Showing papers on "Remanufacturing published in 2000"

Developing a Theory of Reverse Logistics

Abstract: Reverse logistics, a fairly new concept in logistics, has gained increasing importance as a profitable and sustainable business strategy. I describe a holistic view of reverse logistics and distill 11 insights for successful implementation of reverse logistics from the existing literature and published case studies. The strategic factors consist of strategic costs, overall quality, customer service, environmental concerns, and legislative concerns. The operational factors consist of cost-benefit analysis, transportation, warehousing, supply management, remanufacturing and recycling, and packaging. Insights about these factors together form the state-of-the-art knowledge about the keys to successful design and use of reverse-logistics systems.

Reverse-Logistics Strategy for Product Take-Back

Abstract: Product take-back of consumer products is generally expensive, especially reverse logistics. In the take-back program for power tools in Germany, costs exceed revenues for recycling power tools. Systematic analysis of take-back alternatives can make take-back policies more attractive. For example, an alternative take-back system for power tools would combine profitable remanufacturing and unprofitable materials recycling. The profit from remanufacturing could cover the loss from recycling as well as the costs of reverse logistics, allowing the manufacturer a profit. Remanufacturing requires a continuous flow of returned postconsumer products. By buying back end-of-life products, firms could control the flow of returned products. We developed a model that allows us to determine the optimal amount to spend on buy-back and the optimal unit cost of reverse logistics. We can use the latter to select a suitable reverse-logistics system for end-of-life products. We apply our model to the remanufacturing take-back concept for power tools, using empirical data on the current take-back program.

Product acquisition management: Current industry practice and a proposed framework

Abstract: Remanufacturing requires that used products (cores) be obtained from the enduser at the end of their current life cycle so that the value-added may be recovered and the products returned to functional use again. The acquisition of cores to be remanufactured in such recoverable manufacturing systems is a complex set of activities that requires careful coordination to avoid the uncontrolled accumulation of core inventory, or unacceptable levels of customer service. The authors report on current industry practice via an extensive survey of North American remanufacturing firms. The authors propose a formal framework for Product Acquisition Management (PrAM) to coordinate, monitor, and provide an interface between reverse logistics and production planning and control activities. Finally, a series of managerial guidelines for the organization of PrAM activities is proposed. We conclude that managers should take actions that consistently reduce the variance inherent in a remanufacturing environment.

Design and implementation of an adaptive process planner for disassembly processes

Abstract: This paper presents a methodology for designing and implementing disassembly plans and processes using Petri nets (PN) for remanufacturing obsolete products. Process modeling and planning using PN are discussed. The proposed PN accommodate product topology and precedence relations during disassembly. Decision values are attached to PN to enable consideration of uncertainty during process execution. The resulting planner guarantees the plan's optimality when product remanufacturing parameters are known. In cases of uncertainty about product parameters, an adaptation scheme is designed and implemented to facilitate the goal of maximum benefit. Three planning and execution algorithms (globally fixed, limited adaptive, adaptive) are presented for disassembly processes. They are demonstrated comprehensively through a robotic disassembly system, and its use is demonstrated in disassembly of a car radio.

Disassembly modeling, planning and application: a review

Abstract: Industrial recycling and remanufacturing is practice of growing importance due to the increasing environmental and economic pressures. It involves product disassembly to retrieve the desired parts and/or subassemblies by separating a product into its constituencies. The disassembly process modeling and planning is more challenging than assembly since its termination goal is not necessarily fixed depending on the system status. Moreover, it is uncontested that disassembly is charged with more uncertainty in system structures and component conditions than assembly. The paper reviews methods for modeling and process planning in disassembly. Its purpose is to survey the state-of-the-art of this emerging area to supply important information for future study.

A Decision Support System for Planning Remanufacturing at Nortel Networks

Abstract: We developed a decision support system (DSS) for Nortel Networks, an international digital and internet network equipment manufacturer, to improve its planning of its remanufacturing operations for circuit assemblies. This has resulted in economic benefits to the company during the past three years. The system embodies a reverse-logistics model that allows decision makers to better plan the outbound and inbound product flows involved in making design changes. Careful modeling of the decision-making process and its embodiment in appropriate information technology were keys to the successful implementation of the project in Nortel's operations.

