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© Fraunhofer Project Group Process Innovation, Bayreuth

Slide 1 / 35 | 20.04.2016 | Steffen Butzer

M.Sc. Steffen Butzer

European Remanufacturing Network

Assessing and Improving

Remanufacturing Processes



Agenda

Introduction


Generic Remanufacturing Processes

Case Studies

Remanufacturing and Advanced Materials

Todays and Tomorrows Challenges

Remanufacturing Processes Toolkit

Remanufacturing Process Assessment



Agenda

Introduction



Case Studies







IntroductionBayreuth

Images: maps.google.de

Europe

Germany

Munich

Bayreuth

Population: 75,000

World-renowned for

Richard Wagner

Festival

Half way between

Munich & Berlin

Bayreuth



IntroductionOur Team



Resource efficiencyTechnology management

Remanufacturing Production management

Fraunhofer Project Group Process

InnovationScopes of business



Fraunhofer Project Group Process

InnovationScopes of business – Regenerative and Lean Production

Production system planning and

optimization

Quality management within the production

Factory and process planning for

remanufacturing operations

Technology development and assessment

for remanufacturing

Business development for remanufacturing

and the circular economy



Agenda

Introduction



Case Studies







Remanufacturing ProcessesERN – European Remanufacturing Network

• Encourage new businesses to take up

remanufacturing

• Help existing remanufacturers improve their

operations

• Improve competitiveness of remanufacturers

• Create greater awareness of remanufacturing



Remanufacturing ProcessesRemanufacturing: „Good as New“ in Five Steps

Markets and Legislation

both drive Remanufacturing

Multiple

Product

Lives

Disassembly

Assembly

Cleaning

Testing

Reconditioning

UP

Recycling

Downcycling

UPcycling



Agenda

Introduction



Case Studies










Agenda

Introduction



Case Studies







Case StudiesRemanufacturing Process Assessment - Overview



Case StudiesOne pagers



Case StudiesBorg Automotive

Company and business model:

One of Denmark‘s largest automotive companies

One of the largest independent remanufacturing companies

40 years of experience

More than 1000 employees

Remanufacturer of the year in 2015

Products:

Wide and diverse range of brands

Commercial vehicles, passenger cars, marine and agricultural sector

Alternators, starters, steering racks

Remanufacturing process:

Disassembly

Cleaning

Inspection & sorting

Reconditioning & replacement

Reassembly

Final testing

Unique characteristic:

Produced-to-order concept



Case StudiesMotorenservice Bieberstein GmbH


Independent remanufacturer

15 employees

86 years of experience

Products:

Diesel engines

Agricultural and construction machines

All sizes including older series


Incoming analysis

Cost estimation

Disassembly

Cleaning

Detailed analysis

Reconditioning and replacement

Reassembly

Final testing


Extensive experience in the sector of diesel engines



Case StudiesBosch Service Lehner


Two business units: „Bosch Service“ and „Bosch Diesel Center“

Cores from own car repair shop and regional car repair shops

Products:

Injectors

Fuel pumps

Injection nozzles


Check on a test bench

Disassembly

Cleaning

Analysis of parts

Replacement of damaged parts

Reassembly

Final check


Franchisee of the Bosch GmbH



Case StudiesKnorr Bremse


The original equipment manufacturer remanufactures a wide range of different

products in the company’s plant in Liberec (Czech Republic)

The remanufacturing activities take place in a remanufacturing facility with 9,000

square meters

Products:

Spring brakes

Compressors

Electronic air control and modules of the electronic braking system


Sorting and grading

Disassembly

Cleaning

Reconditioning

Quality checks

Assembly of some products on assembly line for new products


Know how as well as data and information regarding the technical and qualitative

specifications based on the manufacturing of new products are accessible and

rigorous applied

Knorr Bremse Production System



Case Studiesrobotif GmbH


The company was founded in 2009 and is focused on repairing Adept, Bosch, Denso

and Stäubli robots

With its meanwhile 18 employees, robotif offers repairing, maintenance, modification

and remanufacturing of industrial robots and their components

Products:

6-axis robots

Scara robots (Selective Compliance Assembly Robot Arm)


Disassembly

Cleaning

Analysis of parts

Remanufacturing

Reassembly

Final check


Robotif increasingly tries to improve spare parts in their remanufacturing process

Intense documentation (e.g. malfunctions, worn parts, damages) at a central data

base

High know-how of the mechanics



Case StudiesAir France Industries KLM Engineering & Maintenance


Air France Industries KLM Engineering & Maintenance is one of the three

businesses of AIR FRANCE KLM Group

Workforce of approx. 14,000 employees

Different locations such as Amsterdam-Schiphol, Paris Orly or Toulouse

Products:

The range of products for the companies business reaches from airframes to

engines of Airbus, Boeing as well as regional Aircraft (e.g. Bombardier, Embraer)

Remanufacturing respectively overhaul process:

The process steps are ranging from the disassembly to the repair of

components and the reassembly which is followed by various validation

tests

The single process steps are carried out by experts in accordance with

proven processes

Individual modules repairs alongside the full overhaul services.


Experience due to approx. 11,000 completed engine shop visits

Privilege relations with the manufacturers

High number of various approval and certifications such as ISO 9001, EN

9100, FAR 145 and much more



Case StudiesHerrenknecht AG


Tunnel boring machines (TBM) are developed and manufactured according to specific project requirements

After a tunnelling project is finished, the machine typically did not reached its technical life time. Therefore,

Herrenknecht conducts a machine analysis, rebuys the complete TBM or the reusable components and takes

them back to the Herrenknecht Rebuilt Services in Kehl (Germany).

Products:

Tunnel boring machines (TBM)


Identification

Disassembly

Initial analysis on components level

Calculation of TBM – Integration of reman components

Design of TBM including remanufactured components

Disassembly

Cleaning

Remanufacturing

Cleaning

Painting

Reassembly


Design for remanufacturing



Agenda

Introduction



Case Studies







Remanufacturing and Advanced MaterialsInternet Research

0

5

10

15

20

25

Countries

10

46

31

11

1 3

Industry Sectors

Aerospace

Consumer goods

Furniture

Machinery

Marine

Medical

none

Preliminary results



Agenda

Introduction



Case Studies







Todays and Tomorrows ChallengesSWOT Analysis – Today

Preliminary results based on a workshop in Bayreuth with 42 participants



Todays and Tomorrows ChallengesSWOT Analysis – Tomorrow

Preliminary results based on a workshop in Bayreuth with 42 participants



Agenda

Introduction



Case Studies







Remanufacturing Processes ToolkitMock-up



Agenda

Introduction



Case Studies






Remanufacturing Process AssessmentRemanufacturing Process Assessment - Two day assessment approach



Remanufacturing Process AssessmentRemanufacturing Process Assessment - Topics

Parts management (cores, spare parts and finished products)

Technology know how

Costs

Information flow

Material flow

Quality management and assurance

Technical cleanliness

Resource efficiency (sustainability)



Remanufacturing Process AssessmentRemanufacturing Process Assessment - Results

Value stream map including OBC – Operator

Balance Chart

Results of benchmarking

Detailed analyses of maturity level

List of improvement potentials

Starting point to improve your

remanufacturing processes

and

to increase your competitiveness



Remanufacturing Process AssessmentHow you can participate and profit

short term

low

co

st

long term

exp

en

siv

e

1

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3

4

5

76

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Be a part of

and benefit from the ERN –

European Remanufacturing

Network

Two-day assessment

of your remanufacturing

operations

5.200.-€_______



Thank you for your attention

Steffen Butzer

M.Sc., Dipl.-Wi. Ing. (FH)

Universitaetsstrasse 9

95447 Bayreuth

Phone ++49 (0) 921 / 78516 420

Fax ++49 (0) 921 / 78516 105

[email protected]

www.regenerative-produktion.fraunhofer.de

European Remanufacturing Network Assessing and Improving ...Shows,Events/Birmingham_UK... · European Remanufacturing Network Assessing and Improving ... Knorr Bremse Company and

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