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Energy Efficiency and Environmental Protection through Remanufacturing Presented by Miriam Pye Senior Project Manager Industry Research & Development NYSERDA.

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Presentation on theme: "Energy Efficiency and Environmental Protection through Remanufacturing Presented by Miriam Pye Senior Project Manager Industry Research & Development NYSERDA."— Presentation transcript:

1 Energy Efficiency and Environmental Protection through Remanufacturing Presented by Miriam Pye Senior Project Manager Industry Research & Development NYSERDA Prepared by RITs National Center for Remanufacturing and Resource Recovery

2 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

3 One Solution: Remanufacturing The Ultimate Form of Recycling

4 What is Remanufacturing? An industrial process in which non-functional or retired products are restored to like-new or improved condition.

5 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

6 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

7 Life Cycle of a Product


9 Conserves Energy - avoids energy requirements in raw material acquisition & processing, portion of manufacturing n manufacturing one new automotive starter requires more than 11 times more energy than remanufacturing a starter Benefits of Remanufacturing

10 n manufacturing one new starter requires more than 9 times more new material than a remanufactured starter n manufacturing one new alternator requires more than 8 times more new material than a remanufactured alternator Benefits of Remanufacturing Conserves raw material

11 – 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

12 Benefits of Remanufacturing Cost-effectiveness n Unlike recycling, remanufacturing preserves a products added value – the labor, machinery and production invested to turn raw materials into a product n A remanufactured product costs on average 50% less than a new product

13 Benefits of Remanufacturing Provides jobs n Labor intensive - employs many people n Jobs for low/unskilled workers n Jobs for highly trained engineers


15 What products are remanufactured?

16 What Products are Remanufactured? n anti-lock brakes systems n air conditioners n alternators n armatures n air brakes n brake cylinders n ball bearings n brake shoes n calipers n carburetors n cruise control n cylinder heads n clutches n crankshafts n constant velocity drive shafts n differentials n drive shafts n distributors n electronic control modules n engines n engine parts n fan clutches n fuel injectors n fuel pumps n front wheel drive axles n generators n master cylinders n oil pumps n power brake unites n power steering gear n power window motor n power steering pumps n rack & pinion steering units n rotors n starter drives n speedometers n solenoids n smog pumps n starters n stators n throttle body injectors n torque converters n transmission parts n transmissions n turbochargers n voltage regulators n wiper motors n water pumps automotive

17 Some Examples of Remanufacturing

18 How Do They Remanufacture... Kodaks redesigned Fling cameras* n Snap closures for body pieces means cameras are disassembled instead of broken apart. n 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: Single-Use Cameras?

19 What is the Benefit of Remanufacturing … n ~52 million cameras (or 3.9 million pounds of material) were remanufactured in one year - higher than the recycling rate for aluminum cans. n 67% less energy is required for manufacturing process of the cameras Single-Use Cameras?

20 How Do They Remanufacture... n Remanufactured components include: cylinder block, cylinder head, crankshaft, camshaft, & connecting rods. n Wearable parts - bearings, rings, pistons and gaskets - are replaced. n (Many remanufacturers offer better warranties than OEMs.) Automotive Engines?

21 What is the Benefit of Remanufacturing... n Energy savings of 50% n Remanufactured engines cost $800 to $ versus the cost of a new car Automotive Engines?

22 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

23 Clean technologies Vision: 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

24 Approach: Integrated approach to process development, transfer & evaluation –technical – economic – energy efficiency – resource efficiency – environment, health & safety Clean technologies


26 Targeted Manufacturing Processes: –Surface Cleaning –Surface Coating & Finishing –Process Fluid Recycling and Reuse –Remanufacturing/Service –Machining

27 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

28 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

29 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

30 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

31 Rochester Institute of Technology National Center for Remanufacturing and Resource Recovery (NC3R) Capabilities & Solutions

32 RITs 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

33 RITs 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

34 RITs 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

35 RITs 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.

36 RITs 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.

37 RITs 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.

38 RITs National Center for Remanufacturing and Resource Recovery (NC3R)

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