Unanticipated Inkjet Cartridge Demand at Lexmark Leads to Rapid Deployment of Boneal Clean Room Assembly Plant.

Customer
Lexmark International

Customer Need:
Rapid capacity expansion of after market consumables to support new venture into inkjet printer market.

Project Summary:
Lexmark International, a laser printer manufacturer based in Lexington, KY, strategically entered the rapidly expanding inkjet printer market in the early 1990’s. Subsequently, Lexmark asked Boneal to provide high-volumes of cartridge bodies as a means of meeting exploding global demand. The project required:
1. Rapid installation and deployment of a large clean-room assembly plant.
2. Installation of dozens of computer controlled robotic assembly machines.
3. Assembly and assignment of engineering and maintenance team.
4. Collection of a significant labor force.

Result Summary:
Within 6 months of receiving contract award, several hundred-thousand dollars of Boneal capital had been invested. A 5000 square-foot Class 10,000 clean-room was operating 7 days per week at 24 hours per day. A complete engineering and maintenance staff had been assembled and over 100 hourly production workers were employeed. Completed cartridges were being produced at a rate of 250,000 per week. Sales for the first year of this project exceeded $10M.

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