Remanufacturing: Difference between revisions

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In 1995, the [[United States Environmental Protection Agency]] (EPA) implemented the Comprehensive Procurement Guideline<ref>{{cite web|url=http://www.epa.gov/osw/conserve/tools/cpg/index.htm|title=Comprehensive Procurement Guidelines - Conservation Tools- US EPA|publisherdate=15 November 2016 }}</ref> (CPG) program to promote waste reduction and resource conservation through the use of materials recovered from solid waste, and to ensure that the materials collected in recycling programs will be used again in the manufacture of new products. The EPA is required to designate products that are or can be made with recovered materials, and to recommend practices for buying these products. Once a product is designated, state and federal procuring agencies are required to purchase it with the highest recovered material content level practicable.

== Range of products being remanufactured<ref>{{cite web|url=http://reman.org|title=The Reman Institute-Home|publisher=}}</ref> ==

* Aerospace

* Air-conditioning units

* Gaming Machines

# '''Remanufacturing without identity loss''' With this method, a current machine is built on yesterday’syesterday's base, receiving all of the enhancements, expected life and [[warranty]] of a new machine. The physical structure (the [[chassis]] or frame) is inspected for soundness. The whole product is refurbished and critical modules are overhauled, upgraded or replaced. If there areAny defects in the original design, they are eliminated. This is the case for customized remanufacturing of machine tools, [[airplane]]s, computer [[Mainframe computer|mainframes]], large medical equipment and other capital goods. Because of its uniqueness, this product recovery is characterized as a project.

# '''Remanufacturing with loss of original product identity''' With this method, used goods are disassembled into pre-determined [[Manufacturing|component]]s and repaired to stock, ready to be reassembled into a remanufactured product. This is the case when remanufacturing [[automobile]] components, [[photocopier]]s, [[toner]] cartridges, furniture, ready-to-use [[camera]]s and [[personal computer]]s. Once the product is disassembled and the parts are recovered, the process concludes with an operation notsimilar too different fromto original manufacturing. Disassembled parts are inventoried, just like purchased parts and made available for final assembly. Remanufacturing with loss of original [[brand|product identity]] encompasses some unique challenges in [[Field inventory management|inventory management]] and disassembly sequence development. Some of the open questions relate to the commonality of parts in products of different generations, the uncertainty in the supply of used products, and their relationship with [[production planning]]. The [[National Center for Remanufacturing and Resource Recovery]] (NCR3) at [[Rochester Institute of Technology]] ([[New York (state)|NY]]) is researching remanufacturing processes including testing standards for remanufactured products.

# '''Repetitive remanufacturing without identity loss''' In this method, there is the additional challenge of scheduling the sequence of dependent processes and identifying the location of [[inventory]] buffers. There is a fine line between repetitive remanufacturing without loss of identity and product overhaul. Again, the critical difference is that remanufacturing is a complete process. The final output has aan likeas-new appearance and is covered by a warranty comparable to that of a new product.

'''<big>Remanufacturing by Recoating of Worn Engine Parts</big>'''

In addition to these is a less significant type of remanufacturing, ''remanufacturing by recoating of worn engine parts.'' This type of remanufacturing serves many engine parts and other large and expensive components that become worn after a period of use. An example of such a part is the engine block, in particular the cylinder engine bores, which must withstand explosions during piston firingcombustion. Instead of disposing of large engine blocks, remanufacturing has resulted inenables re-use of the parts by coating them with plasma transferred wire arc spraying ([[PTWA]]). Remanufacturing by recoating of parts is also very popular in theaviation aircraftand field, thewith geothermal pipe field and the automotive engine field.

'''Rebuilding''' is an old name for remanufacturing. It is still widely used by automotive industry. For example, the [[Automotive Parts Remanufacturers Association]] (APRA),<ref>{{citeCite web|url=httphttps://www.apra.org//|title=Automotive Parts Remanufacturers AssociationAPRA|publisherwebsite=apra.org}}</ref> have the new term in their name, but to be safe on their own website use the combined term 'rebuild/remanufacture'.

The term 'rebuilding' is also often used by [[railway]] companies; a [[steam locomotive]] may be rebuilt with a new [[boiler]] or a [[diesel locomotive]] may be rebuilt with a new [[Diesel engine|engine]]. This saves money (by re-using the frame, and some other components, which still have years of useful life) and allows the incorporation of improved technology. For example, a new diesel engine may have lower fuel consumption, reduced exhaust emissions and better reliability. Recent examples include [[British Rail Class 57]] and [[British Rail Class 43 (HST)#Life extension of HSTs|British Rail Class 43]].

# '''Lower Cost''' - One of the biggest factors in choosing a remanufactured engine is cost. Remanufactured engines cost up to 50 percent% less than a new Tier 4 Final engineengines, not including associated engineering costs, and offers even greater savings over the purchase of a new piece of equipment. Maintenance on some new Tier 4 Final engines can be costly as well. In addition to being more complex to service, additional costs for after treatment cleaning and DEF fluid can add up quickly.<ref name=":0">{{Cite web|url=http://www.forconstructionpros.com/article/12189610/4-reasons-why-rental-fleet-owners-should-take-advantage-of-engine-remanufacturing|title=4 Reasons Why Rental Fleet Owners Should Take Advantage of Engine Remanufacturing|access-date=2016-08-08}}</ref>

# '''Less Downtime''' - Opting to replace your existing engineengines with a new oneones typically requires significant engineering time that can render rental equipment out of service for months. The integration and testing process also takes significantly longer with a new Tier 4 Final engine than with remanufactured engines.<ref name=":0" />

# '''Increased Equipment Resale Value''' - There are two main factors currently making it difficult to sell Tier 4 Final-powered equipment in lesser regulated countries: serviceability and fuel availability. The lack of established service programs for the new technology makes supporting the product difficult. This coupled with high product costs, have companies shying away from Tier 4 Final powered equipment. In addition, many lesser -regulated countries don’tdon't have high availability for ultra-low sulphur diesel fuel, which is required by Tier 4 Final engines to operate effectively. Without it, the diesel particulate filter can clog rapidly and cause significant operation issues.<ref name=":0" />

# '''More Sustainable Option''' - Purchasing a remanufactured engineengines keeps an old engine corecores and many usable components out of a landfilllandfills, which can greatly reduce the impact on the environment. According to Perkins Pacific’sPacific's Andy Machin, approximately 73 percent% of the old engineengines can be salvaged during the remanufacturing, process savingkeeping millions of pounds of waste out of landfills. New engine production requires all new materials, substantial amounts of energy for the production process and additional transportation costs. By utilizing recycled components, a remanufactured engine typically uses about 80 percent% less energy than new engine production, making it a much greener option. For rental fleet owners, remanremanufacturing offers the opportunity to expand their sustainability practices while saving money.<ref name=":0" />

* [http://www.apra-europeapraeurope.org/main.php apra- europe.org]