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Energy Efficiency and Environmental Protection through Remanufacturing
Presented by Miriam Pye
Senior Project ManagerIndustry Research & Development
NYSERDA
Prepared by RIT’s National Center for Remanufacturing and Resource Recovery
Hundreds of millions of computers ... obsolete.
*National Safety Council
Each year, 500 million cubic feet of non-recyclable waste is generated from auto recycling activities.
The Problem: Environmental Trends
One Solution: Remanufacturing
The “Ultimate Form of Recycling”
What is Remanufacturing?
An industrial process in which
non-functional or retired products
are restored to
like-new or improved condition.
What is Remanufacturing?
– Primary components come from a used product– Product is dismantled – Condition of parts determined– Components cleaned and restored to original or
“better than new” specifications– Product is reassembled and qualified
Example: Office Chairs
Recycling:• Strip worn fabric and
convert to industrial padding
• Send metal frames to resmelting
• Form resmelted metal into a new product
Remanufacturing:• Replace fabric covers• Repair and repaint
metal frames• Replace worn-out parts,
e.g. fasteners
Remanufacturing vs. Recycling
Life Cycle of a Product
Conserves Energy - avoids energy requirements in raw material acquisition & processing, portion of manufacturing
manufacturing one new automotive starter requires more than 11 times more energy than remanufacturing a starter
Benefits of Remanufacturing
manufacturing one new starter requires more than 9 times more new material than a remanufactured starter
manufacturing one new alternator requires more than 8 times more new material than a remanufactured alternator
Benefits of Remanufacturing
Conserves raw material
– avoids emissions from raw material acquisition & processing, portion of manufacturing
– unlike recycling, metals are not resmelted (a highly air polluting process)
– prolongs product life and keeps products out of landfills and incinerators
Benefits of Remanufacturing
Prevents pollution
Benefits of Remanufacturing
Cost-effectiveness
Unlike recycling, remanufacturing preserves a product’s added value – the labor, machinery and production invested to turn raw materials into a product
A remanufactured product costs on average 50% less than a new product
Benefits of Remanufacturing
Provides jobs
Labor intensive - employs many people
Jobs for low/unskilled workers
Jobs for highly trained engineers
U.S. Remanufacturing Industry
Sector Total Number of FirmsAutomotive 50,538
Compressors 155
Electrical Apparatus 13,231
Machinery 120
Office Furniture 720
Tires 1,390
Toner Cartridges 6,501
Valves 401
Other 250
Sector Total Number of FirmsAutomotive 50,538
Compressors 155
Electrical Apparatus 13,231
Machinery 120
Office Furniture 720
Tires 1,390
Toner Cartridges 6,501
Valves 401
Other 250
Robert T. Lund, “The Remanufacturing Industry: Hidden Giant,” January 1996.
What products are remanufactured?
What Products are Remanufactured?
anti-lock brakes systems air conditioners alternators armatures air brakes brake cylinders ball bearings brake shoes calipers carburetors cruise control cylinder heads clutches crankshafts constant velocity drive
shafts differentials
drive shafts distributors electronic control modules engines engine parts fan clutches fuel injectors fuel pumps front wheel drive axles generators master cylinders oil pumps power brake unites power steering gear power window motor power steering pumps rack & pinion steering units
rotors starter drives speedometers solenoids smog pumps starters stators throttle body injectors torque converters transmission parts transmissions turbochargers voltage regulators wiper motors water pumps
automotive
Some Examples of Remanufacturing
How Do They Remanufacture . . .
Kodak’s redesigned “Fling” cameras*
Snap closures for body pieces means cameras are disassembled instead of broken apart.
77 to 86% of parts are recycled or reused - cardboard was replaced by standardized, recyclable plastic.
*1999 Annual Report. Health, Safety and Environment Department. Eastman Kodak Company. Available through: www.kodak.com
Single-Use Cameras?
What is the Benefit of Remanufacturing …
~52 million cameras (or 3.9 million pounds of material) were remanufactured in one year - higher than the recycling rate for aluminum cans.
67% less energy is required for manufacturing process of the cameras
Single-Use Cameras?
How Do They Remanufacture . . .
Remanufactured components include: cylinder block, cylinder head, crankshaft, camshaft, & connecting rods.
Wearable parts - bearings, rings, pistons and gaskets - are replaced.
(Many remanufacturers offer better warranties than OEMs.)
