Remanufacturing Process Planning (original) (raw)
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Remanufacturing process and its challenges
In the recent years, remanufacture of used-products is becoming an important production activity amongst many companies. This is primarily motivated by the strict environmental regulations, increasing customers' awareness of green environment and economical benefits. Remanufacturing is an industrial process that involves four key processes, namely inspection/grading, disassembly, component reprocessing and reassembly/testing. It is established that the presence and interactions of several unique characteristics within the remanufacturing systems implicates subsequent key processes. These unique characteristics would become challenges to production planning and control activity in any remanufacturing systems. Consequently, it is very imperative that these characteristics are properly taken into account in any production planning and control activity.
2010
Research into effective remanufacturing is recently new and is often concentrated on ensuring that the design of new products to market considers the reuse and reclaim after use. However, the pressure on landfill is already high and remanufacturing solutions are required for products currently at the end of their useful life. The vast majority of these items were produced without consideration of an end-of-life strategy. Remanufacturers are often not the original equipment manufacturer (OEM) but may be third-party contract remanufacturers or independent remanufacturers. OEMs are often very protective of their intellectual property and will not share information even with their contracted partners [1]. Consequently, successful remanufacture is often complicated by the need to “reverse engineer” (often by the disassembly and measurement of new purchased core) a product owing to a lack of available technical information. This can have a significant impact on the speed to market of a re...
Decision makings in key remanufacturing activities to optimise remanufacturing outcomes: A review
Journal of Cleaner Production, 2019
The importance of remanufacturing has been increasing since stricter regulations on protecting the environment were enforced. Remanufacturing is considered as the main means of retaining value from used products and components in order to drive a circular economy. However, it is more complex than traditional manufacturing due to the uncertainties associated with the quality, quantities and return timing of used products and components. Over the past few years, various methods of optimising remanufacturing outcomes have been developed to make decisions such as identifying the best End-Of-Life (EOL) options, acquiring the right amounts of cores, deciding the most suitable disassembly level, applying suitable cleaning techniques, and considering product commonality across different product families. A decision being made at one remanufacturing activity will greatly affect the decisions at subsequent activities, which will affect remanufacturing outcomes, i.e. productivity, economic performance effectiveness, and the proportion of core that can be salvaged. Therefore, a holistic way of integrating different decisions over multiple remanufacturing activities is needed to improve remanufacturing outcomes, which is a major knowledge gap. This paper reviews current remanufacturing practice in order to highlight both the challenges and opportunities, and more importantly, offers useful insights on how such a knowledge gap can be bridged.
Product and process design for successful remanufacturing
2004
Remanufacturing is an industrial process where used products are restored to useful life. This dissertation describes how products can be designed to facilitate the remanufacturing process. It also describes how the remanufacturing processes can be improved to be more efficient. III IV Writing a dissertation is surely not a one man's work; therefore I would like to give my gratitude to people who have been supporting me during my research for this dissertation. First of all I would like to thank my supervisor Professor Mats Björkman who has been supervising and supporting my research from the start to this date. I would also like to thank Dr. Jonas Herbertsson for the comments on my dissertation and the encouragement to reach new goals in my running races. Furthermore, I would like to show my gratitude to the former researchers at Production Systems Dr. Glenn Johansson and Dr. Jörgen Furuhjelm for supporting my research during the first years of research. I would also like to thank all other people at the Division of Production Systems for all their support and especially to Henrik Kihlman, Dr. Mica Comstock and Johan Östlin for fruitful research discussion and cheerful jokes, which have been enhancing the daily work at the office. It has also been a pleasure to collaborate with Dr. Jonas Ammenberg and Sara Tyskeng at the Division of Environmental Technique and Management. I would like to thank all researchers at the environmental division for their support and special thanks goes to Mattias Lindahl with who I have been collaborating much with and who have given much fruitful feedback on the latest versions of my dissertation. I would also like to thank Professor Li Shu for letting me conduct research at University of Toronto. Furthermore, I am very grateful to my friends and researchers at the Life Cycle Design Laboratory at University of Toronto for their friendship and support. My gratitude further goes to Professor Bert Bras, at Georgia Institute of Technology, USA and Professor Rolf Steinhilper at University of Bayreuth, Germany, for their support and feedback on parts of my dissertation. Mr Alf Hedin at Electrolux AB has also been very supportive in my research work over the years and I have had many interesting discussions with him about remanufacturing. Without the founding from Naturvårdsverket (Swedish EPA), the Programme for Production Engineering Education and Research (PROPER), Swedish Agency for Innovation Systems (VINNOVA) and the Swedish Association of Graduate Engineers (CF), this research would not have been possible, thank you. Finally I would like to thank my family back home in Örebro for all their support over the years. They have kept on asking when my studies in Linköping will be finished and I think the moment now has come!
