RANK XEROX

We win top safety honour — again

FOR THE second time, including health screening and has won the British promotions: fire prevention (how Safety Council's Sword of we have equipped our buildings Honour, recognising it as one of with alarms and fire fighting Jiihn Spialley the top 30 safest manufacturing equipment): safety awareness receives the Sword of plants world-wide. measures and campaigns: our Honour from Sir Announcing the award, site conformance with COSHH — Bernard Braine. director Gerry Lane said: "The reducing the use of potentially achievement of a second 'Sword hazardous substances and of Honour" is unparalleled switching to environmentally throughout the Corporation and is friendly chemicals; and our the direct result of consistent training sessions throughout the efforts by all employees in year. working together to a high level "In short. it"s a really of safety performance." comprehensive package on how The last time we applied for, we carry out the total safety and won, this annual award was function." in 1984, since when it has grown The award ceremony was held progressively more difficult for on 7 December at the applicants to achieve success. Apothecaries Hall in London, It was agreed last spring that and John had the honour of we would try for the top honour receiving the sword from Sir again so application forms were Bernard Braine. DL, MP (as filled in. supported by a pile of tradition demanded, he handed documentation. over a coin — a new £2 one — in As John Spratley. manager, exchange). safety & security operations, Congratulating the successful Frcmi left: Chris Rowlings. Robin Fvffe. John Sprallev. Brian Powell, Colin Butler and Dick Delahay pictured after the presentation. explained, "The award is based companies. Sir Bernard said; "In not just on our consistently low receiving these awards you are that you can be infinitely proud." 6) and Chris Rawlings accident statistics but on our not only contributing to the Mitcheldean plant was also (assembly) together with senior whole philosophy of health and efficiency of your company and represented by Robin Fyffe as safety representative Brian safety at Mitcheldean. the cause of safety throughout the chairman of the main safety Powell and works convenor "That embraces our safety world; you are also helping to committee, and facility review Colin Butler. procedures; the medical side. relieve human suffering and of chairmen Dick Delahay (building Designed to catch the eye

WE'RE CERTAINLY not resting right across the site of the need As we went to press we heard display," said Kim. on our safety laurels. for eye protection in building 5/1. that John Richardson, business To promote safety awareness A recent initiative has been a Staff working there have been quality manager, had won first in office areas, a 'Spot the hazard competition for the design of eye provided with eye protection, prize with his poster; second was in the picture' competition has protection posters, open to all while racks of glasses for the use Annie Round (harnesses) while also been organised for employees. of casual visitors have been Beverley Baldwin (5046 employees in buildings 6/7/8 by The competition, one aspect of provided at three entrances. assembly) came third. the facility care committees for a QIP led by Kim Toombs, small These fit over normal "We're hoping to get those buildings. batch section manager, is spectacles and should be put back professional versions made of More about the.se safety moves designed to heighten awareness on a rack after use. the winning posters to put up on next time round. Continuous improvement is tlie message for tfie '90s

