obstacles to and opportunities for growth in the remanufacturing - PowerPoint PPT Presentation

What are the technological obstacles to and opportunities for growth in the remanufacturing industry? Todd Wieland, PhD Director of Engineering – New and ReCon Parts Mfg Cummins Inc.

Trends & Drivers  Internal – Design optimization includes minimum weight, cost – New materials, coatings & surface treatments – New high value components – Permanent assembly methods, fewer fasteners, joints  External – Higher complexity limits local repair options – Greater availability of low cost new part alternatives – More stringent emission laws being adopted globally – Leading emissions markets shift focus to greenhouse gas – Growing environmental sensitivity / stewardship – Growing producer responsibility for end of product life – Global growth and relevance of reman 2

Technology Need – “Additive Manufacturing”  Remanufacturing traditionally includes re-application of new part production processes – Re- grinding, milling, boring, polishing… Cylinder Block Early Later – Requires myriad non-standard parts  Modern analysis and optimization tools enable removal of “excess” material – Excess traditional remanufacturers needed  Thin surface coatings or treatments may prohibit / limit or require specialized finishing methods – Nitriding, Nikasil, Alusil  Wanted: Means to replace worn / corroded mat’l 3

Technology Need – “Additive Manufacturing”  Thermal Spray – Twin wire arc – HVOF – Plasma – Cold Spray  Laser Deposition Sources: http://www.thermalspray.org/index.php?option=com_easyfaq&task=cat&catid=19&Itemid=92 http://www.sulzer.com/en/- /media/Documents/ProductsAndServices/Coating_Services/General/TechnicalArticles/Plasma_Spray_Cylinder_Coatings_in _a_NASCAR_Engine_Expo_2010.pdf 4 http://www.seas.virginia.edu/research/lam/pdfs/speaker%20presentations/Mazumder-NSF-IUCRC%20workshop-2010.pdf

Technology Need – Improved Processes  Environmentally Friendly Cleaning Processes – Effluent disposition, chemical and water usage, ergonomics – e.g. Laser Cleaning  “Fit for Market” Processes – Processes which meet cost requirements in new markets Sources: http://adapt-laser.com/Technology/Lasertechnology.html Engine remanufacturing technologies and application in China.pdf 5

Technology Need – New Processes  Remaining Life Assessment & Damage Reversal – Electronic components It – Electrical insulation systems is not cracked – Pressurized fluid systems not today, but designed for “infinite life” what about tomorrow???  For New Component Types – Exhaust catalysts and filters – cleaning & reactivation – Hybrid battery systems – rejuvenation, replace cells 6

Technology Need – Integrate into OE Design  Need “Design for Design for Remanufacturing” Service Design for – Identify WHAT will likely Assembly be remanufactured Design for Manufacturing – Develop HOW the product will be reman’d Design for – Make design, materials & Environment Design for assembly decisions to Accessibility enable this Design for Logistics  Challenges – Business case not always apparent; may conflict with shorter-term needs 7