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

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

One Solution: Remanufacturing The “Ultimate Form of Recycling”

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

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

Remanufacturing vs. Recycling 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

Life Cycle of a Product

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

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

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

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

What products are remanufactured?

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

Some Examples of Remanufacturing

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: www.kodak.com

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

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.)

What is the Benefit of Remanufacturing . . . Automotive Engines? Energy savings of 50% Remanufactured engines cost $800 to $2500 - versus the cost of a new car

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

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

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

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

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

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

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

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

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

RIT’s NC3R Capabilities & Solutions Structural & Material Analysis Determine how products "age" & how to restore them: Material Salvage Finite Element Analysis Failure Analysis Dimensional Restoration

RIT’s 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

RIT’s 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

RIT’s 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.

RIT’s 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.

RIT’s 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.

RIT’s National Center for Remanufacturing and Resource Recovery (NC3R) www.reman.rit.edu