An explanatory study on electronic commerce for reverse logistics.

Abstract: E-commerce for reverse logistics is an area of web applications that has been active and progressing aggressively, especially in the US, though it has not been explicitly recognised until now. It has given reverse logistics in general and especially remanufacturing of parts and re-use of surplus goods an important stimulus. However, existing E-commerce models are rather restricted and represent simply the migration of conventionally practices over the Web.

Analysis of service selling and design for remanufacturing

Abstract: A focus on selling services or functions instead of physical products can, through remanufacturing, be a way of closing material flows in present society. When a company decides to sell services, a closer connection with the customer can be established and a better control over the products can be achieved. This analysis shows that it is preferable that products aimed for service selling are designed for remanufacturing, since this facilitates the remanufacturing. With remanufacturing, economical and environmental benefits can be gained. Historical cases indicate this, and are described in this article along with an ongoing pilot project of service selling.

Design for recycling and remanufacturing

Abstract: The paper describes methods of designing for recycling and remanufacturing. In the field of design for the environment, the two greatest challenges are: (1) Materials which combine high performance and recyclability. (2) Design for remanufacturability, which implies design for disassembly.

Analysis of toner-cartridge remanufacturer waste stream

Abstract: Environmental concerns with the disposal of laser-printer toner cartridges are being addressed, in part, by the remanufacture of toner cartridges. Remanufacturing, or recycling at a part level, involves the disassembly, restoration to like-new condition and reassembly of a used product. Remanufacturing offers significant environmental benefits by reusing the energy and resources expended during original manufacture, and by diverting solid waste from landfill and incineration. Since the primary purpose of remanufacturing is to reuse parts, the parts that are not reused enter the remanufacturers' waste stream and may be studied to identify difficulties in remanufacture. The research undertaken aims to quantify the amount of product discarded (as opposed to reused) and to categorise reasons for discard in the toner-cartridge industry. From the discard reasons, it may be possible to identify product design factors that directly affect the remanufacturability of the product. This knowledge may be used to formulate design strategies to facilitate remanufacturing. The waste streams of three toner-cartridge remanufacturers were studied. Data gathered over a period of four months showed the main reasons for discard and highlighted areas in toner-cartridge design that are problematic for remanufacture.

Optimal Control of a One Product Recovery System with Backlogging

Abstract: In this paper a product recovery system for one product is investigated. The system contains one inventory for returned and recoverable items and one for serviceable items. Demands are satisfied from serviceable inventory where backlogging of demands is allowed. In addition, there is the possibility of disposal for the returned products. We assume deterministic but dynamic return and demand rates and a linear cost structure. The Pontryagin maximum principle is used to determine the optimal production, remanufacturing and disposal policy.

Reverse logistics is the key for remanufacturing and a sustainable development

Abstract: To establish sustainable development in industrialized countries an areawide, effective logistic network for the redistribution of used products will be necessary. Waste disposal logistics plays the key role in the realization of the closed substance cycle and waste management. Its task is to provide logistic links between the use and the recycling of products to close cycles. In future the development of appropriate transport chains by combining collection, transport, handling, storing, dismantling, reprocessing and treatment will decide on whether the economic and simultaneously ecological closing of material cycles will be successful. The realization of the closed substance cycle and waste management with the help of material cycles will considerably increase the number of the products to be returned and to be processed. The different requirements on collection, dismantling, recycling and reprocessing in the field of the high-grade and preferably short-life products and components will lead to a specialization and centralization of single processing plants. For lower-grade used products of relative high transportation effort, the decentralization of logistic facilities will be successful.

Procedure to Evaluate Alternatives to Transit Bus Replacement

Abstract: The addition of new buses to a transit agency's fleet is a capital-intensive project. In an average year, more than 3,500 buses are purchased by FTA grantees. The annual cost of bus replacement easily exceeds $1 billion. A procedure to evaluate alternatives to bus replacement is presented. Two generic alternatives are identified—rehabilitation and remanufacturing. The former approach focuses on the repair of engines and machine components. The latter approach is to restore a vehicle's structural integrity. The evaluation procedure is based on economic principles and quantifies the benefits and costs associated with postponing a bus replacement, either by rehabilitation or remanufacturing. A modified benefit-to-cost ratio (B/C) technique is proposed that incorporates intangible benefits and disbenefits, as well as a risk penalty associated with the extended use of an older bus. As an alternative to computing the B/C, the recommended approach is to estimate the maximum investment that can be justified in a ...