THE MESSAGE at the third been approved. annual "Year Start' "•JIT delivery contracts are communications meeting, held in being established with a wider the clubhouse on 30 November, range of vendors, coupled with was clear. "systems improvers' which will We are aiming at continuous enable us to input much more improvement towards perfection. information to our vendors so as In his opening address, site to reduce lead time and increase director Gerry Lane explained JIT delivery frequency. that the objectives were to share "These projects include EDI the outline details of the 1991 roll-out. vendor pull system and control plan, and to update the increased automatic release of total management team on three MRP order/reschedules. major initiatives within the ""On the material logistics plant — side, the Inbound Materials • the M2000 strategy; Consolidator project will be completed, and there will be • the electronics transition; and progressive implementation of • the most significant challenge multinational re-usable cartons Gerry Lane, who presided at the 'Year Start' meeting, with Paul Overton, Phil facing us in 1991 —quality King and Kevin Horrohin. and bar-coded labels. improvement. ""The site-wide application of The list of oncoming new level of investment already made SPC (statistical process control) Control plan build programmes involving had resulted in considerable is ongoing, plus a pilot automated Mitcheldean activities such as benefits with improvement in SPC data collection and display Before taking the audience electronics, fuser roll support, and quality, days of supply. JIT project. through an overview of the Interconnect (harnesses) delivery and lead times. "The illustrated assembly control plan. Paul Overton, represented significant business. JIT purchasing had process will be applied to new financial planning & analysis Departmental control plan commenced and 11 vendors were small copier programmes and manager, showed how well roll-out communications sessions locked into EDI (paperless there will be various business at Mitcheldean had would shortly be held to cover the transactions) while the multinational projects on copy grown in the past year, while site overview and specific targets customisation of central quality, harness testing and acknowledging that the good and plans designed to support the electronic printers and the FR&T automation. results had been assisted by a achievement of the site's harness "showcase' had "The 5046 family of products favourable currency. objectives. commenced. will be moved into the focussed At the end of the financial Investments associated with factory and work started on year, he said, we had a very Mitcheldean 2000 M2000 had been higher in the facilities for that and other healthy business, with developer past year than over the last ten oncoming products. Any residual housing and electronics As leader of the M2000 years and "it is putting us in very 5012/14/18/28 build manufacturing making a project, controller Phil King good shape for 1991."" he said, requirements in 1992 will be considerable impact, along with provided a status report and dealt with days of supply down 26 per accommodated in a 'build out' increased new build and with the challenges facing us in cent, lead time down 25 per cent facility," he said. recycling activity. the early 1990s. and rate per hour (which we use "Material for the focussed In 1991, a major initiative is Concentrating first on to quote for business) down 6 per factory will be supplied direct required in all aspects of quality. achievements in the past year, he cent. from JIT vendors or from the The cost targets call for paid tribute to those who had Dealing with future strategies, Consolidator, the logistics decreasing purchase price brought these about. he announced that funds for a changing through the completion variances (PPVs) and eradication The various strategies had new VAX computer to handle of the south wall exit dock, the of manufacturing cost variances been necessitated by competitive additional transaction volumes incorporation of PQA (audit) (MCVs) to achieve our plan. pressures and he showed how the and speed up response times had laboratory from building 12 and Improvements in materials inventory would have to Full htnise in the clubhouse. continue. "We used to operate with 52 days of supply. In 1990 this was 29; our 1991 objective is 23. with an ultimate desired state of around 10 days." Optimising the benefits of Just in Time and M2000 goals would contribute to the corporate objective of improved return on assets. On the people front, an employee satisfaction measurement survey was to be carried out in the New Year; we would also continue to focus our attention on safety, working towards zero accidents, and a reduction in our overall absentee levels would be required to help maintain our competitive position. supporting facilities. materials and control 'streams' — "Automated receiving/stores had been accomplished to plan, will be implemented in early 1992 and, said Kevin, "1 think you will Is this a record? with development and recognise in it a world class COULD BE — we haven't heard purchase orders were facilitisation work taking place in facility." of anyone being able to transmitted, received and 1991. and systems enhancements The transition of the EMC in implement EDI more quickly processed with 100 per cent, will be established to pull the physical sense was over, he than in two days. success. material from EMC, harness said. Now the challenge was to On Thursday, 20 September, How did they do it so assembly and Consolidator. make sure it was a benchmark an initial meeting was held quickly? we asked Malcolm. "In EMC the "fast flow line' quality supplier, and there were between Mitcheldean's MIS EDI "Well, basically it was strategy will mature and a considerable opportunities for project manager Malcolm Pearce because Beckman's are "Boardwatch' quality system will employee involvement in problem and Samantha Birtwistle experienced EDI users," he said. be introduced. solving. (production purchase) and the "They operate it in the same way "On the recycling front, Various initiatives were MIS director and European sales as we do, they conform to materials systems will be already under way — on JIT (set• director of Beckman Industrial industry standards, and are rated enhanced to optimise asset- up reduction, batch size reduction pic (an affiliate of Emerson by Rank Xerox as one of the top recovered parts and control new and EDI, planned at 60 per cent of Electric Co.) with full agreement suppliers in quality, cost and part demands, and the paint shop buy during 1991), on days of being reached. delivery performance." and re-build facilities will be supply, on product quality with On the 21 st, test Since the whole process is consolidated in a single building. engineering, "and SPC is transmissions of live purchase carried out in these three stages "The harness 'showcase' will becoming a way of life in EMC. orders under Tradacoms standard — initial meeting followed by be completed while in parts "This is an area of tremendous via Tradanet (the network) took systems test and implementation manufacturing there will be JIT growth potential." he emphasised. place and no problems were — and each takes a day, it's re-layout of the shop with set-up "Oncoming machines will have experienced. unlikely that anyone could beat and batch size reduction some 50 per cent content that will The following Monday, 24 this Mitcheldean achievement. programmes, and the acquisition be electronic. There is a great September, live production of new equipment required by need for EMC to accommodate oncoming build programmes. that growth." "Total productive maintenance below the previous year's Improvements with regard to will commence with a pilot in the 1991 challenges performance. absence targets were required. harness area, and there is a "That improvement must be "We are now behind some other potential collaboration agreement The foregoing presentations sustained," he insisted. locations." he said. with a company concerning "painted a very good picture of The release of 120K square The MEWS had its lowest plastics manufacture. Mitcheldean and its major feet of space had allowed the level of occupancy for three "A delta T techniques will be achievements." said Gerry Lane. electronics business to come on years; the current economic employed before there is any The electronics transition was site. Inventory had been reduced climate was unfavourable to investment in major projects and particularly significant and he by 25 per cent, delivery was close small businesses, but in some the process will be used to tackle applauded the way in which all to 100 per cent, while as regards cases firms had left because they non-value-added activities." involved had demonstrated their cost we had achieved nine were expanding. However, a M2000 had reduced lead time, strengths in very difficult consecutive months with zero marketing initiative was now days of supply and rate per hour, circumstances. MCV — "It shows you can do under way. it!" "but there is much to do." added Reviewing the good news "Outstanding results through Phil. first, he said that, from the safety The not-so-good news the '80s provided a strong The most important of the aspect, it had been the best year concerned quality, absence and foundation for the 90s and the 1991 projects was, he said, ever — with the Sword of Honour the MEWS. key challenges for 1991," said working with the RX logistics award, the achievement of 3.8 The majority of new build and Gerry. organisation to enable build to million safe working hours in the recycled products had plateaued The latter included new allocation/order. 15 months to June, and recorded on quality, and there was a major product introductions, the further "There is a need to concentrate and lost time accidents well challenge to improve significantly implementation of M2000, on time-based competitiveness in on customer satisfaction. electronic line balance, demand the '9()s. Reduction in overall lead responsiveness, and participation Neil Howell. Tom- time gives time back to our in technology councils. Wood and Phil customers; companies that use Denies discuss the ""There are tough targets for least time are the ones that will presentations. unit cost competitiveness, ^^yk' 'v ^^^^ gain market share. employee satisfaction and, last "Continuous improvement." but certainly not least, quality. he emphasised, "does not cause ""A quality break-out strategy casualties but greatly enhances has been developed which will competitiveness. build on the foundation of full "Words like defect, re-work employee involvement. and purge must disappear from ""This strategy is something the Mitcheldean vocabulary. It is which we will all need to focus not just a management fad. It is our attention on during 1991 something that requires a through the intensification of contribution from everyone in the Leadership Through Quality. company." ""Mitcheldean has always been renowned for its teamwork and it Electronics transition is very important that we work together. Kevin Horrobin's review of ""1 look for the support of the transition of the electronics everyone through the "90s." business underlined the Chris Clarke. immensity and complexity of the Robin Richardson and Bob Tinner project (featured recently in chat during 'Vision'). refreshment time. Nevertheless, the many tasks which had faced the project team — in the technical, operations, quality, human resources. Mitcheldean's first national award winner

