New processes and procedures are also required for the remanufacturing industry in order to promptly prepare for disruptive events such as the structural change towards e-mobility and the associated new technologies and vehicle components. As development is progressing at a rapid pace, it is essential for manufacturers to prepare for this change at an early stage and to position themselves strategically and sustainably. These new technologies and vehicle components must be integrated into the product range. This facilitates the exploitation of cost potentials, but also the creation of unique technological features in comparison to the competition.
In addition to the conceptualisation and design of the individual process steps (disassembly, cleaning, repair and assembly) and the selection of suitable manufacturing technologies, an end-to-end view of the entire process landscape is also required.
Only once the interplay of the quantities from disassembly to assembly of the repaired components is ensured can repairs follow on an industrial scale.
New technologies and manufacturing processes require integration into existing production lines or the implementation of new ones. Among other things, this includes a comprehensive requirements analysis in development, the industrialisation of tools, as well as sustainable and robust quality management.
In addition, an adaptation of the IT systems is indispensable to ensure monitoring and transparency of the defined processes.
Which technologies and core processes are decisive for remanufacturing?
The entire repair process can be complex and extensive and there is no single answer when it comes to technologies which are to be employed. However new technologies can help to remanufacture parts that could not be remanufactured before (e.g. plasma coating etc.). The design of the part itself dictates the technology employed in its remanufacturing. „Design for remanufacturing“ can therefore also play a role in parts design.
What are the challenges in planning and implementing these processes?
In our view, the smooth interaction and detailed coordination of the individual process steps are the critical success factors for a smooth remanufacturing process. Only if each individual process step is coordinated and all interactions and interfaces are taken into account can new repaired components be produced on an industrial scale on the basis of old spare parts.
Which technologies and core processes will be important for me in the future?
It is only through the continuous observation of the competition and cooperation with research facilities and institutes that potential can be identified and exploited at an early stage. New technologies and processes must be integrated into the existing remanufacturing business as early as possible in order to remain competitive in the fast-moving market of the future.
We have already defined and implemented repair processes for our customers in the most varied of projects. We know the typical challenges in the definition of the necessary processes and the challenges posed by the interaction of the interfaces. The complexity of the subject area particularly appeals to us: whether it be the introduction of new part number ranges, the definition of release processes or the complete integration of remanufacturing into your existing plants. When it comes to solving complex problems, we benefit not only from our expertise but also from a certain degree of creativity. For example, we have developed tailored selection tools specifically for our customers, with which old returned parts can be identified not only more reliably but also significantly faster.
Due to our broadly based know-how, we are able to define a comprehensive view of the future target process across all departments. In this regard, the interplay between quality, production, logistics, development and release plays a decisive role. You benefit from our procedural know-how and our expertise in manufacturing and production, which we have continuously acquired in numerous initiatives and projects. Among other things, this includes the complete conceptualisation and planning of an assembly plant in which a 3-digit number of engines is industrially repaired every year.