Remanufacturing: a key strategy for sustainable development

Remanufacturing is a process of bringing used products to "like-new" functional state with warranty to match. It recovers a substantial proportion of the resource incorporated in a used product in its first manufacture, at low additional cost, thus reducing the price of the resulting product. The key remanufacturing problem is the ambiguity in its definition leading to paucity of knowledge and research in the process. Also, few remanufacturing tools and techniques have been developed to improve its efficiency and effectiveness. This paper addresses these issues by describing the findings of in-depth UK case studies, including, a robust remanufacturing definition and an analytic model of the generic remanufacturing business process for improving remanufacturing knowledge and expertise

What makes cleaning a costly operation in remanufacturing?

Part of: Seliger, Günther (Ed.): Innovative solutions : proceedings / 11th Global Conference on Sustainable Manufacturing, Berlin, Germany, 23rd - 25th September, 2013. - Berlin: Universitätsverlag der TU Berlin, 2013. - ISBN 978-3-7983-2609-5 (online). - http://nbn-resolving.de/urn:nbn:de:kobv:83-opus4-40276. - pp. 219–223.Product remanufacturing is a widely accepted product reuse strategy in most industries due to its unique advantage of retaining a greater portion of added value in the initial manufacturing stage. Remanufacturing involves a sequence of operations including disassembly, cleaning, inspection, parts replacement, reassembly and testing. Previous research has shown that the cost of cleaning is only second to the cost of parts replacement. The objective of this study is to illustrate the significance of the cleaning operation in automotive remanufacturing and to identify the factors influencing the cost of the cleaning process. Case studies on four UK remanufacturers, three automotive and one copier, were carried out. Seven key factors causing high cleaning costs were identified and categorised under two dimensions. These are the technical nature of the products and processes of cleaning and the business nature of the remanufacturer

Human resource strategy in disassembly for remanufacturing

Studies on product disassembly for remanufacturing using strategic perspective have been overlooked in current studies. This research uses a strategic approach to examine how product, process and organisational design affect disassembly strategies among different remanufacturers. Three companies that consist of two automotive and one jet engine remanufacturers have been selected as subjects. A case study approach using qualitative data has been adopted to examine how remanufacturers design their disassembly strategies. Our analysis revealed that the two major factors influencing disassembly strategies are product complexity and the stability of supply of cores

End-of-Life decision tool with emphasis on remanufacturing

Remanufacturing is a product recovery strategy resulting in end-of-life products being returned to as new condition or better and receiving a warranty at least equivalent to the original. To differentiate remanufacturing from other forms of product recovery, a clear definition of a remanufactured product is essential. At present two distinct methods for understanding end-of-life recovery strategies exist; a) the use of tools and b) definitions. These current methods fall short however of categorically stating what is and what is not a remanufactured product. Therefore, the responsibility of classifying a product as remanufactured is left to individuals and organizations and so potential exists for products to be incorrectly labelled. By firstly examining the problems associated with using existing methods to determine the status of end-of-life product, and why product identification is important, this paper then goes on to present a new simple innovative method to quickly and accurately determine the status of a product which has undergone an end-of-life recovery strategy, by virtue of a bespoke tool. The tool presented is the result of two rounds of academic and industrial feedback; an initial tool was presented, and underwent critique, at the International Conference on Remanufacturing 2015 with an updated tool then subject to another independent review from academic and industrial stakeholders. The main benefits associated with this tool are, a) a quick way to identify the status of a product, b) a method for researchers to quickly determine the best terminology for end-of-life products which have received a recovery treatment, c) a quick and reliable method to check whether a remanufactured product is labelled as something else, d) an additional way to ensure compliance with existing legislation and standards, and e) an identification of only the essential characteristics of a remanufactured product

Addressing decision making for remanufacturing operations and design-for-remanufacture

Remanufacturing is a process of returning a used product to at least original equipment manufacturer original performance specification from the customers' perspective and giving the resultant product a warranty that is at least equal to that of a newly manufactured equivalent. This paper explains the need to combine ecological concerns and economic growth and the significance of remanufacturing in this. Using the experience of an international aero-engine manufacturer it discusses the impact of the need for sustainable manufacturing on organisational business models. It explains some key decision-making issues that hinder remanufacturing and suggests effective solutions. It presents a peer-validated, high-level design guideline to assist decision-making in design in order to support remanufacturing. The design guide was developed in the UK through the analysis of selections of products during case studies and workshops involving remanufacturing and conventional manufacturing practitioners as well as academics. It is one of the initial stages in the development of a robust design for remanufacture guideline

Design-for-Testing for Improved Remanufacturability

By definition, a remanufactured product must perform to the same (or higher) level as the original product, and must therefore be issued a warranty of the same (or longer) duration. However, many components of remanufactured products will have been subjected to regular stresses in their first cycle of use and may exhibit unseen signs of damage at a microstructural level. This may not affect the remanufactured product’s performance initially but could cause it to fail before its renewed warranty expires. To combat this, we propose that the integrity of individual components is assessed non-destructively before storage. However, lack of remanufacture specific tools and techniques; particularly non-destructive tools, are major hindrances. Furthermore, ease of non-destructive testing (NDT) is not currently a consideration in the design of components; components with complex geometries may therefore be difficult to test. This paper presents, for the first time, a framework for including NDT suitability as a design criterion at the outset in the component’s lifecycle, where the geometry and surface accessibility of the component are optimised for future assessment. Ensuring that components can be easily inspected would not only allow increased confidence in the structural integrity of remanufactured products, but it would also extend the range of products suitable for remanufacturing. This paper serves as a proof of concept, examining simple inspection scenarios in order to demonstrate how the shape of components and data acquisition geometries can adversely affect the coverage of ultrasonic NDT

