Showing papers on "Remanufacturing published in 2003"

Matching Demand and Supply to Maximize Profits from Remanufacturing

Abstract: The profitability of remanufacturing depends on the quantity and quality of product returns and on the demand for remanufactured products. The quantity and quality of product returns can be influenced by varying quality-dependent acquisition prices, i.e., by using product acquisition management. Demand can be influenced by varying the selling price. We develop a simple framework for determining the optimal prices and the corresponding profitability. We motivate and illustrate our framework using an application from the cellular telephone industry.

Analysis and taxonomy of remanufacturing industry practice

Abstract: The remanufacturing industry is a large and economically important industry that includes many market sectors and provides significant societal and environmental benefits. Products are rema...

Optimal control of a one product recovery system with leadtimes

Abstract: In this paper a recovery system for a single product is investigated. Besides a remanufacturing and a manufacturing facility the system consists of one inventory for returned and recoverable items and one for serviceable items. Demands are satisfied from serviceable inventory, which can be replenished by remanufactured returned items, which are as good as new, or by new produced items. Additionally, there is the possibility of disposing of returned items. We determine the cost optimal manufacturing, remanufacturing and disposal rates for the system under the assumptions of a linear cost structure, a finite planning horizon and deterministic and dynamic demand and return rates. Thereby we study two classes of policies, one where backorders are forbidden and another one where they are allowed. In contrast to the existing literature positive leadtimes are considered.

Simple expressions for finding recovery system inventory control parameter values

Abstract: In recent years considerable effort has been devoted to the development of inventory control models for joint manufacturing and remanufacturing. Optimality of control policies is analyzed and algorithms for the determination of parameter values have been developed. However, there is still a lack of formulae or algorithms that allow for an easy computation of optimal or near optimal policy parameter values. This paper addresses the problem of computing the produce-up-to level S and the remanufacture-up-to level M in a periodic review inventory control model. We provide simple formulae for the policy parameter values, which can easily be implemented within spreadsheet applications. The approach is to derive news-vendor-type formulae that are based on underage and overage cost considerations. We propose different formulae depending on whether lead times for production and remanufacturing are identical or not. A numerical study shows that the obtained solutions provide relatively small cost deviations compared to the optimal solution within the investigated class of inventory control policies.

Matching supply and demand to maximize profits from remanufacturing

Abstract: The profitability of remanufacturing depends on the quantity and quality of product returns and on the demand for remanufactured products The quantity and quality of product returns can be influenced by varying quality-dependent acquisition prices, ie, by using product acquisition management Demand can be influenced by varying the selling price We develop a simple framework for determining the optimal prices and the corresponding profitability We motivate and illustrate our framework using an application from the cellular telephone industry

Economic and environmental characteristics of global cellular telephone remanufacturing

Abstract: This paper investigates the state-of-the art in remanufacturing of cellular telephones and discusses economic and environmental issues relative to primary manufacturing. Characteristics of developed countries versus lesser developed countries are explicitly considered in the remanufacturing enterprise, and the corresponding impacts of introducing remanufactured cellular telephones to such markets is discussed. It is shown that while remanufacturing as a process carries a much lower environmental burden than primary manufacturing, the remanufacturing enterprise will likely add to the net environmental burden of the telecom industry, rather than reduce it. The extent of this impact depends on situational issues such as transportation and energy grid technology. The value of expanding the remanufacturing enterprise is also discussed in the context of sustainable development.

Reconfiguring a Remanufacturing Line at Visteon, Mexico

Abstract: Visteon's remanufacturing facility in Lamosa, Mexico was plagued with heavy fluctuations of supply and demand, leading to periods of severe capacity shortage. Management asked us to assess options for improving capacity. We developed a simulation-based line-configuration model that simultaneously considers line balancing and line length (number of production stations) to maximize the remanufacturing system's effective throughput. We computationally analyzed the effect of processing-time variability on line-reconfiguration decisions, the effect of correlated task-processing times on throughput, and the marginal benefits of using dynamic line balancing. Based on the data we collected, we made recommendations for reconfiguring Visteon's remanufacturing line. Management successfully implemented these changes, increased asset utilization, and reduced its planned new investments in capital equipment.

