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