-Product)
Environmental Action Committee
Social ResponsibilityEmployee and stakeholder engagement, improving brand awareness & customer satisfaction
Pollution PreventionPrevention controls, methodology and testing
Legal ComplianceCompliance & incident management
Environmental Action Committee
16
Local Benchmarking
• Energy Efficiency Accreditation Scheme (Top 5 UK) 2004 • Ricoh 5th Sustainable Development Award – Process
Innovation Technology 2007
• BQF UK Gold Medal for Sustained Excellence 2009
• Environment Agency: Best private sector Finalist 2010
• Business Commitment to the Environment Premier Award 2011
• BSC Globe Award 2016
Benchmarking - being leaders and being confident to Harmonise with the Environment
Ricoh Global 18th MTP
1. Energy Conservation / Prevention of Global Warming
2. Resource Conservation and Recycling
4. Biodiversity Conservation 5. Enhancement of Basis for
Sustainable Environmental Management
10
CO2 Reduction 2050
CO2 Reduction Activities
High Efficiency Lighting Continued VSD program New Space / Water Heating Compressor heat recovery De-stratification of heating in Moulding / Warehouse RPLS energy management
Waste 2050
19992001
20032005
20072009
20112013
20152017
20192021
20232025
20272029
20312033
20352037
20392041
20432045
20472049
0
500
1000
1500
2000
2500
RPL Waste 2050
Tonnes2050 target (t)
Axis
Title
Resource Conservation
Zero Waste & RemanufacturingReducing Operational Impact
Ricoh Group's global environmental conservation:
Keeping environmental impact within the self-recovery capabilities of the Earth
1 2
Ricoh Group Standard: Zero Waste to Landfill
All Ricoh Group Manufacturing sites since March 2002
Adaptation of Corporate model Management Commitment Cultural issues Employee involvement Resources Working methods Maintenance and Compliance
Launch 2000: Challenges and Problems
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 - 2000
RPL Office Environment
No personal bins Central segregation
areas
Ricoh Telford waste streams
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.
What is inspiring or special ?
Zero Waste to Landfill (100% recycling) since Sept 2001
Diverted over 16,000 tonnes
= 2100 x
2012/13: 95% of all manufacturing “waste” is now recovered with only 5% being sent for Incineration with Energy Recovery
44%
56%2000 - Material Recovery
LandfillEnergy From WasteMaterial Recovery
5%
95%2009-Material Recovery
Landfill
Energy From Waste
Material Recovery
1999
2000
2001
2002
2003
2004
2005
2006
2007
2008
2009
2010
2011
(£100,000)
(£80,000)
(£60,000)
(£40,000)
(£20,000)
£0
£20,000
£40,000
£60,000
£80,000 Zero Waste Profitability Disposal Cost Revenue
Profit
£Zero Waste Business benefit
Zero Waste “Waste-2-Product” Profitability
- £46k
£50k £59k
Recycling: 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 Conservation - Increasing Reuse
Recycling CentrePackaging for
recyclables
Reject pallets sent for Recycling
Robust Packaging – Re-useable?
Toner Consumables Finished Goods Packaging
Pallet Reuse Flow 2015
Ricoh JapanImported Toner(plastic pallets)
Ricoh UK Products Ltd
(RPL) Toner Filling
BOZ (Netherlands)Distribution Centre(Central Stock of Reused Pallets)
RPL Recycling Centre
(Recycled)2,517
Imported12,538
10,011 Reused
?? Returned to RPL for Reuse
Cost of Pallet: £28RPL Saving:
£28, 308 per year
Capturing Return for Reuse Working with Parts Eng and DCM to add items to MRP
system for reporting (compliance). Capture more opportunities
26
Resource Conservation
RemanufacturingReducing Operational Impact
Ricoh Group's global environmental conservation:
Keeping environmental impact within the self-recovery capabilities of the Earth
1 2
THE PERFECT STORM
2030
World's population
will rise from 6bn to 8bn
(33%)
Demand for food will
increase by 50%
Demand for energy will increase by
40%
Demand for water will
increase by 30%
Professor Sir John Beddington, UK Government Chief Scientist (2009)
What’s the problem?
WHAT’S THE PROBLEM?
OECD Development Centre, Working Paper 285 (Kharas, 2010)gfh
2014
Resource Security - “Peakonomics”
Chris Martenson (Crash Course)
“the next 20 years are go ing to be complete ly un l ike the last 20 years”
Jae Mather (Carbon Free Group)
“Commodi ty pr ices up by 147% s ince 2000”
Heed the warnings …….