Composition and value of returned consumer and industrial information technology equipment

Abstract: Due to continuing technological advances, information technology (IT) equipment has maintained an ever decreasing product lifecycle. In the industrial sector, this usually means a rapid turnover of recent vintage computer systems that are loaded with still remarketable parts and assemblies. In the consumer sector, this rapid turnover coupled with consumer reluctance to discard their outdated equipment, has resulted in the return of aged systems of questionable value. Therefore, as systems are returned to remanufacturing or demanufacturing centers, it becomes key to understand the compositional make-up and characteristics of the systems so that the "breakpoints" of value for resale, parts recovery, or commodity and material disposal options are known. This paper first presents data obtained from characterizing a sample of returns of IBM(R) equipment from the industrial sector. Items such as resale value, expected parts recovery value, and strict material recovery by system vintage are highlighted. Second, data characterizing returns on systems collected during a community personal computer takeback offering is presented. Items such as product composition by component and weight, processor technology, and monitor/display conditions are discussed.

Optimal Production-Inventory Strategies for a Reverse Logistics System

Abstract: Reverse logistics is the term for logistic environments with reuse of product and materials. In these systems products can be manufactured and the returned units be remanufactured. These can be considered as new. The operation of such a system is described by the return process of used products and the disposal activity. The effectivity of a reverse logistics system can be measured by its costs. The costs are inventory holding costs, manufacturing and remanufacturing costs. We investigate two stores. The demand is satisfied from the first store, where the manufactured and remanufactured items are stored. The returned products are collected in the second store and then remanufactured. The costs of this system consist of the linear holding costs for these two stores and the convex non-decreasing manufacturing and remanufacturing costs. There is no delay between the using and return process.

Generator/alternator remanufacturing kit apparatus

Abstract: In accordance with the teachings of the present invention, a remanufacturing kit that reduces the assembly functions and time required for remanufacturing a 50 DN generator is disclosed. The kit includes a box member, a pre-tested 50 DN generator subassembly, a rotor, an installation kit and an insert structure for securing the 50 DN generator subassembly, the rotor and the installation kit within the box member.

Remanufacturing Engineering in 21st Century

Abstract: With the 21st century coming, the excellent quality, high benefit, low expense, less pollution will be the aim of the advanced manufacture and maintenance engineering. Along with the form of the systems engineering of the manufacture and maintenance, remanufacturing technology is formed and has been given more and more attention in recent years. The remanufacturing technology, which utilized advanced surface engineering and forming technology, has become a new branch of the advanced manufacturing technology. The relationship between the remanufacturing and the advanced manufacturing is discussed in this paper. The research direction of the remanufacturing technology is elaborated also.

Eco-Efficiency and Sustainable Product Development

Abstract: 2 Introduction 4 Eco-Efficiency 5 Extended Product Responsibility 6 Design for Environment and Remanufacturing 7 Economics of Remanufacturing 8 Case Study I: Rank-Xerox Corporation 9 Product Stewardship 12 Case Study II: Dow Chemical/Responsible Care Program 13 Services vs. Products 14 Case Study III: Ford Motor Company/DuPont 15 Case Study IV: The Evergreen Program, Interface 15 By-Product Synergy 16 Case V: Chaparral Steel 16 Life-Cycle Analysis 17 Streamlined LCA 20 Case Study VI: AT&T’s Abridged Life-Cycle Assessment 21 Environmental Policy 23 Industrial vs. sustainable economy 27 Linear economy vs. cyclic economy 27 Conclusions 28 References 29

Inline troubleshooting for electronics manufacturing systems

Abstract: A variety of different remanufacturing methods have been successfully developed and tested during the last decades of the 20th century, but it has also been proven that none of them has perfectly produced final reliable joint throughputs from the remanufacturing line. Now, the new objective is to develop alternative methods instead of utilizing manual, semi-automated or automated remanufacturing systems. The new technology, which has been under investigation for less than two years, focuses on eliminating the causes of these remanufacturing problems since the old technologies practiced in remanufacturing are costly, complicated, and require skilled operators. The solution suggested in this paper is to develop a new knowledge based system that can be used by operators in their electronics remanufacturing and manufacturing assembly lines to reduce and eventually eliminate the number of the defects and problems with a zero percent defect rate goal.