FOR THE first time ever, a presentation later at Mitcheldean Mitcheldean plant employee has when Keith Grant, manager, won a NEBSM national award — assembly operations (recycling & at diploma level. manufacturing), gave Sean a Recycling engineer and ex- cheque, on behalf of site director apprentice Sean Mills received his Gerry Lane and his management award, plus a cheque for £300. team, in recognition of his from Charles Fenton. chairman of outstanding achievement. the National Examining Board for "It comes." he said, "with our Supervisory Management, on 21 heartiest congratulations." November at the Cafe Royal. Like his fellow RX-sponsored Sean receives the 1990 national award from NEBSM chairman Charles Fenton. London. students, Sean carried out his Accompanying Sean were diploma work in his own time, John Gumey, recycling operations attending the Ross centre of completing a work-related electrical/electronic support manager, his course tutor Technical College two project. assemblies/sub assemblies.' Bill Hill from Hereford Technical evenings a week. Scan's project was 'The "What I tried to do was plan a College, and his fiancee Caroline Each had to carry out ten development and implementation procedure which could be adapted Jones, who works in our harness assignments on diverse subjects of a structured process for the to any repair facility." he told us. assembly centre. and keep a log book, as well as repair activity for "It defines all associated costs, The presentation was followed justification (including return on by a luncheon, and preceded by a Pictured at the Mitcheldean recognition award presentation to Sean are MOC investment), and all the steps to champagne reception at which the managers Robin Fyffe and Keith Grant and (far right) ROS manager John follow from the receipt of a Gurnev. projects of the regional winners, repair/recycling request, through both diploma and certificate, were the generation of the appropriate on display. processes and manuals, to the John Gumey told us that the finished product leaving the site." standard of presentation of Sean's As John explained. ROS have project was particularly high and been receiving ad hoc requests, demonstrated how skilled he had mostly from Customer Support become in operating the 608.5 Services, for repair activities workstation. which require a wide variety of "He worked into the small information. "With this systematic hours to complete his diploma planned approach we shall be able tasks and no one can fault his to respond promptly; the industry. He is an asset to my procedure will also be used at department." other Rank Xerox locations." There was another

took up employment. Sean — steadily growing Feeling in need of a breather, he took a year off from studying, but not from learning. in stature Carrying out diagnostic tests, repair activities, the development RIGHT AT the start of his award- the completion of the ten prefect. of recycling processes, etc.. gave winning NEBSM project report. assignments he had to carry out. He was accepted as an RX him comprehensive experience of Sean Mills specially thanks two These ranged from a study of apprentice and. having achieved the department's work. people — and a Xerox system — the parking problems of an an A-level in engineering, was ROS also provides technical for their contribution. imaginary company, with sponsored on a three-year HND support to RX Venray and Sean John Gumey. the current recommended solutions, to an course in electrical and electronic went on his first assignment keeper of the LSA archives, assessment of the benefits of a engineering at the Polytechnic of abroad there. assisted with history and pictures weekend of 'Residential Wales. With an eye on future of Mitcheldean site. Mayhem' when NEBSM students His results brought him the progression into management, Mel Alder helped concerning met to do combat 'Paintball- Institute of Electrical & Sean embarked on a supervisory the buy back process and style'. Electronic Incorporated Engineers course in 1988 and gained a company policy. The assignment which Sean 'student of the year' award for the NEBSS certificate the following And Sean's 6085 desktop told us he most enjoyed, however, best overall marks in the final year. publishing system is not took the form of a presentation on year. The tasks for this involved forgotten! the 1992 single European market During his HND sandwich completing a work-related project His I'/2-inch thick report and the effect he estimated it course he was 'industrially too. Sean's concerned the includes 18 appendices, with flow would have on the consumer. placed' in ROS, quality control, development of a method to and time charts, tables, and some Sean was all set to be an finance and product engineering. enable PWBA schematics for eye-catching graphics which engineer right from his Refurbishing engineering (as it electronic printers, held in El demonstrate the capabilities of schooldays at the was then known) was the right Segundo. California, to be the workstation and its user. Grammar School (now Laker's environment for him. he tolt. and transferred electronically via 4 The 6085 also 'co-operated' in School) where he was a senior after college that was whei he Ethernet so that they could be Gerry Lane with successful candidates (from left) Graham Powell. Robert Liddington. Ken Ellway, Tony Nelmes. George Elliott. Jane Meek, John Evans. Terry Jones, Jeff Beavan. Chris Reed. Ken Fo.\. Dave Bufton. Richard Passey and Teny Peates. On the right are Pal Hawkins and Malcolm Taylor. More people are gaming diplomas

THE NUMBER of Mitcheldean rewarding — I know we will — All had completed the such as local sourcing. defect employees gaining NEBSM and that you will develop new Mitcheldean manager reduction, SPC. improvements in diplomas grows ever higher, with projects in the areas in which you development programme which is spares & export packing, 19 candidates achieving 100 per work. recognised as a NEBSM diploma shipment of machines to customer cent, success in 1990. "Congratulations, and thank course provided that candidates requirements, material review In addition to Sean and his you for all the efforts you have also keep a log-book and carry board methods. SQA corrective fellow students, 14 section made." out a work-related project. action, ESD protection, and cost managers qualified for diplomas The successful candidates This was the second group reduction on assembly (mfg) from which they received from site were: Jeff Beavan (production which Pat Hawkins, who acted as the engineering aspect. director Gerry Lane at a purchasing). Dave Bufton (EMC), course manager, had seen through Said Malcolm: "What struck presentation ceremony held in the Ken Ellway (MED), George the manager development me about this group was that, hospitality suite on 10 December. Elliott (5046 family assembly), programme, and she told us that despite their transfers within the Referring to the 'Year Start" John Evans (low volume the percentage of those who had plant, and the heavy workloads communications meeting, Gerry assembly). Ken Fox (recycling), achieved a diploma (14 out of 20) that that must have entailed, the said: 'We have .some tough Terry Jones (MED), Robert was much greater than before. students managed to cope very challenges in the '90s but we also Liddington (production She expressed thanks to the well with the 11 modules of the have great opportunities, and the purchasing), Jane Meek candidates' managers for their programme as well as completing type of projects you have been (import/export), Tony Nelmes support, and to Malcolm Taylor, a work-related project. working on will provide the (human resources), Richard tutor at & "In fact, I think any such foundation for implementation. Passey (spares packing), Terry College of Higher changeover was very good for "That is good from your Peates (5046 assembly), Graham Education, who had assisted them them because it gave them more perspective as well as ours. I hope Powell (harness assembly), and with their projects. varied experience and presented you found the experience Chris Reed (new build QA). The projects covered matters them with new challenges."

