1 Design for Remanufacturing and Reverse Logistics

2 Recycle and Re-Use Recycle: Recycle: A series of activities, including collection, separation, and processing, by which products or other materials are recovered from or otherwise diverted from the solid waste stream for use in the form of raw materials in the manufacture of new products. A series of activities, including collection, separation, and processing, by which products or other materials are recovered from or otherwise diverted from the solid waste stream for use in the form of raw materials in the manufacture of new products. Materials which are diverted for use as an energy source should be documented separately under the category of energy recovery Materials which are diverted for use as an energy source should be documented separately under the category of energy recovery Re-Use: Re-Use: The series of activities, including collection, separation, and in some cases processing, by which products are recovered from the waste stream for use in their original intended manner. The series of activities, including collection, separation, and in some cases processing, by which products are recovered from the waste stream for use in their original intended manner. Remanufactured components fall under the classification of re-use. Remanufactured components fall under the classification of re-use. (Germans refer to this as “product recycling”.) (Germans refer to this as “product recycling”.) Note: Both definitions include collection as a first step. Note: Both definitions include collection as a first step. Reverse logistics and reverse logistics management (RLM) are a (design) concern. Reverse logistics and reverse logistics management (RLM) are a (design) concern.

3 Know Your Life-Cycle Processes Know what process you are designing for! Know what process you are designing for! E.g., there is a clear distinction between manual vs mechanical separation design guidelines when it comes to fastener selection. E.g., there is a clear distinction between manual vs mechanical separation design guidelines when it comes to fastener selection. Manual Separation: Manual Separation: Reduce number of fasteners, commonize fastener types, use fasteners made of same or compatible materials, consider snap-fits (two-way, if necessary), etc. Reduce number of fasteners, commonize fastener types, use fasteners made of same or compatible materials, consider snap-fits (two-way, if necessary), etc. Consider destructive fastener removal (possible inclusion of break points) Consider destructive fastener removal (possible inclusion of break points) Mechanical separation (destructive): Fasteners will not be unfastened and fastener disassembly time is irrelevant! Mechanical separation (destructive): Fasteners will not be unfastened and fastener disassembly time is irrelevant! Material properties are key issue! Material properties are key issue! In order of preference, use In order of preference, use 1)Molded-in fasteners (same material) 2)Separate fasteners of same or compatible material 3)Metal fasteners (easy to remove due to magnetic properties) Plastics should have at least 0.03 density difference for sink-float separation) Plastics should have at least 0.03 density difference for sink-float separation) Integrated Product and Process Design should be pursued.

4 Typical Process Problems Facility level: Facility level: Core pipeline is too long Core pipeline is too long Large core and finished good warehouses Large core and finished good warehouses Inadequate supply of replacement parts & cores Inadequate supply of replacement parts & cores Finished goods warehouse has priority over production Finished goods warehouse has priority over production Mass production mindset Mass production mindset Process and Operations level: Process and Operations level: Setups are too long Setups are too long Cycle times of batch operations are too long Cycle times of batch operations are too long Batching generated delays - long lead times Batching generated delays - long lead times Job shop layout Job shop layout Craft production practices Craft production practices Cores & component parts are damaged during processing Cores & component parts are damaged during processing Parts are cannibalized Parts are cannibalized Clearly, one should not forget PROCESS DESIGN! Clearly, one should not forget PROCESS DESIGN!

5 Modularization and Standardization Modular components: By making designs modular, the assembly and disassembly times can be reduced which enhances remanufacturing. Modular components: By making designs modular, the assembly and disassembly times can be reduced which enhances remanufacturing. Standardization: Standardization always supports remanufacture. Pay special attention to the following: Standardization: Standardization always supports remanufacture. Pay special attention to the following: Components: Use as much as possible standard, commonly and easily available components. Use of specialty components may render remanufacture of assemblies impossible if these specialty components cannot be ontained any more. Components: Use as much as possible standard, commonly and easily available components. Use of specialty components may render remanufacture of assemblies impossible if these specialty components cannot be ontained any more. Fasteners: By standardizing the fasteners to be used in parts, the number of different fasteners can be reduced, thus reducing the complexity of assembly and disassembly, as well as the material handling processes. Fasteners: By standardizing the fasteners to be used in parts, the number of different fasteners can be reduced, thus reducing the complexity of assembly and disassembly, as well as the material handling processes. Interfaces: By standardizing the interfaces of components, a fewer of parts are needed to produce a large variety of similar products. This helps to build economies of scale which also improves remanufacturability. Interfaces: By standardizing the interfaces of components, a fewer of parts are needed to produce a large variety of similar products. This helps to build economies of scale which also improves remanufacturability. Tools: Ensure that the part can be remanufactured using commonly available tools. The use of specialty tools can also degrade serviceability. Tools: Ensure that the part can be remanufactured using commonly available tools. The use of specialty tools can also degrade serviceability.

6 Economic Assessment An Activity-Based Costing model was developed and implemented in MS Excel to obtain an economic assessment. An Activity-Based Costing model was developed and implemented in MS Excel to obtain an economic assessment. Uncertainties in the assumptions, cost drivers, and consumption intensities were included using the Crystal Ball software, resulting in the cost distribution below. Uncertainties in the assumptions, cost drivers, and consumption intensities were included using the Crystal Ball software, resulting in the cost distribution below. Approx. 80% of the forecasted situations is less than $671, the maximum allowable cost to make remanufacture an option. Approx. 80% of the forecasted situations is less than $671, the maximum allowable cost to make remanufacture an option.