Environmental effects of physical life span of a reusable unit following functional and physical failures in a remanufacturing system

Abstract: Reuse of product components is an effective way to conserve natural resources. Likewise, remanufacturing is a new trend in the field of environmentally friendly products. A product undergoes functional failure or physical failure in a remanufacturing environment, where the former failure is equivalent to the state in which the product cannot be used because of functional insufficiency or obsolescence and the latter failure is equivalent to the state of malfunction or breakdown of a product. A unit intended for reuse should be designed to be durable for a period equal to at least two functional lives through remanufacturing. Utilization of excess materials-for example, for improvement of unit strength-can enable a reusable unit to endure over a period equal to at least two functional lives. However, if the environmental impact of such excessive use of materials is taken into account, a strong doubt arises as to whether such a method truly reduces the environmental load from the viewpoint of lifecycle desig...

Market Segmentation and Product Technology Selection for Remanufacturable Products Revised version of INSEAD WP 2001/47/TM/CIMSO 18

Abstract: Remanufacturing is a production strategy whose goal is to recover the residual value of used products. Used products can be remanufactured at a lower cost than the initial production cost, but remanufactured products are valued less than new products by consumers. The choice of production technology influences the value that can be recovered from a used product. In this paper, we solve the joint pricing and production technology selection problem faced by a manufacturer who considers introducing a remanufacturable product in a market that consists of heterogeneous consumers. Our analysis discusses the market and technology drivers of product remanufacturability and identifies some phenomena of managerial importance that are typical of a remanufacturing environment.

Contribution to design for adaptation: Method to Assess the Adaptability of Products (MAAP)

Abstract: A cycle economy, as a paradigm for industry in the 21/sup st/ century, depends on economical and responsible treatment of limited resources. The objective is to achieve more use with fewer resources. Adaptation by maintenance, repair, remanufacturing, upgrading or downgrading, enlargement and reduction, re-arrangement or modernization extends the usage phase of products. Disassembly and re-assembly processes are major elements of adaptation processes and contribute significantly to increase the use-productivity of resources. The adaptability of a product at the end of its life cycle is significantly influenced by its design. Thus, methodologies and metrics to assess and quantify a product's adaptability are required. A dedicated Methodology for Assessing the Adaptability of Products (MAAP) has been developed and is described in detail. Improvement potential within the design of the product, its components and joints can be derived with this method. Its applicability is assessed in a case study using cellular phones as product examples.

Method for managing returns

Abstract: There are many situations where returns (127) are needed to further business or other objectives. For example, in remanufacturing businesses, cores (128) are rebuilt into remanufactured parts (138) that are sold. To sustain remanufacturing cores (128) must be obtained. One way to assure a supply is to collect a deposit against a core return (130) when a remanufactured part (138) is sold. Tracking of cores (128) and the associated liabilities for the deposits is complex. It is also beneficial to control the liabilities. Provided are systems, methods and steps that enable tracking and other effective management techniques to assure returns (127) and liabilities are managed. In one embodiment, each core (128) and an associated entitlement (156) representative of a liability are tracked. Price changes can be made on core (128) deposits without affecting the ability to control liabilities. The systems, processes and methods lend themselves to computer implementation and use in large businesses.

Saving product lives in global and local remanufacturing networks: a scientific and commercial work report and an outlook

Abstract: Remanufacturing is becoming the standard term for recycling by manufacturing "good as new" products from used products. The paper presents 10 thesis to characterize the perspectives of remanufacturing such as markets and legislation, global dimensions, managing safety and reliability issues, essential strategy for affordable spare parts, reuse and repair concepts, multiple and migratory use of products, product cleaning process and test routines, profit from networking and product remanufacturing to modernisation factories.

