Process Of Remanufacturing Research Articles

The Development of a Vehicle Recovery Remanufacturing Tool: An Interior Parts Analysis Indicator

The rapid growth of the automotive industry has placed a significant demand on earth resources such as metal and minerals. This has led to a shortage of materials and an increase in material prices. One of the solutions to enhance resource management is to perform parts remanufacturing during product design to ease the part classification. However, this initiative is not yet widely explored, particularly in terms of guideline or tool development. For example, the recyclers have no idea on how to decide the suitability of an automotive part to be remanufactured. This study aims to develop a vehicle recovery analysis guideline to assist those in the automotive industry in developing vehicles with higher remanufacturing rates during the product development stage. In this study, there are three main criteria, and 11 sub-criteria were determined from the literatures that influences the vehicle part remanufacturing rate. These criteria are classified into three main categories namely: selection of material, method of joining, and mechanical design. Next, quantitative approach namely Analytic Hierarchy Process (AHP) methodology was applied to collect the pairwise comparison data from the automotive industry practitioners. The gathered data were analyzed using Expert Choice V11 software to determine the criteria priority weightage to influence the remanufacturing activities. From the analysis, the three most influencing criteria based on global weightage are type of joining (0.216), durability (0.131), type of material (0.103), whereas the criteria that least being considered are cost of material(0.018), cleanability (0.04), and design complexity (0.041). From the obtained priority weightage, these data were used to develop an assessment tool using Microsoft Excel software. The assessment tool was validated by experts to ensure its feasibility tobe applied as a remanufacturing guideline. Positive feedbacks were obtained from the experts especially on the outputs of assessment tool which able to assist the practitioner in product design and ease the process of remanufacturing.

Remanufacturing of Industrial Electronics: A Case Study from the GCC Region

The Gulf Cooperation Council (GCC) region has witnessed significant growth in the global electrical and electronic equipment (EEE) market, especially in the industrial field due to the high demand from oil and gas and other related sectors. However, the lifespan of these end-of-life (EoL) products has become shorter, leading to electronic failure and generating electronic waste (e-waste). Disposing of such waste in recycling centers and landfills poses a challenge for policymakers and waste management officials due to its environmental impact. However, it is imperative to implement new management practices to overcome e-waste from landfills; thus, we propose the remanufacturing process as a viable and economic strategy for e-waste management. The process of industrial remanufacturing has the potential to decrease e-waste and promote the reuse of obsolete EEE and industrial devices., including those used in the Oil and Gas sector. This paper advocates for industrial remanufacturing as a solution to e-waste, aiming to increase the reusability of EoL EEE products. The authors provide a detailed analysis of the troubleshooting process and the tools employed, emphasizing the requirements for adopting this crucial remanufacturing solution. Moreover, the benefits of remanufacturing to industries and stakeholders are highlighted by offering a cost-effective alternative to replacing equipment, increasing the reusability of obsolete products, and reducing e-waste. By addressing the challenges of adopting remanufacturing, limitations and areas for future focus to enhance sustainability can be identified. Additionally, a comprehensive technical survey of the most common reasons for electronic failure at the board level demonstrates the feasibility and practicality of remanufacturing processes. These valuable insights reveal the possibility of realizing remanufacturing and guide technicians and stakeholders in implementing remanufacturing practices in various sectors, including oil and gas, petrochemicals, power generation, and factories. Lastly, by showcasing an example of a GCC region facility specializing in remanufacturing industrial electronic equipment, the potential contribution to a more sustainable future is emphasized,; this makes it easier to advocate for the adoption of remanufacturing as a more sustainable and economically viable approach in the industrial sector, particularly in oil and gas, for effective e-waste management.

Eco-Revolution: Exploration on Advancing Remanufacturing for a Greener Future

Given the increasing magnitude of environmental concerns, it has become crucial to prioritise the transition towards a sustainable and environmentally conscious future. Remanufacturing is a vital strategy in the forefront of the ecological revolution, as it possesses the ability to significantly mitigate waste, preserve resources, and diminish the carbon footprint associated with contemporary enterprises. This abstract examines the concept of remanufacturing as a potential driver for a more environmentally sustainable future. It highlights the innovative progress, economic advantages, and environmental benefits that can be achieved through its extensive implementation. Remanufacturing represents a significant shift in manufacturing practises, going beyond traditional recycling efforts. Remanufacturing is a process that involves the restoration and refurbishment of previously used products to their original specifications, so effectively prolonging the lifespan of consumer goods, machinery, and electronics. This practise has the dual purpose of limiting the disposal of significant quantities of trash and diminishing the need for new, untapped resources, thereby alleviating concerns related to resource depletion and environmental deterioration. In addition to its economic benefits, remanufacturing plays a significant role in mitigating greenhouse gas emissions. The energy consumption associated with the process of remanufacturing is frequently significantly lower compared to the energy requirements for manufacturing wholly new things. This leads to a significant decrease in carbon emissions, which is a crucial measure in addressing the issue of climate change.

