Ink Manufacturing IOP Meeting 9/15/2010

Reduce Variation 9 th type of waste - Variation Constant change – Moving target Greatly reduce the chance of finding the Root Cause What was the original reason for the ink change?

Ink Type Variations Tack variances within same ink type Pigment loadings (Toner) Varnish Types Oil Type Tack variances within same ink type Pigment loadings (Toner) Varnish Types Oil Type

Work Content Matrix Ink

Insert Series Early 2010 – 5 Insert Ink types

Insert down to 3 types 2010 Current State Going to single insert formula

Future Condition

Conditions that Effect Ink Performance Variables that can make an ink perform poorly Temperature Fountain Solution Misc. Press Variables

Temperature Fountain Solution Blanket Plate Roller Settings –Ink Ball –Vibrator

Fountain Solution pH Conductivity Surface Tension Bacterial Growth Water Setting

Misc Variables Paper –Alkalinity/Acidity –Paper surface Blanket Condition Plate Condition Job Coverage –Light/Heavy

Door to Door VSM (high level)

CRT Raw Materials Purchased Bulk Resin Solutions Dispersion Vehicles Dry Pigment Oil Wax Manufactured Varnish Pigment Dispersion Ink PMS Ink Jet

Varnish Raw Materials Resin 5365 #1 used Solution this year CRT sets specs Measure and Compare

Cloud Point Testing Cloud Point temperature is measured by the Supplier CRT 35 Rail cars = 6.3 million pounds of solution 1. Resin solution 2. Res. soln. & oil mixed via Flacktek prior to testing 3. Test solution at 230 °C (note the clarity as the stir bar is visible) 4. Following the test: the res. soln. crashed out of the oil

Dispersion Raw Materials Pigment Carbon black – 100% 1 supplier Yellow – 90 percent 1 supplier Red – split between 2 supplier Blue – split between 2 suppliers Dispersion Vehicle 3 suppliers Project for making our own in the future

Dispersions Measurements Bleach for strength Viscosity of finished dispersion Grind check Draw down compare against STD –L^A^B values calculated for DE94 –Gloss

Pigment Particle Size Method development being designed for –Yellow –Red Black is showing good signs of repeatability Blue was proved out in a RCA project.

PSA Particle size distribution of Cyan after one pass milling (retain from ink made same time that Rock had piling issue) Mean size: 410nm Median size: 170nm Problematic particle size distribution with blue

PSA (cont) Particle size distribution of Cyan after double milling Mean size: 174 nm Median size: 161nm Desired particle size distribution with blue

Overlay comparison Yellow line—problematic (with tail at larger particle size) Red line------improvement made PSA (cont)

Ink Measurements Tack Viscosity L^A^B Grind Opacity

| 23 DE 94 I DK1001MD through

| 24 Tack DK1001MD through

| 25 Viscosity DK1001MD through

| 26 Variation prevention Gauge R&R of instruments Standard work in Manufacturing –Ink –Varnish –Dispersion Standard work in the Lab QC process Q4 Database

Gauge R&R Type 1 Gauge R&R Gloss Meter Densitometer Shell Cup More to come… A Type-1 GR&R (1x1x25) was conducted to validate the test since the manufacturer does not perform the test The GR&R was successful as the %Var(Repeatability) was < 30 % (26.65 %)

Standards for 59 Ink Making Steps Each standard follows the “check do check” Total Quality Management standard. Check do Check

Q4 Problem Solving Q4 (A3) data base set up and trained to create a “problem solving” culture.