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Remanufacturing is "the rebuilding of a product to specifications of the original manufactured product using a combination of reused, repaired and new parts". [1] It requires the repair or replacement of worn out or obsolete components and modules. Parts subject to degradation affecting the performance or the expected life of the whole are replaced. Remanufacturing is a form of a product recovery process that differs from other recovery processes in its completeness: a remanufactured machine should match the same customer expectation as new machines.
In 1995, the United States Environmental Protection Agency (EPA) implemented the Comprehensive Procurement Guideline [2] (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.
In 2004, the EPA published its third CPG update (CPG IV) which designated seven additional products and revised three existing product designations. One of the new product categories to be added was Rebuilt Vehicular Parts. [3] The EPA defines rebuilt vehicular parts as "vehicle parts that have been re-manufactured, reusing parts in their original form. Rebuilt parts undergo an extensive re-manufacturing and testing process and must meet the same industry specifications for performance as new parts."
In the UK, a market potential of up to 5.6 billion GBP has been identified in remanufacturing, with the benefits said to be improvement to business margins, revenues and security of supply. [4] The United States remanufacturing industry grew by 15% between 2009 and 2011, and in 2020 it accounted for 2% of all manufacturing in the US and 1.9% in the European Union. [5]
Many formal definitions of remanufacturing exist in the literature, but the first published report on remanufacturing, by R. Lund (1984), describes remanufacturing as "... an industrial process in which worn-out products are restored to like-new condition. Through a series of industrial processes in a factory environment, a discarded product is completely disassembled. Useable parts are cleaned, refurbished, and put into inventory. Then the product is reassembled from the old parts (and where necessary, new parts) to produce a unit fully equivalent and sometimes superior in performance and expected lifetime to the original new product". [6]
Furthermore, the Automotive Parts Remanufacturers Association (APRA) realized that communication problems can arise when people from different countries with different language skills talk about remanufacturing. Certain terms can have different meanings as definitions between countries and individuals vary. In 2013, APRA was able to solve these communication problems by publishing a common translation list in many different languages in order to unite all those who deal with the automotive industry.
Rebuilding is an old name for remanufacturing. It is still widely used by automotive industry. For example, the Automotive Parts Remanufacturers Association (APRA), [7] have the new term in their name, but to be safe on their own website use the combined term 'rebuild/remanufacture'.[ failed verification ]
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 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.
There are three main types of remanufacturing activities, each with different operational challenges.
Remanufacturing by Recoating of Worn Engine Parts
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 is the engine block, in particular the cylinder engine bores, which must withstand combustion. Instead of disposing of engine blocks, remanufacturing enables re-use by coating them with plasma transferred wire arc spraying (PTWA). Remanufacturing by recoating of parts is also popular in aviation and with geothermal pipe.
An original equipment manufacturer (OEM) is a company that produces parts and equipment that may be marketed by another company. However, the term is ambiguous, with several other common meanings: It sometimes means the maker of a system that includes other companies' subsystems, an end-product producer, an automotive part that is manufactured by the same company that produced the original part used in the automobile's assembly, or a value-added reseller.
Engine tuning is the adjustment or modification of the internal combustion engine or Engine Control Unit (ECU) to yield optimal performance and increase the engine's power output, economy, or durability. These goals may be mutually exclusive; an engine may be de-tuned with respect to output power in exchange for better economy or longer engine life due to lessened stress on engine components.
Automotive engineering, along with aerospace engineering and naval architecture, is a branch of vehicle engineering, incorporating elements of mechanical, electrical, electronic, software, and safety engineering as applied to the design, manufacture and operation of motorcycles, automobiles, and trucks and their respective engineering subsystems. It also includes modification of vehicles. Manufacturing domain deals with the creation and assembling the whole parts of automobiles is also included in it. The automotive engineering field is research intensive and involves direct application of mathematical models and formulas. The study of automotive engineering is to design, develop, fabricate, and test vehicles or vehicle components from the concept stage to production stage. Production, development, and manufacturing are the three major functions in this field.
The automotive aftermarket is the secondary parts market of the automotive industry, concerned with the manufacturing, remanufacturing, distribution, retailing, and installation of all vehicle parts, chemicals, equipment, and accessories, after the sale of the automobile by the original equipment manufacturer (OEM) to the consumer. The parts, accessories, etc. for sale may or may not be manufactured by the OEM.
A product's service life is its period of use in service. Several related terms describe more precisely a product's life, from the point of manufacture, storage, and distribution, and eventual use. Service life has been defined as "a product's total life in use from the point of sale to the point of discard" and distinguished from replacement life, "the period after which the initial purchaser returns to the shop for a replacement". Determining a product's expected service life as part of business policy involves using tools and calculations from maintainability and reliability analysis. Service life represents a commitment made by the item's manufacturer and is usually specified as a median. It is the time that any manufactured item can be expected to be "serviceable" or supported by its manufacturer.
A replacement automobile engine is an engine or a major part of one that is sold individually without any other parts required to make a functional car. These engines are produced either as aftermarket parts or as reproductions of an engine that has gone out of production.
A car platform is a shared set of common design, engineering, and production efforts, as well as major components, over a number of outwardly distinct models and even types of cars, often from different, but somewhat related, marques. It is practiced in the automotive industry to reduce the costs associated with the development of products by basing those products on a smaller number of platforms. This further allows companies to create distinct models from a design perspective on similar underpinnings. A car platform is not to be confused with a platform chassis, although such a chassis can be part of an automobile's design platform, as noted below.
