Ricoh (RPL) Sustainability Oct 2016

Sustainability at
Ricoh UK
Products Ltd
Oct 2016
Andy Whyle
Environment & Sustainability Specialist
Mark 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
REPC
Established 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
JAM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
JAM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
Solution products
Media qualification
EMQC
Automation tools
for Configuration
750750
+
Plug & Play
Software
development
“More Than Just a Factory”
Factory Show Case
& Consultancy service

Concept of IMS
Annex SL
CMS
ISO 27001
ISO 9001
OHSAS
18001 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 Ichimura
defined the RICOH
Group’s founding
principles, which instruct
us how to do business,
encouraging us to
constantly improve
and contribute to
the well-being of
our families,
customers,
and society.
RICOHRICOH
Founding
Principles
Spirit of 3 Loves
R
&
D
R
&
D R
S
V
I
C
E
E
R
S
V
I
C
E
E
D
E
S
G
N
I
D
E
S
G
N
I
A
S
L
S
E
A
S
L
S
E
The RICOHRICOH Way
Mission, Vision, Values
Essential Principles: S, E, Q, C, DEssential Principles: S, E, Q, C, D
12 Key Fundamentals12 Key Fundamentals
R
P
O
T
C
I
O
N
D
U
R
P
O
T
C
I
O
N
D
U
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 five
Essential Principles:
SEQCD.
We use 12 Key
Fundamentals
to improve
performance
in 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 Procurement
Suppliers
environmental
management
systems
Biodiversity
Conservation on and off site
Recycling of Products
Recycled machines, parts and
cartridges
Energy & Water Reduction
Management of CO2/Water
Resource
Conservation
Minimisation &
Zero Waste
to Landfill
(Waste-2-Product)
Environmental Action Committee
Social Responsibility
Employee and stakeholder engagement,
improving brand awareness & customer
satisfaction
Pollution Prevention
Prevention controls,
methodology and testing
Legal
Compliance
Compliance & 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 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
0
500
1000
1500
2000
2500
AxisTitle
RPL Waste 2050
Tonnes
2050 target (t)

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
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

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%
0%
56%
2000 - Material Recovery
Landfill
Energy From Waste
Material Recovery
0%
5%
95%
2009-Material Recovery
Landfill
Energy From Waste
Material Recovery

(£100,000)
(£50,000)
£0
£50,000
£100,000
£150,000
£
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 Centre
Packaging for
recyclables
Reject pallets sent for
Recycling
Robust Packaging –
Re-useable?
Toner Consumables
Finished Goods Packaging

Pallet Reuse Flow 2015
Ricoh Japan
Imported 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
Imported
12,538
10,011 Reused
?? Returned to RPL for Reuse
Cost of Pallet: £28
RPL 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
Remanufacturing
Reducing 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)
Jae Mather (Carbon Free Group)
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
23/01/2017 31

IEMA – From Waste to Resources report
23/01/2017 32

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

Ricoh Comet Circle
23/01/2017 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 Profit
Profit

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

Leasing Eco-Line products
 UK Remanufactured
Products

TELFORD FACTORY
Ricoh Remanufacturing
Green centre
Firmware
upgrades
Technical
modifications
PRODUCTION LINE
COMPONENTS

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 Analysis
Raw material Manufacture Customer usage
Recycle
& disposal
Remanufacturing = 38% Environmental impact reduction

Life Cycle: Comet Circle
deployment
Customer
Operating
Company
Product
Manf.
Parts
Manf.
Materials
Manf.
Materials
Supplier
Maintenance
Parts
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

Business Benefits
23/01/2017 Version: [###] Classification: Internal Owner: [Insert name] 42
Asset Remanufacturing of Ferrite Rollers
Product /
Process
Apollon C1 Fuser
How
Much
200 units per month
Business
Benefit
Saving compared to manufacturing
new = £13/Roller
Comment
s
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 unit
Product /
Process
Remanufacture of unit including
reuse of aluminium drum and weight
(rather than recycling).
How
Much
7000 drums saved over 1 years
production.
Busines
s Benefit
Savings compared to buying new
units = £61,000
Commen
ts
extension and development of the
Ferrite roller process
+ Comet
Shifts
2

Business Benefits
23/01/2017 Version: [###] Classification: Internal Owner: [Insert name]
Asset Supplies Remanufacturing Department
Product /
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.
Comment
s
Now established as part of European
manufacturing operations
+ Comet
Shifts
3

Business Benefits
Asset Machines Remanufacturing
Product /
Process
Remanufacturing of copiers and production
printers following BS887-2
How Much 160 units per month
Business
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
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
PersonnelDevelopment
The RICOH Way
Production System
Business Excellence Model

Site Map: Biodiversity Buffer Zones
Buffer zone area:
Paths:

Natural Capital with Health & Well-being

BESST / SBA
Pollinator Support
(Hives Map)
2017 plan
2014
2015
2016
Honey Bee
2016

Strategic Biodiversity 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
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 Greenlinks
6. Business in Sandwell Network of Environmental Support (BISNES)
7. Herefordshire and Worcestershire Chamber Environmental and Resource Efficiency
8. 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 Route
Wesley 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.’
RPL2
Building
RPL1
Building
RPL3
Buildin
g
Site
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
RPL2
Building
RPL1
Building
RPL3
Building
RPL
Unused
Land
RPL Land
Available
for
Possible
expansion

RPL Proposed Site layout with SuDS
Upper level pool
Cascade
Lower Level
Water Pool
Employee Walkway
Employee access
Bird Observation
Hide
Employee
Walkway with
interpretation
boards
RPL2
Building
RPL1
Building

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

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 Way
Production 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.

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’

Ricoh (RPL) Sustainability Oct 2016

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