the remanufacturing headache

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The remanufacturing headache

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Post on 02-Jul-2015

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How can we understand what to expect, if we're hoping to remanufacture a product at the end-of-life? What condition will the parts arrive in, and when? Our simulation attempted to capture what really goes on, when products are out in "the wild".

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Page 1: The remanufacturing headache

The remanufacturing headache

Page 2: The remanufacturing headache

ContentsReduce, reuse, recycle...?remanufacturing to the rescue ?The remanufacturing headachetime to simulatescenarios consideredproblems identifiedconclusions

Page 3: The remanufacturing headache

Reduce

Reuse

Recycle

Page 4: The remanufacturing headache

Recycling.

Making cars out of old cars is a lot easier than making cars out of rock.

Problem solved?

Page 5: The remanufacturing headache

• Carbonconsequences

• Once scrap steel has been collected, heat it to melting point, around 1370°C

• To do this, most foundries use 500 to 800 KWh of energy per tonne

• Using grid electricity, emissions of 0.44528 kg CO2e per KWh...

• Which means 223 – 356 kg CO2e emitted to melt a tonne of steel

• Additional energy usage to shape the material into a new, useful product.

Page 6: The remanufacturing headache

The elephant in the room

Page 7: The remanufacturing headache

Remanufacturing to the rescue?Making products as good as new... or better: the £5bn industry you probably never heard about.

Page 8: The remanufacturing headache

• (Wikner & Tang, 2008)

the ‘closed loop’

Page 9: The remanufacturing headache

What about...

Impact upon primary manufacturing operations ?

Capacity requirements ?

Logistic consequences ?

Costs as well as savings ?

Sources of risk ?

Page 10: The remanufacturing headache

Time to simulate...

• Mathematical analysis could tell us approximately how many components we might expect to get back, but it won’t say anything about the timing of material flows.

Lost

Cannibalize

Refurbish

Sell immediately

Remanufacture

Recycle

Discard

Returned

Page 11: The remanufacturing headache

Make andship

Use

End ofLife

Install

Page 12: The remanufacturing headache

•RModel constructionockwell Automation, ‘Arena’

Page 13: The remanufacturing headache

•Rockwell Automation, ‘Arena’

Cyclicuse phase

Page 14: The remanufacturing headache

•Specifying the scenario to be explored in the simulation...

Page 15: The remanufacturing headache

Qua n

tity

Month

basic scenario

Page 16: The remanufacturing headache

shorter product redesign cycle

Quan

tity

MonthHigh volume demand period reduced to two years

No time for significant remanufacturing activity

Page 17: The remanufacturing headache

less durable product?

Quantity

MonthIncreased the risk of accidental damage to 1 in 20, each month

More remanufacturing, starting earlier

Page 18: The remanufacturing headache

extended reuse of components

Quantity

MonthComponent 3 continues to be used in a successor product

Page 19: The remanufacturing headache

further simulation work

Month

Products supp lied

Tota l pro ducts in s ervic e

•Modelling the total utility derived from the whole ‘fleet’ of products, over their useful life. Considering the energy and materials invested, does society get a good bargain?

Page 20: The remanufacturing headache

• remanufactured scooters, imported from india

Page 21: The remanufacturing headache

•The carburettor on the right was modernised, uprated.

Page 22: The remanufacturing headache

•Cylinder heads had been welded up, and drilled and tapped to take a new spark plug.

Page 23: The remanufacturing headache

•Cylinder barrels were drilled out, and fitted with a new sleeve.

Page 24: The remanufacturing headache

•Hubs simply weren’t round enough, and had to be replaced with new.

Page 25: The remanufacturing headache

•An engine mounting lug sheared off while one scooter was in use.

•Metal fatigue?

Page 26: The remanufacturing headache

•Teeth where the kick start lever engages.

Wear can be accommodated by packing the assembly with a suitable shim.

Page 27: The remanufacturing headache

Required...

manufacturing system that can accommodate

variations caused by recirculated materialcontrol over

the amount of things that come back, and whena

business model that is compatible with what actually

happenssupport from head office

a way to prove that remanufactured goods really are

remanufactured - not bodged

Page 28: The remanufacturing headache

ConclusionsRemanufacturing introduces considerable

logistic strainRelatively easy to do a little(maybe twenty percent) but much harder

to ‘close the loop’some expensive surprises for theill-preparedwe have not yet ‘saved the planet’

conc

lusi

ons

Page 29: The remanufacturing headache

Further articlesfrom Richard Farr at:

http://capacify.wordpress.com