Proposal of life cycle design support method using disposal cause analysis matrix

Abstract: This paper proposes a decision support method for determining life cycle scenarios in environmentally conscious product design. Here, decision of life cycle scenarios includes decision of objectives of design modification and selection of appropriate life cycle options, such as upgrading, remanufacturing, maintenance, and reuse. Since main objectives of this research include offering a simple and convenient tool to designers, quality function deployment is employed. The basic idea of this methodology is to analyze main disposal causes of a product by using “disposal cause analysis matrix,” which is proposed here, and to modify design of the product so as to reduce analyzed disposal causes. This will results in extension of product life and long-term usage of components. The method consists of four steps; namely, analysis of disposal causes of a product, selection of life cycle options and components to be replaced and reused, modularization of the product, and determination of life cycle scenarios. This paper also illustrates result of a case study using a cellular phone in order to show how the proposed method supports the decision process of life cycle scenarios.

Design of a Modular Housing Platform to accommodate the remanufacturing of multiple cellular telephone models

Abstract: Concern over the negative environmental impacts associated with the production, use, and end-of-life (EoL) of cellular telephones is particularly high due to large production volumes and characteristically short time scales of technological and stylistic obsolescence. Landfilled or incinerated cellular telephones create the potential for release of heavy metals or halocarbons. While recycling of components other than batteries is still not a widespread activity, cellular telephone remanufacturing is becoming a reality. In fact, third party re-manufacturers of cellular telephones are already making significant profits from sales in emerging markets. The acquisition of OEM cosmetic parts, such as housings, is among the highest costs of the remanufacturing process, especially when considering the large number of different cell phone variants that re-manufacturers must be able to accommodate. To address this issue, the research described in this paper involves the design and prototyping of a Modular Housing Platform (MHP) for cellular telephones. The MHP has the capability to accommodate components from different cellphone models as a means of achieving cost savings and increased efficiency in the remanufacturing process.

Remanufacturing: Impacts of sacrificial cylinder liners

Abstract: Remanufacturing presents tremendous potential for recovering the economic value of manufactured components, and improving the environment. Some design features make remanufacturing less expensive, and/or increase the proportion of components that can be remanufactured. For example, sacrificial components can be used to protect key parts from wear. However, tradeoffs are sometimes involved, and product designers need tools to support design for remanufacturing. This paper presents models for estimating the costs and environmental impacts of employing sacrificial components (cylinder liners) in engine blocks. These models are incorporated into a spreadsheet-based design decision tool. Three illustrative examples demonstrate that 1) remanufacturing lowers overall costs when two lifecycles are considered, 2) sacrificial cylinder liners should be employed for small (2 liter) engines, and their superiority increases with multiple remanufacturing cycles, and 3) for large engines (5.3 liter) using cylinder liners is equally preferred to not using them, with respect to both overall cost and environmental impacts.Copyright © 2003 by ASME

Assessing the benefits of remanufacturing option under one-way substitution and capacity constraint

Abstract: textIn this article, we investigate the profitability of remanufacturing option when the manufactured and remanufactured products are segmented to different markets and the production capacity is finite. It is assumed that remanufactured products can be substituted by the manufactured ones. A single period profit model under substitution is constructed to investigate the system conditions under which remanufacturing is profitable. We present analytical findings and computational results to show profitability of remanufacturing option under substitution policy subject to a capacity constraint of the joint manufacturing/remanufactruing facility.

Analysis of the dynamic impact of environmental policies on reverse logistics

Abstract: This paper studies a production system, which combines product remanufacturing and the original production. The analysis tool employed is the System Dynamics (SD) methodology. Specifically, using SD a dynamic model of a dual system (forward and reverse supply chain) is built. The system includes production, remanufacturing, consumption and disposal of used products. The dynamic model is used to study the system behavior under external influences, such as the environmental legislation and investments on remanufacturing facilities. These influences are examined both during the transient and the steady state. Using the model, it is possible to evaluate alternative strategies and to determine the optimal one towards the objectives.

Sealing device useful in remanufacturing a xerographic photoreceptor module

Abstract: In a module for use in a xerographic printer, a substantially single-piece device includes thereon a cleaning blade, seal flap, and side seals for engaging a photoreceptor. The device can be easily replaced when the module is remanufactured.