In an era of rising raw material costs, increasing sustainability pressures, and stricter regulatory requirements, remanufacturing is becoming more and more important. Remanufacturing not only offers ecological benefits but can also be economically attractive by reducing material costs and extending product lifecycles. But how can this concept be effectively incorporated into product development and Product Lifecycle Management (PLM)? This blog post explores the role of remanufacturing in discrete manufacturing and outlines how it can be successfully integrated into product development.
Remanufacturing is an end-of-life strategy that reduces the use of raw materials and energy necessary to manufacture new products. Economically, remanufacture is an interesting strategy due to preserving the product’s value added during the design and manufacturing processes. The remanufacture process can be defined as a product recovery strategy focused product restoration and reconditioning of its parts, in order to rebuild it according to its original design within the whole product lifecycle management1.
Remanufacturing is the process of restoring used or worn products to the same or even better condition than new products. Unlike recycling, which focuses on recovering raw materials, remanufacturing aims to retain and reuse as many components as possible. This means that products or components are cleaned, repaired, and rebuilt to restore their original performance, or even enhance functionality.
For discrete manufacturing – the production of distinct, individually recognizable products – remanufacturing is particularly valuable, as complex parts like machinery, vehicles, or electronics often require expensive materials and precise manufacturing processes.
Product Lifecycle Management (PLM) encompasses the management of a product throughout its entire lifecycle, from conception and development to production and eventual disposal or recycling. PLM aims to optimize information, processes, and resources throughout this cycle.
To integrate remanufacturing into the PLM process, companies must move beyond the traditional “cradle-to-grave” approach and instead adopt a “cradle-to-cradle” model. This means that the product is not discarded at the end of its life cycle but rather reintegrated into the production process, either through direct reuse or remanufacturing.
A PLM system can ensure the traceability of requirements and components and also supports the standardization or modularization of components and assemblies.2
Incorporating remanufacturing into PLM presents many challenges, but also opportunities. The key lies in considering all subsequent lifecycle phases during the product development stage.
Remanufacturing should be considered as early as the product development phase. The concept of “Design for Remanufacturing” (DfRem) plays a crucial role here. Products must be designed to allow for easy disassembly, repair, and refurbishment. Below are some key principles of DfRem:
A core aspect of Remanufacturing is developing modular products. A modular architecture allows for easy separation and replacement of individual components or assemblies, significantly simplifying the remanufacturing process. This reduces the effort required for repair and refurbishment and increases the likelihood that products can undergo multiple remanufacturing cycles.
Example: In the automotive industry, vehicles are increasingly being designed so that major assemblies, such as engines or transmissions, can be easily disassembled and refurbished. Modular design simplifies the replacement of defective parts, reducing the need for new resources.
For products intended for remanufacturing, using durable and high-quality materials is essential. These materials must withstand multiple cycles of use, repair, and refurbishment without losing their functionality.
In the long term, investing in high-quality materials reduces overall costs as the need for new raw materials decreases. Additionally, the longevity of the products improves customer satisfaction, which in turn can positively impact brand perception.
The ability to easily disassemble and reassemble a product is critical for successful remanufacturing processes. Automation and digitization also play a significant role here. Using digital twins or augmented reality (AR), assembly and disassembly processes can be virtually simulated and optimized. This leads to more precise planning and allows potential bottlenecks or difficulties to be identified early on.
Example: In the aerospace industry, engines are designed to be efficiently disassembled, inspected, and repaired. These processes are supported by digital tools that ensure all parts are correctly reassembled and tested.
Another step towards better remanufacturing is the standardization of components. Standardized parts can be used across various product lines, significantly simplifying both production and remanufacturing. This not only facilitates the procurement of replacement parts but also ensures that remanufacturing processes are more efficient.
Integrating remanufacturing into PLM offers numerous benefits, both from an ecological and economic standpoint. Here are some of the key advantages:
By reusing parts and materials, companies can significantly reduce their production costs. As raw materials become scarcer and more expensive, remanufacturing provides a way to reduce dependence on new materials. At the same time, energy and other resources can be saved, as manufacturing new components is often more energy-intensive than refurbishing used parts.
Another benefit of remanufacturing is the extension of product lifespan. Products designed for remanufacturing can be refurbished multiple times and reintroduced into the market. This not only reduces waste but also increases the product’s value over its entire lifecycle.
Remanufacturing offers companies the opportunity to build closer relationships with their customers. By taking back used products and refurbishing them, companies can offer customers more affordable and sustainable alternatives. Many consumers increasingly value sustainable products and are willing to remain loyal to brands that offer such options.
The growing number of environmental regulations is forcing many companies to implement more sustainable production methods. Remanufacturing provides a way to meet these requirements while simultaneously improving the company’s sustainability image.
Despite the many benefits, there are also some challenges that must be considered when integrating remanufacturing into PLM and product development.
Designing a product for remanufacturing can be more complex than a conventional design. Developers not only need to consider the product’s functionality but also ensure that it can be easily repaired and refurbished. This requires a high level of interdisciplinary collaboration between designers, engineers, and manufacturing experts focusing on design and disassembly operations.
Disassembly is an integral part of maintenance, upgrade, and remanufacturing operations to recover end-of-use products. Optimization of disassembly sequences and the capability of robotic technology are crucial for managing the resource-intensive nature of dismantling operations.3
The initial investments in technologies and processes for remanufacturing can be high. Companies may need to invest in new machinery, training, and systems to support the transition to a remanufacturing-oriented business model. However, these investments typically pay off over time, as operating costs decrease through reduced material costs and improved efficiency.
The return of used products to the manufacturer, along with storage and transport, presents further challenges. A well-thought-out return system, as well as partnerships with logistics providers, are necessary to ensure an efficient remanufacturing process.
Incorporating remanufacturing into Product Lifecycle Management is a promising strategy for combining economic and ecological benefits. By considering remanufacturing early in product development, companies can increase the longevity of their products, save resources, and offer customers sustainable and cost-effective alternatives.
Companies in discrete manufacturing that manage to anchor remanufacturing as an integral part of their PLM can not only reduce costs but also position themselves as leaders in sustainability – a crucial advantage in a world that is increasingly focused on resource-efficient production methods.
1: Remanufacturing on a Framework for Integrated Technology and Product-System Lifecycle Management (ITPSLM); Proceedings of the 1st CIRP Industrial Product-Service Systems (IPS2) Conference, Cranfield University, 1-2 April 2009, p274
2: Product Lifecycle Management (PLM) als Rückgrat einer nachhaltigen Produktentstehung; https://manager-wissen.com/product-lifecycle-management-plm-als-rueckgrat-einer-nachhaltigen-produktentstehung; besucht am 18.09.2024
3: Optimization-Based Disassembly Sequence Planning Under Uncertainty for Human-Robot Collaboration; Liao, H., Chen, Y., Hu, B., and Behdad, S. (November 1, 2022).” ASME. J. Mech. Des. February 2023; 145(2): 022001. https://doi.org/10.1115/1.4055901
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