Automotive design is the process of developing the appearance of motor vehicles, including automobiles, motorcycles, trucks, buses, coaches, and vans.
Retread is a re-manufacturing process for tires that replace the tread on worn tires. Retreading is applied to casings of spent tires that have been inspected and repaired. It preserves about 90% of the material in spent tires and the material cost is about 20% compared to manufacturing a new one.
Precycling is the practice of reducing waste by attempting to avoid buying items which will generate waste into home or business. The U.S. Environmental Protection Agency (EPA) also cites that precycling is the preferred method of integrated solid waste management because it cuts waste at its source and therefore trash is eliminated before it is created. According to the EPA, precycling is also characterized as a decision-making process on the behalf of the consumer because it involves making informed judgments regarding a product's waste implications. The implications that are taken into consideration by the consumer include: whether a product is reusable, durable, or repairable; made from renewable or non-renewable resources; over-packaged; and whether or not the container is reusable.
Design for the environment (DfE) is a design approach to reduce the overall human health and environmental impact of a product, process or service, where impacts are considered across its life cycle. Different software tools have been developed to assist designers in finding optimized products or processes/services. DfE is also the original name of a United States Environmental Protection Agency (EPA) program, created in 1992, that works to prevent pollution, and the risk pollution presents to humans and the environment. The program provides information regarding safer chemical formulations for cleaning and other products. EPA renamed its program "Safer Choice" in 2015.
Valve guides are cylindrical metal bushes, pressed or integrally cast into the cylinder head of most types of reciprocating engines, to support the poppet valves so that they may make proper contact with its valve seat. Along with a corresponding valve spring, they are one component of an engine’s valve train.
Conservation and restoration of road vehicles is the process of restoring a vehicle back to its original working condition. Vehicles, whether partially scrapped or completely totaled, are typically restored to maintain their roadworthiness or to preserve those with antique status for use as showpieces.
Title 40 is a part of the United States Code of Federal Regulations. Title 40 arranges mainly environmental regulations that were promulgated by the US Environmental Protection Agency (EPA), based on the provisions of United States laws. Parts of the regulation may be updated annually on July 1.
Vehicle recycling or automobile scrapping is the dismantling of vehicles for spare parts. At the end of their useful life, vehicles have value as a source of spare parts and this has created a vehicle dismantling industry. The industry has various names for its business outlets including wrecking yard, auto dismantling yard, car spare parts supplier, and recently, auto or vehicle recycling. Vehicle recycling has always occurred to some degree but in recent years manufacturers have become involved in the process. A car crusher is often used to reduce the size of scrapped vehicles for simplified transportation to a steel mill.
A parts washer is a piece of equipment used to remove contaminants or debris, such as dirt, grime, carbon, oil, grease, metal chips, cutting fluids, mold release agents, ink, paint, and corrosion from workpieces. Parts washers are used in new manufacturing and remanufacturing processes; they are designed to clean, degrease and dry bulk loads of small or large parts in preparation for assembly, inspection, surface treatment, packaging and distribution. Parts washers may be as simple as the manual "sink-on-a-drum" common to many auto repair shops, or they may be very complex, multi-stage units with pass-through parts handling systems. Parts washers are essential in maintenance, repair and remanufacturing operations as well, from cleaning fasteners, nuts, bolts and screws to diesel engine blocks and related parts, rail bearings, wind turbine gears boxes and automotive assemblies.
A toner cartridge, also called laser toner, is the consumable component of a laser printer. Toner cartridges contain toner powder, a fine, dry mixture of plastic particles, carbon, and black or other coloring agents that make the actual image on the paper. The toner is transferred to paper via an electrostatically charged drum unit, and fused onto the paper by heated rollers during the printing process. It will not stain like ink cartridges, but it can get messy if handled improperly.
The RemaxWorld Expo is an annual trade show comprising vendors from within the print consumables industry. The event began in 2007, resulting from a joint venture between the China Council for the Promotion of International Trade (CCPIT) and Recycling Times Media Corporation. Centered in Zhuhai, widely recognized as being the print consumables capital of the world, the exhibition currently takes place in the newly constructed Zhuhai International Convention & Exhibition Center. In 2015, the show accommodated 463 exhibitors and 13,938 visitors from 83 countries.
The Motor & Equipment Manufacturers Association (MEMA) was founded in 1904. MEMA represents more than 1,000 companies that manufacture motor vehicle components and systems for the original equipment and aftermarket segments of the light vehicle and heavy-duty motor vehicle manufacturing industry in the United States. Motor vehicle component manufacturers are the largest employer of manufacturing jobs in the U.S., contributing nearly 3 percent of the U.S. gross domestic product. Motor vehicle parts suppliers generate a total direct and indirect employment impact of 4.26 million jobs, up nearly 18 percent since 2012.
Demanufacturing is a process where a product after extensive usage, often at the end of its lifespan, is then disassembled or dismantled into its components. Demanufacturing is also commonly referred to as the reverse process of manufacturing and, hence, can next to disassembly or dismantling also include various other processing steps. For example, demanufacturing commonly starts with product manipulation and next a classification step to evaluate the functionality of the product and/or the herein contained components to assess if these are suitable for reuse or are deemed unusable and need to be recycled, so the materials can be used in new products. Demanufacturing was proposed to be used in all industries as a means reduce the environmental footprint while preserving economic viability of the processes involved. This term was first coined by Professor Walter W. Olson and Professor John W. Sutherland in 1993.