Business Case Oce: Reverse Logistic Network Re-Design for Copiers

Abstract: The introduction of extended producer responsibility forces Original Equipment Manufacturers to set up a logistic network for take back, processing and recovery of discarded products. In this paper, we discuss a business case study carried out at Oce, a copier firm in Venlo (NL). It concerns the installment of remanufacturing processes. There is a choice from two locations in Venlo (NL) and one in Prague (Czech Republic), where assignments are subjected to managerial constraints. The study is meant to verify whether the strategic decision of Oce to move remanufacturing activities to the Czech Republic is also economically feasible. We limit ourselves to an optimisation of the HV02-machine network. We follow our general approach, in which we first determine how return products are processed (recovery strategy) and subsequently optimise the reverse logistic network design. We optimise on total operational costs over all possibilities and also compare three pregiven managerial solutions (=network designs) with a Mixed Integer Linear Programming model. Differences in economic costs appear to be very small, hence installing recovery activities in Prague for the HV02-machine must be well motivated from a strategic point of view. Moreover, we argue that besides cost minimisation, Oce should include performance indicators, such as JIT, reliability, in logistic optimisation to support its quality oriented business strategy. In addition, we discuss aspects regarding specific modelling elements in this case situation, the definition of cost functions, the possibility of optimising the forward and reverse logistic network and the use of LP- versus MILP-models in this kind of situations. Key words: Reverse logistics - Remanufacturing - Copying machines - Oce - Location-allocation - Case-study - Mixed integer linear programming

Hybrid approach to forecast returns of scrapped products to recycling and remanufacturing

Abstract: Forecasting of scrapped products to recycling poses severe problems to recycling and remanufacturing companies due to uncertainties in available data. In this paper an extended prediction method to forecast return values (amount and time) of scrapped products to recycling is presented. The suggested model is based on important influencing factors and product life cycle data and has been applied to a case study (photocopiers) for evaluation. The approach employs a simulation study, the design of a fuzzy inference system for the prediction of the return in a specific planning period and the design of a neuro-fuzzy system for the prediction of return values with respect to time.

Near optimal buffer allocation plan for remanufacturing systems

Abstract: A remanufacturing system is prone to inefficiencies because of built-in uncertainties and complexities of the nature of the operations. One way to improve the performance of the system is to distribute a given number of available buffer slots among the stations in a strategic manner. In this paper we present a near optimal buffer allocation plan (NOBAP) specificially developed for remanufacturing systems. To this end, we introduce an algorithm that analyzes the system using an open queueing network with finite buffers and unreliable machines. In order to analyze the queueing network, we use the decomposition principle and expansion methodology. The results obtained by using the algorithm are compared with the ones found using the exhaustive search. The results show that the NOBAP is very rigorous and remarkably accurate.

An NPV and AC Analysis of a Stochastic Inventory System with Joint Manufacturing and Remanufacturing

Abstract: While the net present value (NPV) approach is widely accepted as the right framework for studying production and inventory control systems, average cost (AC) models are more widely used. For the well known EOQ model it can be veri_ed that (under certain conditions) the AC approach gives near optimal results. This paper investigates whether the same holds for two-source systems with joint manufacturing and remanufacturing. It appears that the performance of the AC approach stands or falls with the right choice of the holding cost parameters. Through the analysis of a deterministic model a theoretical basis is provided for choosing the parameters. Then, given this set of holding cost parameters, the performance of the AC approach is tested in a stochastic model.

Material Planning for a Remanufacturing Facility

Abstract: This article describes the first fully integrated material planning system to facilitate the management of a remanufacturing facility. A number of firms are already engaged in this activity. They remanufacture automobile, truck, and other vehicle components, like starters, alternators, transmissions, and so forth. These firms take in used components, disassemble them, and assemble saleable products from the good parts they find. There is considerable uncertainty in the supply of used components, the good parts in those components, and the demand for remanufactured products. Our system is based on material requirements planning logic, something that many firms in the industry are already familiar with. Meetings with experts in the industry were used to set the parameters of the system and evaluate its approach.