Challenges of Remanufacturing Using Powder Bed Fusion Based Additive Manufacturing

Remanufacturing is an industrial process of turning used products into products with the same quality as new ones. Of the processes comprising remanufacturing, the repair process poses the greatest challenge. Additive manufacturing (AM) is expected to bring innovation to the repair process of remanufacturing. Although, so far, the directed energy deposition (DED) type AM has been most frequently applied to remanufacturing and only a few studies applied powder bed fusion (PBF) type AM to remanufacturing, PBF demonstrates great potential for application in remanufacturing. This study aims to assess the feasibility of the application of PBF to remanufacturing. We conducted an experimental PBF-based repair and attempted to identify its challenges. In the experiment, 1) we used AlSi10Mg powder, 2) we first fabricated a 5 mm square cube sample by using PBF, 3) we next removed 0.4 mm of thickness from the sample with milling, 4) then we restored 0.44 mm of thickness using PBF, and 5) we observed the restored sample. The observation showed that: 1) misalignment in the restoration occurred, 2) keyhole defects and gas pores were found more in the boundary area between the original and restored parts, and 3) the microstructures showed polycrystals in the restored part. These factors impaired the quality and reliability of PBF-based repair and present challenges of enhancing the feasibility of applying PBF-based repair to remanufacturing. This study also examined the whole process of PBF-based remanufacturing, which includes not only the repair process but also the processes of component inspection, process design, pre-repair process, and post-repair process, and discussed the challenges in these processes. The challenges include the development of repair process design methods, supportless fabrication processes, and non-destructive test (NDT) techniques.

Application Research of Laser Cladding Remanufacturing Technology to Repair Worn Mold

In recent years, with the development of laser technology and the transformation and upgrading of domestic manufacturing industry, the application of laser cladding remanufacturing technology is increasing. Mold as a common equipment of industrial production, its service life directly affects the production cost and efficiency of the enterprise.Wear is a common form of mold failure. In order to restore the performance of the mold and prolong the service life of the mold, The laser cladding remanufacturing technology to repair worn mold is studied in this paper. Firstly, the laser cladding remanufacturing is outlined, and the main technological process of the mold laser cladding remanufacturing is introduced. Then, taking 45 mold steel as an example, based on the analysis of the die material and weldability, the laser cladding material is selected reasonably, the mold is remanufactured by the experimental method, and the metallographic microscope analysis, hardness test and wear test are carried out.The research results show that the average hardness of the worn mold surface is about 55.5HRC after being remanufactured by laser cladding, and the wear resistance is doubled, and a good application effect has been achieved. Therefore, the laser cladding remanufacturing technology has a broad application prospect in repairing worn mold.

Research on Strengthening Process of Laser Additive Remanufacturing of Mill Housing

Based on the analysis of the wear mechanism of the mill housing, the results show that the main failure forms of the mill housing are corrosion wear and stress wear. Therefore, it is proposed to remanufacture and repair the housing to improve the hardness and impact resistance of the wear part of the housing. In order to strengthen the wear resistance of the wear part of the housing, Fe45+5%WC alloy powder was prepared to strengthen the wear resistance of the worn part of the housing. The sample of the alloy layer was produced by high power semi-conductor laser, the hardness, impact toughness and surface PT were tested, and the microstructure was observed by metallographic and EDS experiments. The results show that the alloy layer has high hardness and wear resistance, and the grains are fine and the alloy layer is metallurgical bonded to the substrate. The 3500mm reversing mill housing was repaired by laser re-manufacturing technology, and it was found that the alloy layer had good bonding and surface hardness was improved, thus strengthening the housing.

