ricoh (rpl) sustainability oct 2016

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


Bottle Assy

Cap Assy

Vacuum form tray

Reuse

Sponge seal

Bottle (Taurus)

RFIDCap

Poron Seal

Holder Gear (Taurus)Agitator (Taurus)

Shutter


Reuse

Mandatory Parts


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


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


RemanufacturingReducing Operational Impact



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


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


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


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



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


Members


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

http://www.telfordbesst.co.uk/

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 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


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’