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
01/05/2023 31
IEMA – From Waste to Resources report
01/05/2023 32
The Circular Economy
Landfill
Energy recovery
Service provider
Product manufacturer
Parts manufacturer
COLLECTION
Extradition of biochemical feedstock2
Anaerobic digestion
/composting
Biogas
Restoration
Biologicalnutrients
Mining/materials manufacturing
Technical nutrients
Farmingcollection1
Biochemical feedstock
COLLECTION
1. Hunting and fishing2. Can take both post harvest & post consumer waste as an inputSource: Ellen MacArthur Foundation economy team
Ricoh Comet Circle
01/05/2023 34
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
Ricoh reacts to the market conflict of “1st Life vs. Sustainable Customer Demand” through
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
20502000
100%
80%
60%
40%
20%
0%
Ricoh’s 2050 Plan Impact reduction
Virgin Fossil and Mineral materials
Bio Materials
Recycled Materials
Reuse of productsand parts
50%of incoming
materials from Recycledor Reused
Leasing Eco-Line products
UK Remanufactured Products
TELFORD FACTORY
Ricoh Remanufacturing
Green centre
Firmware upgrades
Technical modifications
PRODUCTION LINE
COMPONENTS
Con
tract
War
rant
y
Eco Line - Remanufacturing Process
Remanufactured machines (BS-MADE 8887-220)
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 AnalysisRaw material Manufacture Customer usage Recycle
& disposal
Remanufacturing = 38% Environmental impact reduction
Life Cycle: Comet Circle deployment
Customer
OperatingCompany
Product Manf.
PartsManf.
MaterialsManf.
Materials Supplier
Maintenance Parts Recovery
MaterialsRecovery
MaterialSeparation
Raw material recovery
Incineration with Energy Recovery
Final Disposal
Recovery
Secondary User of Materials
RecyclingCentre
Green Centre
Remanufacturing Zero Waste
Business Benefits
01/05/2023 Version: [###] Classification: Internal Owner: [Insert name] 42
Asset Remanufacturing of Ferrite RollersProduct / Process
Apollon C1 Fuser
How Much
200 units per month
Business Benefit
Saving compared to manufacturing new = £13/Roller
Comments
First stage of Remanufacturing development, development and justification of the process was challenging, but ultimately developed a low skill cost effective process requirement.
+ Comet Shifts
2
Business Benefits
01/05/2023 Version: [###] Classification: Internal Owner: [Insert name] 43
Asset Jupiter OPC unitProduct / Process
Remanufacture of unit including reuse of aluminium drum and weight (rather than recycling).
How Much
7000 drums saved over 1 years production.
Business Benefit
Savings compared to buying new units = £61,000
Comments
extension and development of the Ferrite roller process
+ Comet Shifts
2
Business Benefits
01/05/2023 Version: [###] Classification: Internal Owner: [Insert name]
Asset Supplies Remanufacturing DepartmentProduct / Process
European wide sourced Toner cartridge Remanufacturing of AIO / PCU / Fuser units
How Much reverse logistics return 55tonnes / month. 52 tonnes are remanufactured (Process yield is 95%, with 5% sent for recycling).
Business Benefit
Based on the avg selling cost within the Ricoh demand chain the process is worth €11 million per month, the direct benefit to the manufacturing process compared to buying virgin materials and parts is €2 million per month.
Comments
Now established as part of European manufacturing operations
+ Comet Shifts
3
Business Benefits
01/05/2023 Version: [###] Classification: Internal Owner: [Insert name] 45
Asset Machines RemanufacturingProduct / Process
Remanufacturing of copiers and production printers following BS887-2
How Much 160 units per monthBusiness Benefit
40% cost savings compared to new models, reducing environmental impact by 38%
Comments Established as part of RPL manufacturing operations
+ Comet Shifts
3
Resource Conservation
Concept: develop business strategy to maintain materials for productivity – Compliance – Long term approach (2050 Plan)– Supply Chain awareness and change in procurement– Life Cycle - Comet Circle deployment– Diversification of operation (remanufacturing)
Result: Reduced environmental impact of operation, extended life cycle of materials, resulting in a changing operation to maintain future business continuity (Sustainability).
Social Contribution
CSR and Stakeholder engagement
Ricoh Group's global environmental conservation:
Keeping environmental impact within the self-recovery capabilities of the Earth
1 2
The Ricoh Way – Social Contribution
The Ricoh Way: Practical Contributions to Society
Global Environmental Conservation
Employee Engagement & Advocacy
Interest(Contract)
Supporting(Volunteer)
Environmental Leader
(Stakeholder)
Biodiversity(Advocate)
Specialist(Partnership)
Social Responsibility
Per
sonn
el D
evel
opm
ent
The RICOH WayProduction System
Business Excellence Model
Site Map: Biodiversity Buffer Zones
Buffer zone area:Paths:
Natural Capital with Health & Well-being
55 - 01/05/2023
700 NEW TREES PLANTED !
BESST / SBA Pollinator Support
(Hives Map)
2017 plan
2014
2015
2016
Honey Bee
2016
Strategic Biodiversity Development
Community Development
BESST partners with Telford & Wrekin Council
Business Environmental Support Scheme Telford
• Business led Environmental Network (Re-formed 2002)
• Mission: “To enhance the environmental performance of local business; In turn boosting efficiency and reducing the impact on the global environment”
• Providing a forum to share BESST practice between companies to improve sustainability
BESST partners with Telford & Wrekin Council
Members
BESST partners with Telford & Wrekin Council
BESST Practice
Developing and Sharing Sustainability best practice for business facing issues –
• Low Carbon & Energy Reduction• Recycling & Waste Management• Water Quality & Reduction• Pollution Control• Resource Conservation – Circular Economy• Natural Capital – Corporate Biodiversity• Legislative Compliance• Cross sector development
– Manf, Tourism, Agri, Construction, Govt., NGO,
62
Networking Business Solutions
Ricoh working with the NISP program (2005-2007)
• Accessed Environment Agency specialist who helped us reclassify the waste,
• Sourced a sustainable solution to handle both toner and cartridge waste
Ricoh Savings• recycled 574 tonnes of
waste • saving £378, 000
processing costs
• Model deployed in Europe, China, Brazil, etc.
NISP: Telford Area Deployment
IS
IS
IS
International Model
1. Business Environmental Support Scheme Telford (BESST)2. Meres & Mosses Business Environmental Network & Metnet (MMBEN)3. Hereford Business Environmental Network (HBEN)4. Staffordshire Business & Environment Network (SBEN)5. Herefordshire Greenlinks6. Business in Sandwell Network of Environmental Support (BISNES)7. Herefordshire and Worcestershire Chamber Environmental and Resource Efficiency8. Sustainability Solihull
1
2
3
4
5
6
7
8
BESST partners with Telford & Wrekin Council
BESST Agenda 2015
Events• Environmental Technologies• Back-2-Basics• Conservation Management• Corporate Biodiversity • Environmental Legislation• Sustainability Awards
2015 Business Theme: Water– Reduction (costs)– Quality (Water Framework Directive aspects, pollution)– Business Continuity (flooding, prosecution)
EU / UK Water Legal Context - March 2014
Current worldwide focus on reduction of water use, water flood management and improvement in water quality.
In EU latest legislation is focusing on drainage systems, especially with regard to drainage discharge quality into rivers & lakes.
The EU “Water Framework Directive” (WFD) has been issued to manage water quality. Existing Legislation ‘Water resources act & regulations 2009’ requires all companies to ensure risk of pollution is minimised and water use is monitored and reduced.
WFD target is to improve water quality in rivers / lakes so that all can achieve “Good Ecological Status” by 2027.
In UK target areas for improvement including:– Run-off from trading and industrial areas (i.e. RPL)
Telford area (RPL) has been identified as a “failing catchment” and will be subject to
increased EA monitoring and action. Telford Area
RPL Existing SW Drainage - Out To Lake
RPL Surface Water Drainage RouteWesley Brook water course
Priorslee Balancing
Lake
Outfall to BrookIn the case of a Toner
spill during rainy UK weather there is Large risk
of toner washing into drains and then into brook and lake – If this Occurs, RPL May have to STOP all operations under direction
of UK Environment Agency
Surface Water (Rain)
Drainage
Existing RPL Drainage designed in 1993, based upon OLD Hydrocarbon toners. New SPR toner
types need different pollution protection
strategy designed for ‘Diffuse Pollution.’
RPL2Building
RPL1Building
RPL3BuildingSite
Entrance
Friends of Apley: water quality
BESST / EA: Electric Fishing
SWT /Eco Ninjas – Sampling methodsLocal Partners: Pollution monitoring
CROW BROOK POLLUTION
30 November 2015
RPL Existing site layout
RPL2Building
RPL1Building
RPL3Building
RPL UnusedLand
RPL Land Available for Possible expansion
RPL Proposed Site layout with SuDS
Upper level pool
Cascade
Lower Level Water Pool
Employee Walkway
Employee accessBird Observation Hide
Employee Walkway with interpretation boards
RPL2Building
RPL1Building
BESST partners with Telford & Wrekin Council
Awards 2015
• Blue Business Awards (Env. Agency)– Reduction: ARRIVA– Quality: Bridgnorth
Aluminium
• BESST Sustainable Business Award– Stadco
National & International Brand Awareness
International Conference on Applied Industrial Symbiosis 2012
National Catchment Based Approach Conference 2015
International G7 Alliance for Resource Efficiency Conference 2015
UK Govt .Office of Science – From Waste to Resources Workshop 2016
Developing CE Policy & Operational models
Working with Govt Office of Science / Defra CSA’s on Waste & Resources Report to influence Ministers to develop CE policy (“Business” chapter)
UCL Conducting a Life Cycle Assessment (LCA): from Theory to Practical Application workshop, developing CE Operational Models
Raising the Next Generation
Direct Educational Support
Business Development Support
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 £1 Million per year.
The Waste -2-Product program increases the life cycle of materials whilst increasing profitabilityRemanufacturing
Eco Line and Supplies Recycling increase the sustainability of raw materials and our manufacturing process
Waste-2-Product
The RICOH WayProduction System
RPL Energy Reduction (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 Lean & Green Services
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 Circular Economy - 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).
Sustainability: Making 3P’s real …..
‘Making Life better’ ‘Adding Value’
‘Looking after where we live’