Risk assessment for circular business models : a fuzzy Delphi study application for composite materials

Circular economy (CE) implementation requires the transition from linear business models (BMs) to circular ones, with related uncertainties and multi-disciplinary risks, which often discourage organisations. However, there is still a lack of understanding of risks associated with this process. This work thus aims to identify, classify and prioritise key risk factors for innovative circular BMs in order to enable the development of appropriate risk management strategies. A fuzzy Delphi method was tailored to assess the risk factors obtained from the literature and was applied to the industrial case of composite materials. 24 major risk factors for innovative circular BMs were identified and classified into six categories. The probability and impact of the risk factors were evaluated by experts and the risk factors were then ranked by calculating their risk scores. The resultant major risks appeared to be related to the external context in which organisations operate. Among those risks, the greatest were those generated by take-back systems and low customers’ acceptance of CE products. This research is the first to address risks for circularity in a structured way and contributes to the field of CE by providing an extensive list and classification of risk factors for innovative circular BMs as they are perceived by industry, acting as a reference for academics and practitioners. Furthermore, it provides the first evaluation and prioritisation of risk factors within the CE domain, highlighting critical risks within the specific industrial context of composite materials and suggesting action priorities for the establishment of circular BMs

Incorporating remanufacturing into the end-of-life vehicles directive : current presence and the waste problem

Within the End-of-Life Vehicles (ELV) directive, various terminology and practices are outlined to ultimately divert waste from landfill, including reuse, recycle, recovery, treatment, prevention and economic operators. Remanufacturing terminology is not explicitly stated however. Further, leading global automotive remanufacturers, have recently agreed upon a collective definition of what constitutes automotive remanufacturing. With a view to establishing remanufacturing as a stand-alone process within the ELV directive going forward, this research analyses where remanufacturing is currently situated within the ELV directive, highlighting obstacles, with a strong focus on ‘waste terminology’, of directly incorporating remanufacturing into the ELV directive and presents guidance on incorporating remanufacturing moving forward. By ignoring the concept of waste, this study found that remanufacturing processes are generally classed under reuse, recycling and recovery terminology with remanufacturing also having a tenuous relationship with treatment facilities and economic operators. In addition to highlighting the issues caused by remanufacturing spanning across recycle and reuse terminology, by incorporating waste, this research also found that automotive associations definition of remanufacturing is not able to be incorporated into the ELV directive directly. A workable solution, taking both the objectives of the ELV directive and the view of the automotive associations into consideration, was however found, and is presented in this wor

Ultrasonic bulk wave measurements on composite using fiber from recycled CFRP

This study investigates the velocity profile for both a virgin carbon fiber reinforced plastic (v-CFRP) and a reused fiber CFRP (rf-CFRP) which exhibit quasi-isotropy; all samples have 3 iterations of symmetry type [0, -45, +45, 90]s. An isotropic virgin CFRP (v-CFRP), produced by using a hand layup process, is presented along with a pyrolysis recycling process (at 600oC) designed to extract the carbon fibers. A virgin carbon fiber mat with a similar architecture was also thermally conditioned under the same pyrolysis conditions. Both resultant carbon fiber mats were used to produce the rf-CFRPs. Ultrasonic wave velocities at different angles of incidence for both v-CFRP and rf-CFRP were recorded. In the case of v-CFRP, two samples were studied and it was recorded that the velocity for both a longitudinal wave and transverse wave remained relatively constant up until these waves completely attenuated at observed angles, indicating what would be expected from an isotropic sample. A close relationship in terms of waves speed was also recorded for the two v-CFRP samples. In the case of rf-CFRP, the longitudinal wave velocities were generally less closely related when compared to the v-CFRP, with a maximum of approximately 32% difference being recorded. The transverse wave velocity was also found to decrease incident angle indicating sample anisotropy. The authors suggest that the more severe decreasing velocity with increasing incident angle, when compared to v-CFRP, may be caused by resin impregnation issues and not by changes that occur during the recycling process. Therefore, a hypothesis that both the rf-CFRP and the V-CFRP will return a similar wave profile given an identical resin fiber content is put forward

Building a holistic understanding of Reverse Logistics for SME Automotive Remanufacturers

Within global economies, there is a growing concern with regards to the excessive production and consumption habits of the manufacturing industry. Due to the scarcity of raw materials, the environment's inability to absorb residues and emissions, and the consumption needs of a growing population, present manufacture and waste patterns are not sustainable. This research is concerned with the development of an emergent product recovery strategy called Remanufacturing, where used/failed/obsolete products are returned to an as good as new condition through the reclamation and recovery of used parts. Through investigations with Remanufacturers in the UK, this research is concerned with how a Reverse supply chain infrastructure can be set up and controlled to ensure that used products can be collected from a customer site, transported to a remanufacturing facility for recovery, and consequently redistributed back onto the market. This paper presents the findings from the first stage of investigations where key operations, activities and processes have been identified, together with the management systems and strategic factors that underpin and control the overall Reverse Logistics proces