In last century, the world has witnessed a great deal of technological and industrial progress. Branded products manufacturers have been competing in introducing new versions of their products frequently. Retailers and banks have been developing relaxed paying systems to fund the purchase of these new products. Exchanging strategies have been initiated by companies for customers to exchange their old version product for the latest versions. Such exchanging strategies are famous for vehicles, mobiles, and electrical appliances. Hence, a huge amount of unused or spent products are generated every day. Many researchers have been developing different models for dealing with the decisions related to remanufacturing operations. However, there is no decision making system the manufacturers could use for cost / benefit assessment of disassembling and recovering these products that considers the following points: (1) evaluating the value of recovering the whole product versus value associated with recovering its disassembled items , (2) using Multi-Objective Mixed Integer Linear Programming (MILP) to assign spent products and their items to various recovery alternatives considering their received physical conditions, (3) selection of operations for items is not limited by a fixed regular production-hour capacity for each operation, (4) model assumptions, constraints, and formulation that satisfy the three aspects of sustainability, which are economic, social responsibility, and environmental aspects in one step model , (5) considering other vital dimensions which are the quality of recovered products and the minimum batch size for vending recycled materials, (6) utilizing the recycling operation in the optimum way that increases revenue from vending isolated materials. The thesis addresses these points using mathematical modeling and optimization for the remanufacturing operations of spent products.
Innovation and Supply Chain Management, 2014
In product recovery the disassembly process has an important role since it allows for separation and retrieval of desired parts and materials. End-of-life (EOL) products with missing and/or nonfunctional components increase the uncertainty associated with disassembly yield. Sensor-embedded products (SEPs) eliminate a majority of uncertainties involved in EOL management by providing life-cycle information of products. This information includes the content of each product and component conditions, and enables the estimation of remaining useful life of the components. Once the data on the products are captured, it is possible to make optimal EOL decisions without any preliminary disassembly or inspection operations. This paper presents an Advanced Remanufacture-To-Order, Disassembly-To-Order and Refurbishment-To-Order (AR-TODTORTO) model with disassembly precedence relationships among components of an air conditioner (AC). It also inspects and analyzes the impact of using smart sensors in End-of-Life products (EOLPs) on system performance. Various experimental design studies are conducted based on orthogonal arrays (OAs). The customers' demands may be satisfied either by purchasing new components, reassembling components from the returned used products, refurbishing products, or remanufacturing used products based on customers' needs. Discrete event simulation models are used to calculate various performance measures under different experimental conditions.
A Review on the Lifecycle Strategies Enhancing Remanufacturing
Applied Sciences, 2021
Remanufacturing is a domain that has increasingly been exploited during recent years due to its numerous advantages and the increasing need for society to promote a circular economy leading to sustainability. Remanufacturing is one of the main end-of-life (EoL) options that can lead to a circular economy. There is therefore a strong need to prioritize this option over other available options at the end-of-life stage of a product because it is the only recovery option that maintains the same quality as that of a new product. This review focuses on the different lifecycle strategies that can help improve remanufacturing; in other words, the various strategies prior to, during or after the end-of-life of a product that can increase the chances of that product being remanufactured rather than being recycled or disposed of after its end-of-use. The emergence of the fourth industrial revolution, also known as industry 4.0 (I4.0), will help enhance data acquisition and sharing between diff...