fuser cost redutions - 6-9-09

8/8/2019 Fuser Cost Redutions - 6-9-09

1/21

Fuser Cost ReductionIdeas

6-9-2009


2/21

Summary

18 Projects

Total weighted cost savings = $0.36


3/21

Change AC wire

Use lower rated wire and teflon tube.

Probability: MediumUnweighted unit cost savings: $0.23Weighted unit cost savings: $0.12 Schedule: TBD

Issue(s)Requires long section of wire to stripped.


4/21

Change DC thermistor wire

Use of one of the UL alternatives for the DC thermistorwire. Insulation material would change.


Issue(s)

None.


5/21

Exit drive rollers

Change material type.

Probability: TBDUnweighted unit cost savings: TBDWeighted unit cost savings: TBD Schedule: TBD

Issue(s)Need to investigate materials for contamination, velocity control,

life.


6/21

Lower cost grease/oils

Use lower cost alternative for grease and oil used ongears/studs.


Issue(s)

Requires life testing.


7/21

Heater adhesive with no refrigerated storage

Use Dow Corning alternative for adhering heater toheater housing.

Probability: HighUnweighted unit cost savings: $0.06Weighted unit cost savings: $0.05 Schedule: TBD

Issue(s)

Need to confirm oven curing temperatures and times.Requires life tesing.


8/21

Heater adhesive with no refrigerated storage and reduced

oven curing time

Researching for an alternative heater adhesive.

Probability: LowUnweighted unit cost savings: TBDWeighted unit cost savings: TBD Schedule: TBD

Issue(s)Alternative not yet identified.


9/21

Replace anti-static bag with standard bag

Static bag needed only over thermistor circuit.


Issue(s)None.


10/21

Switching from Rynite to alternate material

Based on one current proposed material at a savings of7%.

Probability: LowUnweighted unit cost savings: $0.05Weighted unit cost savings: $0.01 Schedule: TBD

Issue(s)

Material not yet rated or qualified.


11/21

Changing exit sensor wire

Change from 125C rating to 85C rating with connectorfor wire outside of fuser frame or 105C wire throughout.


Issue(s)

None.


12/21

Remove Kapton tape from heater frame

Replace with a plastic part.


Issue(s)Using the existing heater frame design may require the plastic

part to be too expensive. May need to change the heater frame.


13/21

Remove Kapton tape from BUR gear

Change gear design.


Issue(s)None.


14/21

Remove (or lower) oil retention bumps on heater

Remove or lower the oil retention bumps on the heater.


Issue(s)Needs significant life testing.


15/21

Less expensive static brush system

Investigate using carbon or acrylic fibers.


Issue(s)Need to understand impact of brush material on belt wear.


16/21

Use epoxied thermistor

Use epoxy to attach thermistor to the back side of theheater instead of welding.


Issue(s)

Quote for epoxied vs welded thermistor needs to updated.


17/21

Combine Dell and Lxk labels



18/21

Integrate fuser frame into machine

Goal is to limit fuser replacement parts to those thatwear (belt assembly, back-up roll, skeleton frame).


Issue(s)

Concept not yet determined.

Need to address FRU servicing, machine tear-up


19/21

Thinner frame material

Change fuser frame thickness from 1.6mm to 1.2mm.


Issue(s)Drop test results.


20/21

Decrease length of high temp DC thermistor wire

Move connector closer to the fuser frame allowing forsome of the 200C wire to be replaced with 85C wire.

Probability: MediumUnweighted unit cost savings: TBDWeighted unit cost savings: TBD Schedule: TBD

Issue(s)

Need to ensure that the connector is in a location easily reachablefor assembly and service.


21/21

Summary Table

Project Description Issues ProbabilityUnweighted UnitCost Savings

Weighted CostSavings

Change AC wire Use lower rated wire and teflon tube. Requires long section of wire to be stripped. M $0.23 $0.12Change DC thermistor wire

Use one of the UL alternatives for the DC thermistorwire. Insulation material would change.

None. M $0.15 $0.08

Exit drive rollers Change material type.Need to investigate materials for contamination,velocity control, life.

TBD TBD N/A

Lower cost grease/oilsUse lower cost alternative for grease and oil used ongears/studs.

Requires life testing. TBD TBD N/A

Heater adhesive with no refrigerated storage Dow Corning alternative identified.Need to confirm oven curing temperatures, times.Requires life testing.

H $0.06 $0.05

Heater adhesive with no refrigerated storage ANDreduced oven curing time

Researching alternative. Alternative not yet identified. TBD TBD N/A

Replace Anti-Static bag with standard bag Static bag needed only over thermistor circuit. None. M $0.05 $0.03

Switching from Rynite to alternate materialBased on one current proposed material at a savings o7%.

Material not yet rated for qualified. L $0.05 $0.01

Changing Exit sensor wireChange from 125C rating to 85C temp rating withconnector for wire outside of fuser or 105C wirethroughout.

None. H $0.05 $0.05

Remove kaptone tape from heater frame Replace wi th a plastic part.Using the existing heater frame design may require theplastic part to be too expensive. May need to changethe heater frame.

TBD TBD N/A

Remove kaptone tape from BUR gear Change gear design. None. H $0.0072 $0.0065

Remove (or lower) oil retention bumps on heater Needs significant life testing. L $0.04 $0.00

Less expensive stat ic brush system Investigate using carbon or acryl ic f ibers.Need to understand impact of brush material on belt

wear.TBD TBD N/A

Use epoxied thermistorUse epoxy to attach thermistor to the back side of theheater instead of welding.

Quote for epoxied vs weldd thermistor needs to beupdated.

L $0.35 $0.04

Combine Dell and Lxk labels TBD TBD N/A

Integrate fuser frame into machineGoal is to limit fuser replacement parts to those thatwear (belt assembly, back-up roll, skeleton frame).

Concept not yet determined. FRU servicing, machinetear up.

TBD TBD N/A

Thinner frame material Change fuser frame thickness from 1.6mm to 1.2mm. Drop test results. TBD TBD N/A

Decrease length of high temp DC thermistor wireMove connector closer to the fuser frame allowing for

some of the 200C wire to be replaced with 85C wire.

Need to ensure that the connector is in a location easil

reachable for assembly and service.M TBD N/A

$0.99 $0.36

fuser cost redutions - 6-9-09

Documents