Six Stages of New Product Development

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1

Product dimensions or product sample sent to KE.

2

Develop 3D CAD prototype drawing for client review and approval.

3

Produce product sample for client approval. Provide product options and estimate.

4

Conduct load, movement, and stability tests.

5

Product is submitted for client final approval.

6

Mass production begins and product is shipped to local warehouses.

OUR SERVICES
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KE has more than 40 years’ experience in designing photocopier stand solutions. Our team works closely with our clients to ensure all of their needs are met. We continually invest in the most modern design technology to provide optimum efficiency and total customer solutions. 3D modeling technology allows us to supply our clients with accurate, computer generated models in order to meet their often tight launch deadlines.

  • Design and engineering
  • New product development
  • Manufacturing, low and high volume
  • Production and logistics cost evaluations
  • Assembly instructions and manuals available in multiple languages
  • Global supply chain solutions and logistics
  • Quality assurance
  • Global technical support
MANUFACTURING
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KE flexible, automated facilities ensure high quality and quick delivery

The main stages for the production of the sheet steel components used in the photocopier cabinets are stamping, punching, forming, MIG & TIG or spot welding, a five stage iron phosphate pre-treatment process followed by fully automated electrostatic powder painting.

Significant investment has been made in metal stamping, folding and plastic mold tooling to ensure all products meet and maintain our client’s high quality standards at a competitive price in a global market.

Powder Coating:

Our factories are equipped with fully automated, 5 stage, Iron phosphate pretreatment, fully automated reciprocators, on line booth, including powder recovery sieve and recycle facility, 103 meter conveyor tracks with curing oven on line. Auto electrostatic powder coating, paint thickness between 60 – 90 microns as specified. Offline booth available for smaller quantities and prototypes. KE color matching standard +/- 0.5 delta e (LAB scale).

Assembly:

Our Automatic assembly lines incorporate:

Full electro mechanical and pneumatic assembly

Threaded insert and riveting for pre or post-powder coating operations

Roller conveyor packing line.

Facilities to palletize and stretch wrap larger quantities of products.

Tooling:

Metals

Depending on the volume and expected product life, KE produces sheet metal products by NCT Production or Power Press Stamping using hard tooling. We can design and manufacture our own or utilize client tooling.

Plastics:

For high volume products KE offers Plastic Injection Molded components to reduce product costs, and we design tooling in-house with our manufacturing partners.

Typical product volumes in excess of 6000 units per year are sought to recover initial tooling costs.

Vacuum forming is used for medium-product volumes, with lower-cost tooling.  Products are non-rigid and so we incorporate metal for strength where required.

DESIGN / ENGINEERING
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KE Group has more than 40 years’ experience in designing photocopier stand solutions and our design team works closely with our clients to ensure their needs are met, often to comply with tight launch deadlines. We continually invest in the most modern-design technology to provide optimum efficiency and total customer solutions.

KE offers our customers the most efficient and effective route to cabinet production. Our design, development and production teams work from initial concept through to prototype and finally to finished product, completing full product performance testing in order to ensure total quality and customer satisfaction.

3D modeling technology allows us to supply our client’s needs accurately, quickly and efficiently.

Our project management solution approach, from design concept through to competitively priced, quality-assured products, gives our customers distinct advantages in the market place.

Standard Options:

Doors: A wide variety of door designs are available.  When sufficient product volumes are available, KE can provide cost savings to the client by producing high quality plastic doors.

Locating pins and brackets: KE provides a positive location for the machine on the cabinet using steel pins that attach using threaded inserts. Custom brackets are available to enable machine and peripheral accessory attachments (such as collators) to attach to the cabinet.

Stability Equipment: KE engineers, in conjunction with our clients, ascertains the requirement and design of stability feet. Plastic or metal feet of varying designs can be offered to suit different aesthetics and performance criteria. KE offers fast fit, clip-in stability feet with no screws required. Adjustable leveling feet are also available, if required.

Casters: Standard KE casters are rated between 60-80 kg load bearing capacity (LBC) each, depending on performance requirements.

  • Caster body available as field replacement part
  • Twin locking casters as standard on KE products to prevent accidental movement of cabinet
  • KE cabinets only use high strength, virgin nylon casters
  • Strong caster peg plates are riveted to a steel base

Weather robust castors are also available (80kg LBC) to prevent failures in very cold climates (down to -15 degrees C)

Hinges: KE offer a range of different hinge arrangements to suit customer needs.

SUPPLY CHAIN / LOGISTICS
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Our logistics department configures custom-tailored solutions to minimize transport costs, including the use of high-cube containers. We can handle your delivery via road, rail, sea or air anywhere in the world. KE offers:

  • Shipments from local warehouses
  • Custom-sized pallets to ensure minimum use of warehouse space / maximum units per truck
  • Each product marked with batch number to ensure traceability
  • Proven capability in local and worldwide logistics with strong partnerships with 3PL providers
  • We move over 400 TEU per year
  • Specific time slots and daily deliveries are available

KE Packing:

Complete packaging solutions are available from purpose-built cartons and fittings to inexpensive wrapping options to suit customer needs.

When required, the suitability of packaging is subject to product carton drop tests to PIRA ASTM Standard D5276, to ensure contents remain undamaged during transit. KE uses only high-quality materials & optimized packing design.  Carton markings and labels are designed to individual OEM requirements including bar code labeling.

Boxes are stacked to an agreed-upon height. The stack is cling wrapped to form a rigid load for safe onward shipping.

QUALITY / ENVIRONMENT
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KE Group regards quality as paramount in all that we do. Quality assurance and traceability are intrinsic to the way we work – ‘right first time – every time’.

The KE Group has been registered by BSI to ISO 9001 since August 1993 – Registration Number FM25212. The quality management system has been audited and approved by our leading global clients.

KE Group has made considerable investment in a new, integrated manufacturing system. All members of the KE Group have the collective responsibility to satisfy our high standards. Attention to detail, careful planning and use of the state of the art technology and systems ensure successful project management. New product designs, including packaging, are developed and tested to ensure client satisfaction and confidence. Products are designed and manufactured from high quality materials, to strict supply specifications.  Where applicable, we comply with all International regulatory standards (e.g., UL, NSF, CE,CB, RoHS, REACH, EMC & RF approvals.)  Agreements with recognized test agencies means that type test requirements can be carried out to prove products are designed and meet regulatory, safety and customer-required standards. The manufacturing and inspection controls throughout the manufacturing process ensure reliability, repeat-ability and interchangeability of product and components.

Testing:

Load testing, dynamic, stability and tilt testing available on-site. Full electro-mechanical testing facilities are available at our factories to ensure compliance to electrical standards. Final inspection packing and dispatch are coordinated on-site, so our customers are assured products will arrive at final destination in prime condition.

Environment:

KE is aware of our responsibility to the environment and climate. From recycling materials to reduction in energy usage, there are always new initiatives being pursued within our organization. All KE cabinets and packaging are 100% recyclable. The company promotes environmental awareness in all areas of the business. Recent Investments include:

  • Energy saving factory lighting
  • Electrically driven press brakes
  • Reclaim powder process
  • Recycled cardboard
  • Recycled paper
  • Recycled metal
  • Returnable / re-usable packaging
  • ISO14001 Approved Manufacturing