Collaborative optimization of robotic disassembly sequence planning and robotic disassembly line balancing problem using improved discrete Bees algorithm in remanufacturing✰

Abstract Remanufacturing helps to reduce manufacturing cost and environmental pollution by reusing end-of-life products. Disassembly is an inevitable process of remanufacturing and it is always finished by manual labor which is high cost and low efficiency while robotic disassembly helps to cover these shortages. Before the execution of disassembly, well-designed disassembly sequence and disassembly line balancing solution help to improve disassembly efficiency. However, most of the research used for disassembly sequence planning and disassembly line balancing problem is only applicable to manual disassembly. Also, disassembly sequence planning and disassembly line balancing problem are separately studied. In this paper, an improved discrete Bees algorithm is developed to solve the collaborative optimization of robotic disassembly sequence planning and robotic disassembly line balancing problem. Robotic workstation assignment method is used to generate robotic disassembly line solutions based on feasible disassembly solutions obtained by the space interference matrices. Optimization objectives of the collaborative optimization problem are described, and the analytic network process is used to assign suitable weights to different indicators. With the help of variable neighborhood search, an improved discrete Bees algorithm is developed to find the optimal solution. Finally, based on a gear pump and a camera, case studies are used to verify the effectiveness of the proposed method. The results under different cycle time of robotic disassembly line are analyzed. Under the best cycle time, the performance of the improved discrete Bees algorithm under different populations and iterations are analyzed and compared with the other three optimization algorithms. The results under different assessment methods and scenarios are also analyzed.

Remanufacturing for Sustainable Development

Sustainable development is the need of the hour as population booms on a planet with a finite resource pool. Employing the process of remanufacturing is essential in achieving this. Busting the myths surrounding the field of remanufacturing by studying the components and characteristics of this process and the obstacles faced by it in the market will ensure the absorption of this methodology in the mainstream, commercial sector. A key aspect of remanufacturing is the close association between remanufacturing opportunities and product cannibalization. This paper touches upon the challenges faced by this sector, like the End-of-Life Product cost, the hindrances in the reverse logistic chain, the perception of remanufactured product quality, to name a few. Acquiring a significant, profitable market share for remanufactured products is decided by elements like Product Acquisition Management, Reverse Logistic Collections, Supply and Demand of remanufactured products. The analyses of two cases, one from the cartridge industry and the other from the PC Monitors industry expound on these elements and their influence on the decision to remanufacture.

Product recycling of automotive parts – trends and issues

Remanufacturing is a dynamically developing area of the automotive industry. It allows the original equipment manufactures to diversify their activities and sell manufacturer-warrantied subassemblies through a dealership network but at lower prices compared to new products. The paper presents the process of remanufacturing of automotive subassemblies and characterizes the benefits for the industry and vehicle end-users. Examples have been shown of the activities of vehicle manufacturers in the area of product recycling and development of remanufacturing technologies.

Balancing Disassembly Line in Product Recovery to Promote the Coordinated Development of Economy and Environment

For environmentally conscious and sustainable manufacturing, many more manufacturers are acting to recycle and remanufacture their post-consumed products. The most critical process of remanufacturing is disassembly, since it allows for the selective extraction of the valuable components and materials from returned products to reduce the waste disposal volume. It is, therefore, important to design and balance the disassembly line to work efficiently due to its vital role in effective resource usage and environmental protection. Considering the disassembly precedence relationships and sequence-dependent parts removal time increments, this paper presents an improved discrete artificial bee colony algorithm (DABC) for solving the sequence-dependent disassembly line balancing problem (SDDLBP). The performance of the proposed algorithm was tested against nine other approaches. Computational results evidently indicate the superior efficiency of the proposed algorithm for addressing the environmental and economic concerns while optimizing the multi-objective SDDLBP.

Production planning in the presence of remanufactured spare components: an application in the airline industry

The process of remanufacturing is attractive economically and environmentally for both manufacturers and customers. This paper addresses a problem in the repairable spare parts remanufacturing industry to find the cost-optimal production strategy incorporating reconditioned components. New and reconditioned components are used to carry out replacements in order to honor warranty commitments. Key production decisions, such as when remanufacturing should commence, how long the warranty period should be, and how many returned components should be reconditioned are considered. The availability of reconditioned components and their discounted costs are also incorporated in the mathematical model. The goal is to investigate the interaction between these decisions and their impacts on the manufacturing system and the customer. An application to the remanufacturing of rotable spare parts in the airline industry is presented.