Sean's fellow diploma students — Now he trains several times a (from left) Fred Meek (recycling). week, and was recently placed Jeremy Barnard (group human resources). Barry Clein (5046 fifth in the Gwent championships. assembly QA) and Julian Priest His training partner is Martyn (MED). Fred's project was on setting Wynn (son of Fred in recycling). up 50I8I2H build lines. Jeremy's on "I think he did marvellously," design and implementation of change says Sean of Martyn's recent notes: Bariy dealt with identification of rejects while statistical analysis of success in the 'Mr Universe' problems was Julian's project. championships. ""We're delighted the Council "It's a challenge to my are going to open a new Fitness knowledge, and I get a feeling of Centre in Heywood School. We satisfaction when the problem is get all ages doing bodybuilding solved." — one member is nearly 60. It Sean has grown steadily in develops you mentally as well as stature — in more ways than one. physically." Captain of his school's first Music is another interest and promptly accessed by ROS result seen here. XV, he also played rugby for Sean gets more exercise beating engineers working on the repair of Sean is particularly interested Cinderford first XV and colts. He hell out of his drum kit. defective boards. in computers (he plays computer was 16 when he started With the £300 that came with The project won through the games during his lunchtime) and bodybuilding in order to get "a bit his national award Sean has regional finals, where he came in Xerox office systems. more size and weight" for his bought a CD player so he can second, going on to become a Currently engaged in setting sport. Then a back injury put paid listen to his favourite rave candidate for a national award at up repair and recycling facilities to rugby. recordings — local band EMF certificate level. for some extremely complicated Weight training, too, lapsed and "alternative music". He then went on to do a laser printers and office systems, while at college and on his return He's just bought a new house, diploma course, and his certificate he says: "I enjoy design work and he decided to take up so what about the neighbours? we project led logically into his fault finding/repair of PWBAs bodybuilding again at the Forest asked. "I'm thinking about having diploma one. with the excellent and systems as a whole. Fitness Centre. it sound-proofed." he said. 5 A new small copier that has great copier capabilities

capabilities." says Keith Wilding, who is the 5034 programme manager for Mitcheldean. "and it is seen by Marketing as a very strong machine against the competition." It is the first 50 Series copier in its class to be equipped with a duplexing automatic document feeder (DADF) that can invert The Xerox 5034 is the first 50 Series copier in its class to offer automatic originals for two-sided copying. duplexing. Here Sue Harrison (materials) and production manager Norman When duplexing, the 5034 can Riidge study the copy quality of a double-sided print. also shift the image on the second side of the copy to automatically chapter dividers automatically at alphanumeric, two-line message provide extra margin space for any point in the copied set. centre on the machine's control binding or three-hole punching. Operators load blue or green panel. The LED display guides Based on the Xerox 5028, it sheets at desired points among the the user through jobs with step- has the same copy count (28 cpm originals, and the 5034 recognises by-step instructions supported by on A4 paper) and comes equipped the coloured sheets and inserts graphic "prompts'. It also FR&T operator Dave Williams and with a 10-bin sorter that can make divider stock at these places in the provides diagnostic information section manager John Evans read the alphanumeric, two-line message on collated or stacked sets of up to copied sets. for servicing. the control panel of a Xerox 5034. 40 pages per bin. If the blue or green sheets bear Also new to the product line is A productivity capability an image, the 5034 will copy the an electronic auditron for which is unique to the 5034 is its image on to the divider so controlling copier usage, NOVEMBER SAW the wraps one-step overhead presentations chapters or sections may be titled. restricting it to people with access come off a new 50 Series low programme. In addition, the 5034 can codes or account numbers. volume copier — the Xerox 5034 Using its automatic document automatically place both front and As in the 5028. the 5034 has — now being assembled in our feeder and sorter, the machine back covers on a copy set; cover an auto-contrast feature to adjust focussed factory. copies a set of originals on to stock can be pre-copied and re- exposure levels for each original, The advertisements for this acetate transparencies, fed through the machine so that and a photo-mode control for latest model bill it as "a great little automatically interleaves the finished sets have the appearance copying half-tone.s/photographs. copier that thinks it's a great big transparencies set with plain of a professionally prepared Four paper trays are standard one'. paper, and delivers up to nine report or booklet. and give the 5034 a total paper "It moves the low volume collated copies of the presentation The new model is the first in capacity of 950 sheets, and copier upwards towards the mid for use as hand-outs. its family of 50 Series low- there's a 20-sheet by-pass tray for range with its power and The machine will also insert volume copiers to feature an quick jobs.

Keith Johnson (MED) looks into things with Vince James in the CCT area.

