Ricoh Reduces Inspection Time By 94% with Zebra’s Handheld RFID Readers
Ricoh Co., Ltd., a major Japanese manufacturer of multifunction printers, faced challenges with human error and lengthy inspection times during the product warranty process. To improve efficiency, Ricoh implemented RFID technology to enhance inspection processes.
Zebra Success Story: Ricoh
Overview: Manufacturing Challenge
Ricoh previously relied on inspection methods using SD cards and QR codes. With the introduction of Zebra’s RFD8500 handheld RFID reader, Ricoh has achieved a significant increase in inspection accuracy and a reduction in inspection time, allowing frontline workers to focus on more strategic tasks.
Benefits / Outcomes
- 94% reduction in operation and inspection time
- Improved process and delivery quality
- Contributes to reduction of environmental impact such as reduction of packaging materials
Customer
Ricoh Company, Ltd
Tokyo, Japan
Industry
Manufacturing
Solutions
About Ricoh
Ricoh Company, Ltd. is a major Japanese multifunctional printer (MFP) and copier manufacturer that provides digital services, and printing and image solutions to a global customer base. Ricoh provides digital transformation support for businesses through MFPs, 360° cameras and other unique software solutions. Its goal is to help other companies maximize business results.
When shipping MFPs, Ricoh performs logistics processing (logistics base + manufacturing base) to improve delivery quality. Instead of assembling products at the customer's site after delivery, Ricoh tailors and assembles products in advance, set to each customer's requirements and then ships directly. This helps improve delivery efficiency, and reduces the amount of packaging materials needed for shipment, thus reducing impact on the environment. In this workflow, many different types of jigs and tools are used for product assembly, and it’s important to conduct periodic inspections to ensure consistent tool quality.
The Challenge
Previously, SD cards were used to install and inspect data inside the delivered products. The number of cards required depends on the product model. Some need as few as three, others require as many as 40. A production line for multiple models requires the management of a considerable number of cards. Prior to 2018, the system was managed and operated by visual checks using paper-based inspection forms. This method was time consuming and prone to manual errors and omissions. To address this issue, QR codes were attached to the SD cards, and inspections were performed using a QR code-reading system. While this method had its benefits, it also took longer than the conventional visual inspections.
We considered readers from three other manufacturers, but considering Zebra readers could also be used in overseas factories, and Zebra is a top global supplier that meets the regulations of each country and has excellent availability and support, we knew they were the best choice.
The Solution
Following its previous inspection systems, Ricoh considered ways to further improve operational efficiency. It decided to focus on RFID, which is widely used in logistics and sales. The new inspection system now operates by attaching RFID tags to each SD card, which can be instantly and accurately read by Zebra RFD8500 readers. The RFID reader does not read individual objects like a QR code, it covers an area where many objects are located. The RFD8500 reads all RFID tags at once by holding it over the area where many tags are placed. The readers, equipped with a third-party device and an application that was created in-house, digitalizes the inspection process and reduces the amount of space required for storage of inspection forms.
“In selecting Zebra’s RFID tag reader, we placed importance on its ability to capture tags stably and quickly in any environment,” said Yu Furusawa, Head of Digital Products Business Unit, Ricoh. “Another benefit was its worldwide availability. We considered readers from three other manufacturers, but considering Zebra readers could also be used in overseas factories, and Zebra is a top global supplier that meets the regulations of each country and has excellent availability and support, we knew they were the best choice.”
The following criteria were used as reasons for selection, keeping in mind that the system should be usable on a global basis.
- Multi-OS, multi-platform support
- High-speed capture of RFID tags in diverse environments (Supported standards: EPC Class 1 Gen 2, EPC Gen2 V2)
- Easy switching between RFID scanning and barcode scanning
- Can be deployed worldwide:
Frequency range / RF output
USA: 4.5 to 34.5dBm
Europe: 4.5 to 34.5dBm
Japan (LBT): 4.5 to 33dBm
Japan: 4.5 to 27.5dBm
The Zebra Difference: Outcome and Benefits
The most noticeable results of the new inspection process were a significant reduction in work time and improvement in process quality. The time required to visually check and manually complete the inspection form totaled about 223 minutes per month. Additionally, the time required by the QR code reading system was about 427 minutes per month. The new RFID-based inspection system only requires about 13 minutes per month, a 94% improvement.
In terms of process quality improvement, when inspection sheets were used for visual checks by human operators, there were cases of leakage to the market due to omissions such as removal of SD cards, etc. However, by using RFID and applications to identify inspection results, leakage to the market due to omissions such as removal of SD cards has been eliminated.
Currently, three distribution centers in Japan (Gotemba, Kawasaki and Osaka) are conducting digital inspection with RFID. In addition, the company has adopted Zebra Technologies' RFID handheld reader, which can be used globally, and is aiming to expand its business to overseas bases.