Automotive Engines?
What is the Benefit of Remanufacturing . . .
Energy savings of 50%
Remanufactured engines cost $800 to $2500 - versus the cost of a new car
Automotive Engines?
Impact of Cleaning in New York State
• Cleaning is an energy-intensive process • Significant amounts of hazardous wastes, solvents,
and contaminated wash water are generated • Cleaning is very labor-intensive • Potential for competitive advantages• 24,000 manufacturing companies are located in New
York State, of which 4,800 are involved in remanufacturing
Clean technologiesVision:
Develop cost-effective technologies that promote transformation of conventional factories to eco-efficient, safe factories.
- little or no hazardous material
- highly resource efficient: raw materials, energy, water
- safe for workers, the public and the environment
Approach:
Integrated approach to process development, transfer & evaluation
– technical– economic– energy efficiency – resource efficiency– environment, health & safety
Clean technologies
Clean technologies
Targeted Manufacturing Processes:– Surface Cleaning– Surface Coating & Finishing– Process Fluid Recycling and Reuse– Remanufacturing/Service– Machining
Automotive Parts Cleaning Project
• Objective: Identify, evaluate, and transfer cleaning technologies that are – cost-effective– environmentally sound– energy efficient
• Worked with 23 partner companies in New York State• Constructed Surface Cleaning Evaluation Facility• Generated significant savings in energy and operating costs
for several companies
Project Results – Arc Remanufacturing
• Replaced mid-pressure spray washer with high-pressure spray washer
• Reduced electricity consumption by 1,200 KWH/year• Extended cleaning bath lives from 3 weeks to 6 weeks• Eliminated precleaning and rework processes, saving labor• Saved $105,000/yr from an installed equipment cost of $67,000• Generated 8-month payback period on investment from just
one part type
Project Results – D&W Diesel
• Installed washwater filtration system• Reduced electricity consumption by 12,600 KWH/year• Reduced consumption of natural gas by 79,000 cubic feet/yr• Extended cleaning bath lives from 4 weeks to 3 months• Saved $5,300/yr from an installed equipment cost of $7,200• Generated 16-month payback period on investment
Expert System Project
• Objective: Create a computerized tool to efficiently develop customized cleaning system improvement recommendations
• Worked with partner companies in New York State to “test-drive” coded system and implement results
• 4 industries evaluated:– Transmission rebuilders– Aircraft engine rebuilders– Machine tool manufacturing– Locomotive turbocharger remanufacturers
Rochester Institute of Technology National Center for Remanufacturing
and Resource Recovery (NC3R)
Capabilities & Solutions
RIT’s NC3R Capabilities & Solutions
Structural & Material Analysis
Determine how products "age" & how to restore them:– Material Salvage– Finite Element Analysis– Failure Analysis – Dimensional Restoration– Structural & Material Analysis
RIT’s NC3R Capabilities & Solutions
Clean Technologies • Make remanufacturing and manufacturing operations
more sustainable by developing better methods of:– Surface Cleaning– Waste Minimization– Surface Finishing – Pollution Prevention
RIT’s NC3R Capabilities & Solutions
Intelligent Testing & Diagnostics • Assess health of components and predict remaining
useful life through development of:– Test Fixture Design– Test Protocols– Signature Analysis.
• Enhance business decision making • Extend product life
RIT’s NC3R Capabilities & Solutions
Operational Assistance
• Find opportunities for companies to improve business & process efficiency, using:
– Quality Systems– Production Control– Information Technology– Industrial Assessment– Facility Design– Lean/Six Sigma– Ergonomic Health and Safety.
• Provide process assessment, quality system development, and logistical support.
RIT’s NC3R Capabilities & Solutions
Logistics & Policy
• Serve as an analysis and information clearinghouse for industry and policy makers.
• Provide Life Cycle Analysis to quantify the many logistical aspects of a product's relationship to the environment.
RIT’s NC3R Capabilities & Solutions
Sustainable Design for Remanufacturing
• Develop tools and methods to create sustainable product systems that help manufacturers become more competitive and enhance environmental quality, using: – Reverse Engineering– Design for Remanufacture– Competitive Benchmarking – Total Cost of Ownership.
• Develop and promote design strategies that help companies create closed-loop, sustainable product systems that maximize product reuse and remanufacturing.
RIT’s National Center for Remanufacturing and Resource
Recovery (NC3R)
www.reman.rit.edu