BUILT TO the highest possible European safety, quality and environmental standards, the Xerox 5034 is compact, quiet, safe and very low in ozone emissions. The copier's packaging uses recyclable wood and paper-based materials rather than expanded polystyrene, and brown unbleached cartons are made use of wherever possible. Model mix The preconfigured system is then lifted on to the stand (which Travelling on a modified comes from Belgium). John learns the product mover, the new machine Full testing of the machine is assembled in batches on the takes place on the line in FR&T, same line as the 5028 but there's giving more customer protection ropes, and loses a 40 per cent difference between as well as saving on installation the two models. time. And whereas the 5028 is pre- The machine is shipped with a hang-up configured in Venray, the developer in place and the preconfiguring of the 5034 takes copy cartridge (a customer AMONG OUR industrial "Another was to cross the place on the line. replaceable unit) packed inside placements is John Collins, who moors after dark and find a The processor of this the stand. is taking a degree in 'triangulation point' about 2 multinational system is built on First customer machines were manufacturing engineering at kilometres distant. top of the automatic document released in November and Nottingham Polytechnic. "We were given a map and a module (which comes from production is expected to reach Placed with the technical team grid reference, and we had to Webster), then the DADF (from the top of the learning curve early in the building 1 "focussed establish exactly where we were Toronto) goes on top of the this year. factory'. John has already coped and then, using a compass, find processor. As we went to press, further with several challenges. our way to the point and get back The sorter (made in Brazil) is developments were envisaged, not He has built two machines, within two hours. We were just 10 the only part that is added in the only on the 5034 pack line but with assistance from engineers minutes late returning." field, a slave sorter being used on also in the general handling of Keith Johnson and Pat Burke. It got wetter still when they the build line for testing purposes. materials in the assembly facility. He has dealt with in-line had to do a river crossing. problems and trials and helped ""One person was chosen to with the creation of illustrated wade first across the 30ft wide assembly processes (""which is a waterway and I had the privilege new concept to me." he says). because I was best at the rope A rather different challenge work. The fact that 1 was the only was joining the second group of one who couldn't swim didn't industrial placements who were seem to count! "Outward Bound' last September. •"1 had to take ropes across and There were four in the team tie them to a tree so that the others besides John — Jane Emberson could then attach their harnesses (MIS) and Andrea Griffiths to the ropes and get across the (purchasing). Dale Williams river, and back again, within a (works engineering) and Russell certain time. Davis (control). •"The water was 5ft deep — ""Our long weekend in North and about 6ft to my right was a Devon proved to be a very wet weir. It was the most terrifying one all round."" John told us. experience 1 have had."" (Muttered ""The only time it was fine was John George: ""He hasn't had the during our initial indoor training: initiation ceremony yet!") all the outdoor activity was But they had good fun and lots carried out in pouring rain on of laughs. ""We worked well as a Bodmin Moor and Dartmoor. team and I think that is largely "We started off rock climbing, why we managed to be winners abseiling and "ravine' crossing in for the weekend, scoring 454 a quarry. Jane had a head start, points compared with the other having done this sort of thing two teams' scores of 391 and before. 392," said John. Adrian Griffin cusliion.s a 5034 machine with pads made from corrugated hoard "Unfortunately, she twisted What did the whole experience prior to shipping. On tlie right is Pat Burke (MEDi. her ankle on the first day, but she do for him? we asked. "It helped stoically went through the whole me to overcome my hang-up course. about heights, and I've made up Rank Xerox guarantee "We were awarded points for my mind to learn to swim." each task. One was to erect our Which should ensure he'll be own bivouac with the plastic well equipped if he gets to the top Total Satisfaction sheet given us — and then spend — or into deep waters — in his SHORTLY AFTER the press typewriter or printer, they can a night in it. chosen career! launch of the Xerox 5034, Rank ask for it to be replaced with an /// the new lAP studio in building I .John Collins takes a photograph of a Xerox made a new and radical identical or similar machine. component for use in an illustrated assembly process. promise to its customers — one The guarantee lasts for three that is expectefl to revolutionise whole years: all that is needed the industry and the way we do is continuous maintenance business. under a full service At a conference in maintenance agreement. Barcelona, where RX managing A blanket nationwide director Bernard Foumier campaign with advertisements announced the company's in national papers told of Rank sponsorship of the 1992 Xerox's initiative. Employees Olympic Games and World were given the inside story in Trade Fair (both to be held in copies of The Xeroid, a specially Spain), he revealed that Rank produced tabloid. Xerox was introducing a Total They also received a Satisfaction Guarantee (TSG). personal letter from Bernard This is a bold undertaking Fournier with a wallet size card that, if our customers are not defining the guarantee so each absolutely satisfied with a Rank can help carry the news into the Xerox copier, fax. workstation. marketplace. Bill Starkey, manager, packaging and distribution engineering, writes about — Packaging and the environment