Pengembangan Framework untuk Mengukur Tingkat Keberhasilan Implementasi Reverse Logistics

Electronic Waste (E-waste) is growing attention at the end of this decade. E-waste must be managed properly. E-waste has a negative impact on the environment. E-waste contain B3 (Bahan Berbahaya dan Beracun). Reverse Logistics (RL) is one approach that able to solve these problems. The use of secondary materials through the process of remanufacturing, recycling, refurbishing, recondition are strategy to minimizing the number of e-waste. Many companies claim successfully implementing of RL. However, there are no clear indicators or parameters to assess the success of RL implementation. In this research we propose the design of reverse logistics maturity framework. Grounded Theory (GT) is chosen to design this framework. GT is a research methodology involving the construction of theory based on phenomena. This framework will be divided into five levels of maturity: Level Conventional, Managed, Developed, Innovative and Optimized. Results of research from three consumer electronics companies were in the Level Managed.

Energy consumption model and its simulation for manufacturing and remanufacturing systems

This paper adopts a method of researching the process of energy consumption in manufacturing/remanufacturing systems to achieve lean energy. This method can be used in typical machining systems, especially including the machining process of manufacturing and remanufacturing. To validate this approach, we model and simulate the system with the DEVS theory and input-output model. This model establishes the machining process of a product. On the basis of work station, which is used for receiving work pieces and energy, exporting products and information of different kinds of energy consumption. We can simulate manufacturing/remanufacturing of integration machining process and material flow, information flow, and energy flow of the coupling process. After that, classify the energy consumption according to the quality of the products. The solutions, which are the margin of error between simulation and measurement, show that this method is effective. The output results help manage energy resource and provide train of thought for saving energy and reducing consumption.

Joint replenishment modelling of a multi-item system with greening policy and volume flexibility

Nowadays, more concentration is being given to cut down in resource utilisation and ecosystem safety due to rising competitive stress, shortened life cycle and ecological awareness. Green manufacturing has attained much interest in recent times, because its concept of product design noticeably affects the various cost related to the process of remanufacturing and recycling. This article considers an integrated production inventory system for multi–items. The proposed model is based on the vendor managed strategy with the concept of green approach through remanufacturing. A non–linear problem is formulated for the purpose of total cost minimisation and solved using genetic algorithm. A numerical example is presented to illustrate the model. Also, the effects of parameters involved in the modelling are examined with the help of sensitivity analysis. This study can provide the decision–making outline for enhancing the structure of a green–supply chain.

Research on Remanufacturing of Gear Reducer

Gear reducer is widely used in various fields of industry, as a kind of sustainable development technology, the remanufacturing of gear reducer is significant and has great potential. This paper introduces the technological process of remanufacturing of gear reducer，the discussion major focus on the key parts, such as gear, shaft, and box. their failure forms are analyzed and corresponding remanufacturing process are presented. The remanufacturing technology extends the life cycle of gear reducer, is conducive to energy conservation and emissions reduction.

Current Situation in Cleaning Process of Remanufacturing in Malaysia: A Case Study

Remanufacturing process among industries is relatively new in Malaysia. In USA, Europe, Japan, China and India, remanufacturing is already viewed as a huge business opportunity that significantly stimulates growth in Gross Domestic Product (GDP) and employment. The aim of this paper is to expose all possible causes of failures using the Ishikawa diagram and identify the most significant failures using Failure Mode and Effect Analysis (FMEA) with two Risk Priority Number (RPNs). The cleaning process is both time-consuming as well as the most costly of the entire remanufacturing processes. The case study is performed in an automotive contract remanufacturing environment in Malaysia, specifically the remanufacturing of cylinder heads. This work outcome explores the current situation pertaining to the cleaning process in a real world situation, and attempts to promote among researchers green ideas that will bring Malaysias remanufacturing on par with that of other developed countries.

Development of Monitoring and Control System for Laser Remanufacturing

In order to monitor the process of laser remanufacturing and control the quality of remanufacturing, a monitoring and control system for laser remanufacturing was constructed with its hardware and software. The schedule of the system including signal condition, software interface, sampling and control method, was introduced. Infra-red thermometer with dynamic aiming device was designed to track the molten pool location. Photoelectric sensor was developed to measure the flow of powder. The contrast test results show that the fuzzy PID control system for powder feeding could achieve stable flow.