1. Ink Manufacturing IOP Meeting 9/15/2010

2. 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?

3. 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

4. Work Content Matrix Ink

5. Insert Series Early 2010 – 5 Insert Ink types

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

7. Future Condition

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

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

10. Fountain Solution pH Conductivity Surface Tension Bacterial Growth Water Setting

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

12. Door to Door VSM (high level)

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

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

15. 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

16. 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

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

18. 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.

19. 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

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

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

22. Ink Measurements Tack Viscosity L^A^B Grind Opacity

23. | 23 DE 94 I DK1001MD 6-1-10 through 8-5-10

24. | 24 Tack DK1001MD 6-1-10 through 8-5-10

25. | 25 Viscosity DK1001MD 6-1-10 through 8-5-10

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

27. 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 %)

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

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