A YEAR ago the alarm bells cannot be moulded it can be cut to With Marketing concurrence, started to ring both in the US and the required lengths, mitred to we are now changing from white Europe, warning that the amount form right angled bends, and to kraft (brown) cases with just of municipal solid waste disposed fabricated to form desired black printing. of by landfill was reaching thicknesses. It is worth mentioning that Bill Starkey intolerable levels, and that the Once the product is delivered Marketing have been totally number of available landfill sites to a customer, the Corrupads can supportive of our "green production volumes. would be exhausted in the next either be sold to a waste merchant initiative"; in fact, it is being Xerox are now placing decade. for recycling or landfilled — perceived as a selling point, considerable emphasis on being Legislation, particularly in the preferably the former. particularly in Germany, Austria an environmentally friendly US, was being issued like During our development and Scandinavia, notably with the corporation, and while we have confetti, aimed at banning or process we carried out extensive 5034 launch. played a small part in helping to restricting the use of expanded laboratory tests (vibration and We are also introducing pulp achieve this goal, there is still polystyrene, and certainly shock) to simulate a journey from mouldings to contain goods, considerably more to do with; banning the use of CFC as a Mitcheldean to an RX Operating another replacement for EPS. We • More use of pulp containers. blowing agent. Company by road, rail and air. have identified suppliers both in • Finalisation of an exercise In Europe, although not The shock transmission rate the UK and on the Continent to with Aston Polytechnic to restricted by so much legislation, was equivalent to EPS. The test better develop the process. develop a pulp cushion that can the 'Green Lobby' is growing in sequences were continued after Many of our smaller cases be moulded in the conventional stature, particularly in Germany, the Corrupad had been subjected (cartons) are now manufactured sense. Austria and Sweden with to severe humidity/temperature from 100 per cent recycled board, considerable political sway. conditions (90 per cent RH 38°C) again giving a unit cost saving, • The implementation of Historically, we (the for one week. and the appearance to the retum/re-use procedures for packaging designers) have used pallets and cartons. moulded expanded polystyrene Mark Hoole-Jackson. the (EPS) to cushion, contain and senior packaging engineer on site, protect our product from in-transit has been actively developing the shock. It is relatively cheap and packs for Mitcheldean-based can be manufactured to tight products, and he will be only too tolerances, and suppliers are willing to answer any queries or plentiful. show you various examples. I must stress that all European manufacturers of EPS ceased using CFCs as a blowing agent at least five years ago. and although Corporate candidate EPS is not biodegradable SINCE THE foregoing article was (therefore unsuitable for landfill) written, the QIP has been selected it can be recycled; but currently at European level as one of three the manufacturers do not have the EMO projects to go forward as infrastructure or process to collect candidates for a Corporate Team the waste. Excellence Award at Leesburg, To pre-empt the inevitable, we USA, this March. formed an EMO QIP to develop Led by Bill Starkey. the team an environmentally friendly members include RXMP's Mark cushioning material which met Royston Prilchuid (purchasing) and senior packaging engineer Mark Hoole- Hoole-Jackson, Royston Pritchard our requirements to protect a unit Jackson with examples of the environmentally friendly packaging. and Des Weyman (ROS) plus from in-transit shock, was staff from Venray, Lille and economically viable, and whose One of our big concerns was uninitiated is similar to a kraft Welwyn. supply could be guaranteed within moisture retention, resulting in case. our JIT environment. delamination of the Corrupad Mitcheldean has very much a A supplier in the Midlands had layers, loss of cushioning benchmark role within EMO and developed a process, mainly for properties and — one of our worst evidence of the new packs can be the furniture industry, to enemies — product corrosion. seen in buildings 1,3, 12 and 13, manufacture a 'cushion' made up But our fears were unfounded, as with Xerox 5046, 5034 and 5028 of layers of single-faced the pack and product survived developer housings/1025 and corrugated board, which could be without fault. 1038 machines affected. mitred to suit circular objects Along with this activity, we Products currently under (tables), formed into right angled have been looking at other areas investigation include the 5018/28 If you have, then please — channels, etc. where packs we specify could be and 5012/14. and packaging for mail it to me in hid. 5/2. Over the past nine months we made more environmentally the latter is expected to be have worked with and built on the friendly. introduced in coming months. or leave it at any gatehouse for suppliers' experience to develop In the past, our Marketing The activities of our QIP collection by me, cushioning pads that suit our department have required a have given packaging or post it to me at Tree Tops. application. 'product' outer ca.se to have a designers, buyers and production Plump Hill. Mitcheldean GLI7 The material used (single white Xerox image. To obtain a personnel a new dimension and OEU. faced corrugated) is manufactured pure white liner involves a attitude to their normal function, or ring me •xt.566 or Dean from 100 per cent recycled board bleaching process which is not and at the same time we have 542415. and is glued with a starch-based only expensive but also identified total acquisition cost Myrtle Fowler, editor adhesive. Although the material ecologically unfriendly. savings of $0.5m based on 1991 High tech — and Aztec — down Mexico way

