Presentation on theme: "Energy Efficiency and Environmental Protection through Remanufacturing"— Presentation transcript:
1 Energy Efficiency and Environmental Protection through Remanufacturing Prepared by RIT’s National Center for Remanufacturing and Resource RecoveryPresented byMiriam PyeSenior Project ManagerIndustry Research & Development NYSERDA
2 The Problem: Environmental Trends Each year, 500 million cubic feet of non-recyclable waste is generated from auto recycling activities.Hundreds of millions of computers ... obsolete.*National Safety Council
3 One Solution: Remanufacturing The “Ultimate Form of Recycling”
4 What is Remanufacturing? An industrial process in whichnon-functional or retired productsare restored tolike-new or improved condition.
5 What is Remanufacturing? Primary components come from a used productProduct is dismantledCondition of parts determinedComponents cleaned and restored to original or “better than new” specificationsProduct is reassembled and qualified
6 Remanufacturing vs. Recycling Example: Office ChairsRecycling:Strip worn fabric and convert to industrial paddingSend metal frames to resmeltingForm resmelted metal into a new productRemanufacturing:Replace fabric coversRepair and repaint metal framesReplace worn-out parts, e.g. fasteners
9 Benefits of Remanufacturing Conserves Energy - avoids energy requirements in raw material acquisition & processing, portion of manufacturingmanufacturing one new automotive starter requires more than 11 times more energy than remanufacturing a starter
10 Benefits of Remanufacturing Conserves raw materialmanufacturing one new starter requires more than 9 times more new material than a remanufactured startermanufacturing one new alternator requires more than 8 times more new material than a remanufactured alternator
11 Benefits of Remanufacturing Prevents pollutionavoids emissions from raw material acquisition & processing, portion of manufacturingunlike recycling, metals are not resmelted (a highly air polluting process)prolongs product life and keeps products out of landfills and incinerators
12 Benefits of Remanufacturing Cost-effectivenessUnlike recycling, remanufacturing preserves a product’s added value – the labor, machinery and production invested to turn raw materials into a productA remanufactured product costs on average 50% less than a new product
13 Benefits of Remanufacturing Provides jobsLabor intensive - employs many peopleJobs for low/unskilled workersJobs for highly trained engineers
18 How Do They Remanufacture . . . Single-Use Cameras?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:
19 What is the Benefit of Remanufacturing … Single-Use Cameras?~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
20 How Do They Remanufacture . . . Automotive Engines?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.)
21 What is the Benefit of Remanufacturing . . . Automotive Engines?Energy savings of 50%Remanufactured engines cost $800 to $ versus the cost of a new car
22 Impact of Cleaning in New York State Cleaning is an energy-intensive processSignificant amounts of hazardous wastes, solvents, and contaminated wash water are generatedCleaning is very labor-intensivePotential for competitive advantages24,000 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 Clean technologies Approach: Integrated approach to process development, transfer & evaluationtechnicaleconomicenergy efficiencyresource efficiencyenvironment, health & safety
27 Automotive Parts Cleaning Project Objective: Identify, evaluate, and transfer cleaning technologies that arecost-effectiveenvironmentally soundenergy efficientWorked with 23 partner companies in New York StateConstructed Surface Cleaning Evaluation FacilityGenerated significant savings in energy and operating costs for several companies
28 Project Results – Arc Remanufacturing Replaced mid-pressure spray washer with high-pressure spray washerReduced electricity consumption by 1,200 KWH/yearExtended cleaning bath lives from 3 weeks to 6 weeksEliminated precleaning and rework processes, saving laborSaved $105,000/yr from an installed equipment cost of $67,000Generated 8-month payback period on investment from just one part type
29 Project Results – D&W Diesel Installed washwater filtration systemReduced electricity consumption by 12,600 KWH/yearReduced consumption of natural gas by 79,000 cubic feet/yrExtended cleaning bath lives from 4 weeks to 3 monthsSaved $5,300/yr from an installed equipment cost of $7,200Generated 16-month payback period on investment
30 Expert System ProjectObjective: Create a computerized tool to efficiently develop customized cleaning system improvement recommendationsWorked with partner companies in New York State to “test-drive” coded system and implement results4 industries evaluated:Transmission rebuildersAircraft engine rebuildersMachine tool manufacturingLocomotive turbocharger remanufacturers
31 Capabilities & Solutions Rochester Institute of Technology National Center for Remanufacturing and Resource Recovery (NC3R)Capabilities & Solutions
32 RIT’s NC3R Capabilities & Solutions Structural & Material AnalysisDetermine how products "age" & how to restore them:Material SalvageFinite Element AnalysisFailure AnalysisDimensional Restoration
33 RIT’s NC3R Capabilities & Solutions Clean TechnologiesMake remanufacturing and manufacturing operations more sustainable by developing better methods of:Surface CleaningWaste MinimizationSurface FinishingPollution Prevention
34 RIT’s NC3R Capabilities & Solutions Intelligent Testing & DiagnosticsAssess health of components and predict remaining useful life through development of:Test Fixture DesignTest ProtocolsSignature Analysis.Enhance business decision makingExtend product life
35 RIT’s NC3R Capabilities & Solutions Operational AssistanceFind opportunities for companies to improve business & process efficiency, using:Quality SystemsProduction ControlInformation TechnologyIndustrial AssessmentFacility DesignLean/Six SigmaErgonomic Health and Safety.Provide process assessment, quality system development, and logistical support.
36 RIT’s NC3R Capabilities & Solutions Logistics & PolicyServe 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 RIT’s NC3R Capabilities & Solutions Sustainable Design for RemanufacturingDevelop tools and methods to create sustainable product systems that help manufacturers become more competitive and enhance environmental quality, using:Reverse EngineeringDesign for RemanufactureCompetitive BenchmarkingTotal Cost of Ownership.Develop and promote design strategies that help companies create closed-loop, sustainable product systems that maximize product reuse and remanufacturing.
38 RIT’s National Center for Remanufacturing and Resource Recovery (NC3R)