WHEN QUALITY calls, PQA company is." (product quality audit) staff are Larry went out in July, ready to respond — even at very initially to help with the start-up short notice. of 5018/28 recycling. He had Our 'flying consultants' have expected to stay for four weeks provided support for start-up but it stretched to ten. programmes in many countries — Aguascalientes is not a place India. Egypt, Eastern Europe and name very familiar to us. It means The Street of the across the Atlantic. 'hot springs' and. once you get Dead, seen from the This past year the accent has used to saying it. it does tend to Pyramid of the been on Mexico, with Graham ripple off the tongue. Moon, at the Aztec site ofTeotihuacdn. Cooper and Larry Williams going Geographically the centre of near Mexico City. out to join a multinational team at Mexico, it is a base for major Aguascalientes. companies like General Electric, "Their mission," explained Texas Instruments and Nissan. PQA manager Ian Hale, "was to It is also the location of the assist with re-certification and re• manufacturing plant of Xerox training on PET (product Mexicana, or XMEX, which is evaluation test) to ensure part of the Americas Operations consistency with all product organisation and has its HQ in quality labs world-wide." Mexico City. The notice reads 'These donkeys Along with PQA staff from About ten years old, the plant drink beer' —.so Lariy treats them to a bottle each. Venray. Webster and Toronto, is a single building, about the size they brought specialist knowledge of our building 1, and it houses The staff have workwear. as In contrast with the high tech. of specific products to the task. the assembly, recycling, harness. we do. but their hours of work are industries of Mexico City and The exercise has been master• PWBA, parts manufacturing and rather different. People work a Aguascalientes. the villages minded by Aubrey Bryant, plastics facilities as well as morning shift (6am to 3pm) for specialise in hand-crafted goods. manager, multinational PQA. in administration. three months, alternating this with In one village it would be all conjunction with Michel Fasen, Many Xerox low and medium three months on evening shift embroidery, in another pottery, or EMO/PQA manager. volume copiers, input/output (3pm to 11pm). silver or leatherwork. ("They will Michel has a base at devices, typewriters and other Graham and Larry started make a leather jacket for you in Mitcheldean as well as at Venray products are recycled here, not work at 7.30am. had an hour for three hours." said Larry.) and Lille, and his area of just for the domestic and South lunch, and finished at 5pm — Graham made a trip to operations covers not only Europe American market but for the USA officially. But with meetings Mazatlan. a western coastline but also Modi Xerox and too. and there is a certain amount starting at 5pm every day, work resort one weekend. Larry went licensing projects in countries of new build activity. actually went on into the evening. further afield, flying east to the ranging from Egypt to China. The staff of about 1.600 are As for the weather, it proved Yucatan peninsula. Graham went out to Mexico mostly recruited from young, similar to our own, they told us. It Here he visited CancUn. a on three occasions — in June for local labour. "Smashing people, was warm and dry in June, but in newly created resort — its a fortnight, in July for a month, the Mexicans," said Larry. "They July and August (the rainy location, with a lagoon on one and again at the end of have a good work attitude." season) the temperatures were side and the Caribbean on the September, returning shortly "I found them very friendly." actually higher back in this other, was selected by computer! before Christmas. added Graham. "They appreciated country. Chichen Itza, a restored site of This last time he was involved that we were there to help." Mexican food, however, is the ancient Maya/Toltec cultures, in the co-ordination of audit lab. Their language is Latin consistently hot. with chillies provided a very different activities with a staff of 28. "We American Spanish, and only a few featuring strongly. "And their experience. had Indians. Brazilians. speak English, so the PQA team chips are very different from ours, On another occasion, they Columbians, Venezuelans, worked with the help of as I soon found out." said went to Guanajuato, once Canadians as well as Mexicans in interpreters, going through all the Graham. Mexico's most prominent town the plant — it brings home to you processes with operators on the But with restaurants offering and a former silver mining centre. just how multinational the line. Japanese, German, Italian and The mines are now mainly Seen with the multinational team in the PQA lab at Agiiascalientes are (seated other international fare, there was disused and the tunnels have been far left) Graham Cooper and (centre) Larry Williams. plenty of choice. converted into subterranean Aguascalientes town (about roadways. the size of ) is situated This place is also famed for its on flat ground, but forming a museum, where the rather backdrop to the plant is a range of gruesome exhibits are corpses, mountains, called The Sleeping some 100 years old. Giant on account of their shape. They had been buried in their Both Graham and Larry made normal clothes and had been trips into the mountains, where preserved by the chemical there are puma and lynx as well properties in the soil of the local as deer "but we didn't see any." cemetery! Talking of wildlife, on one The PQA re-certification and re• visit to the mountains Larry saw training exercise is ongoing and we some bandits on horseback, their hope to be able to piihlish further bandoliers slung across their features in 'Vision' about chests! assignments in e.xotic places. 9 CBA new build before joining the of the Labour Party. recycling department. "It was anything but a quiet life The only time he ever worked and 1 gave it up some five years Service awards on small copiers was for about six ago." months on the first of the 10 Series. He is still chairman of the George has served the union Cinderford branch of the GMBU Welwyn pilot plant for two years. movement, too, for a long time — but has retired from union work on "It was a good experience to take about 20 years. A GMWU shop site — "for a time anyway." the 5046 from design stage and help steward in the 2400 era, he was George is a dedicated follower bring it through and up the teaming made a full-time senior steward, a of Gloucester RFC. Last year he curve back at Mitcheldean," says post he held for a decade. and his wife Louise went across the John. "For three years I was a trade Channel to see play France On his return, he was appointed union safety co-ordinator and I in the championships. "But the only production engineering manager, particularly enjoyed that, carrying time we got to see the team was on mid volume machines. Then just out audits with management," he TV and in the bar. I'm going back over a year ago he took over told us. next year for the 1991/92 season technical responsibility for low He has led a busy life in the though." volume products, and this led to a community as well. At one time he George likes a game of 'don and visit to Japan for a quality was a crib' at his local. All his family sing workshop on the 5012/14 in January councillor, a member of Cinderford (there are strong connections with 1990. town council and vice president of Male Voice Choir) and John Ovei'hiiry "We're going to be very busy as the Soldiers & Sailors Club in though he has a strong bass voice, Cinderford, as well as being a he has resisted joining so far. "But 25 years new products in this range come along," he told us. representative in the West Midlands I'll willingly join in a sing-song," "IT WAS only going to be for 12 During his career with us, John region of the GMBU (as it is now he says. months." said John Overbury. has seen changes in the called) and the South West division Having completed his requirements for manufacturing apprenticeship with Dowly Rotol. engineers. "Instead of specialists in he had taken a 'temporary" job in a particular aspect, we need to have 20 years our former tool room while engineers who can cover the whole Making up the final group of people who qualified for 20-year awards in deciding on his future career. process, right down to the last 1990 are (from left in pictures below) Eric Woodman (fuser rolls). John Then a product engineer was label."' Pacey (recycling). Des Ellway (MED). Dave Sanderson (commodity needed in parts rrtanufacturing and Fly fishing was John"s main operations) and Glyn Howells (small hatch), plus Ruth Knight (itew build he applied, coming into MED as we sporting activity until he took up operations). John Maichant (ROS). Ernie Priest (fuser rolls). Dave know it today on the 2400/.3600 squash; then he switched to playing Richards (commodity operations) and Colin Worgan (recycling), who family. golf at . missed the photocall. In the '70s he spent 18 months Soon due for a 25-year award is in the USA as resident liaison John's brother Mike, who is a QC engineer for all EMO sites, and inspector. when he returned he brought with him the 4500 project, complete with Big as the CBA machines are in sorter. recycling assembly, six-footer It was while working on the (Jeorge Cresswell towers over CBA family of machines that he them as he carries out his job as spent a month in Bombay, along mechanical copy quality adjuster. with Colin Williams and Mike He is well used to large Smith, assisting IXS with the re• machines. After having started work assembly of 9500 machines shipped on the 914 line, he moved on to the out in kit form. 2400/3600 models as mechanical His next assignment took him to adjuster. He subsequently worked in

Fine finisln to tiie season

FOLLOWING THE cancellation Surprisingly, scoring was not The 'post dinner' speech and of the visit to Henbury GC, due as high as some anticipated and presentation of prizes were to a very poor response, it was the morning round was won by expertly handled by the captain encouraging to see 30 members Mark Barnard with 36 points off and the winners of his excellent on the starting sheet for the final his 2 handicap. Close behind in prizes were: best am round — outing of the year at the second and third places were vice Mark Bamard; best pm round — Worcestershire GC. Malvem, on captain Wilf Jones and Graham Dave Tyler; nearest pin (15th) — Friday. 14 September. Beach with 35 and 34 points Mike Hinton: longest drive (18th) Captain's Day is always respectively. — Dave 'Muscles" Robin.son. popular, but this year there were After a splendid lunch, it was The Summer Cup was won many prizes to be won. The back to the course which was with some consistent golf from captain, Dave James, had put up now made more hazardous by a Graham Beach, his scores being some prizes and the Team Cup stiffening breeze. two rounds of level par, 71 net was up for grabs — teams of The afternoon round also (142). Second equal were Mark three players, best two cards am contained some extra excitement Bamard and Denis Ede. and pm. with a 'nearest the pin' on the par The Team Cup, despite the The committee had also 3, 15th hole and a 'longest drive' calls of "fixed draw!", went to decided to carry the Summer Cup on the 18th hole, tempting Mark, Dave James and Dave forward to Malvem, in view of players to go for distance on this Tyler with an aggregate score of the Henbury cancellation. already difficult driving hole. 134 points. Runners up were Wilf Shirt-sleeve weather prevailed The afternoon scores were Jones, Graham Beach and Ivor as the morning began and it much the same as the morning Thomas on 127 points with Roy T

Wild about the West Fewer outings in 1991 a fly-drive ten-day holiday for two in Arizona last August. THE MAIN topic at the Golf help and commitment during a He and his wife Maureen Society's annual general meeting difficult year and wished the stayed, not on a dude ranch, but at held on 14 November was the society members success in 1991. a top class hotel in Old Tucson lower attendance levels during the The trophies and prizes were (pronounced 'too sahn'). "It's an year on society days out. presented by the captain to the old cowboy town kept in its Following earnest discussion, winners in the past season: Spting original state, where they make a proposition requesting the Bowl — Ken Ellway and Trevor westerns. We saw plantations of Jones; Order of Merit — Neil giant cacti in the area, some secretary to arrange three outings growing up to over 30ft," Brian for 1991 was carried by a small James; Scratch Cup — Dave told us. majority, the venues selected James; Powell Cup — Dave "We were even given a hired being: Hereford (19 April). Tyler; Summer Cup — Graham Chevrolet and spending money, Knowie (27 June), and Rolls of Beach; America Cup — Neil and were free to do whatever we Monmouth (16 September). The James; Team Cup — Mark Brian .'ia\s: "H()wdx.foll

A TEENAGE Mutant Ninja drag, with female outriders, Turtle, a punk fairy, a clown, brought it back by the bucketful. some St Trinian"s schoolgirls — Together with a raffle (the these were some of the odd prizes all being donated by characters to be seen in harness harness staff), naming-the-doll, assembly on 23 November when sponsored multi-colour hair staff repeated their charity drive spraying and other imaginative of two years ago for Children in efforts, a total of £1,400 was Need. raised, nearly double their earlier Collections from other achievement, reported Pam departments on site had been Heathcote who acted as co• made, and six men in (sponsored) ordinator. The girls who kepi quiet about their charity effort — Amanda Buffrey and Karen Jones — with spokesperson Mandy Laskey. their lips were sealed

"THE MEN kept telling us we'd Their sponsored silence was never keep it up — but we did!" indeed golden — it enabled them said Karen Jones and Amanda to raise around £179 for the Buffrey triumphantly. Children in Need appeal which From lOam to 12.30pm on 16 they collected solely from the November they never said a word. recycling floor in building 3/2. Colleague Mandy Laskey acted as their spokesperson in 5046 recycling sub assembly.

A novel Type of workwear in harness assembly'

He also pointed out: "People don't realise that you can still be A drive to cut casualties 'over the limit' even after eight hours' sleep if you've had more THE BLUE lights flashed as at home. Rank Xerox various statistics alerting people than four pints of ordinary beer police cars, an ambulance and a Mitcheldean fully supported to the dire consequences of the night before." fire & rescue vehicle converged Gloucestershire's efforts in the drinking and driving were outside building 7. national campaign for road highlighted. A team in protective gear safety. The unit was on site for two Obituaries worked to free 19-year-old Further backing up the days before touring the county, WE REGRET to report the deaths secretary Cathy Ellsmore from initiative, all health education and everyone visiting it was of the following retired her wrecked car and she was boards on site were promoting given a 'Better driving course' employees: Jock Cruickshank on 11 carried away on a stretcher. safe driving. pack with lots of facts and November aged 79. He joined as a figures. Then she returned to her Shock tactics were employed storekeeper, later becoming a work in the training department in the mobile exhibition unit Senior road safety officer progress chaser, shop loader and with nothing worse than a pair which the Gloucestershire Garry Handler also offered finally a member of production of damaged tights. Constabulary had brought along some sound advice. "Counting control department, where his wife By posing as a seriously with them. units is dangerous because so Ellen also worked. He had clocked injured driver in a smash-up — The centrepiece was a gift- many factors affect the risk. If up nearly 28 years' service when staged for the benefit of the wrapped coffin among an array you drink at all, don't drive," he he retired in 1975: Ellen retired some 12 months later after 16 media. Cathy was doing her bit of Christmas presents and said. years' ser\'ice. His son Gordon, to help launch Gloucestershire's cost accounting manager in Smash 'victim' Cathy Ellsmore is extricated from the wrecked car. Drink/Drive Campaign on 4 finance department, told us that December at Mitcheldean. Jock had suffered greatly from Senior officers of the three arthritis and was eventually unable emergency services were to get about at all. present at the launch and each Cyril Hinton on 1 December said a few words to drive home at the age of 75. He took early the message. retirement in 1980 after eight years with us, working in As well as aiming to increase assembly. public awareness, chief Ted Matthews on 8 December superintendent Joe Skipsey aged 69. 'Big Ted', as he was warned that the police were known, joined us in 1948, and stepping up their action to worked as a grinding setter protect road users from the operator in the machine shop, drinking driver. becoming a leading hand. He was Speaking on behalf of a member of the LSA committee RXMP, Des Halliday said that when in 1976 he decided to retire on account of ill health. His wife as a company keen to promote Eva also worked at Mitcheldean awareness on all aspects of and was in engineering depanment health and safety, not only at when she retired. 12 work but also while travelling or