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Sustainable Manufacturing and Factory Planning Remanufacturing 05.04.2017 Technische Universität Berlin Institute for Machine Tools and Factory Management Univ.-Prof. Dr.-Ing. Holger Kohl © IWF TU Berlin Page 1 Table of Contents  Global Resources  Product Life Cycle Perspectives  Remanufacturing Processes  Remanufacturing Cases  Chances for Implementation  Literature and References Technische Universität Berlin Institute for Machine Tools and Factory Management Univ.-Prof. Dr.-Ing. Holger Kohl Page 2 Table of Contents  Global Resources  Product Life Cycle Perspectives  Remanufacturing Processes  Remanufacturing Cases  Chances for Implementation  Literature and References Technische Universität Berlin Institute for Machine Tools and Factory Management Univ.-Prof. Dr.-Ing. Holger Kohl Page 3 Environmental and Social Challenges  Distribution of wealth among global population Challenge: How to convert from 1/5 of global population exploiting 4/5 of global resources to acceptable distribution of wealth within ecological limits. Technische Universität Berlin Institute for Machine Tools and Factory Management Univ.-Prof. Dr.-Ing. Holger Kohl Source: [Dfg-13a] Page 5 Scenarios on Oil Availability  Caused by the finiteness and the limited extraction possibilities from non-renewable resources like oil, aluminum, copper and lead, the prices of raw material are currently rising.  The exact date from peak oil, the moment when the oil extraction volume is stagnating or reducing is planned according to the estimations between 2010 and 2100. trendlines.ca Illustration: The most important peak oil scenarios 1950 1975 2000 2025 2050 2075 2100 2125 2150 Technische Universität Berlin Institute for Machine Tools and Factory Management Univ.-Prof. Dr.-Ing. Holger Kohl 2175 2200 2225 2250 2275 2300 Page 8 Energy Demand from 1980 to 2035  The worldwide primary energy consumption increased by 25% within the last 10 years Projections according to IEA Gtou Other energy sources Biomass Hydraulic energy Nuclear energy Natural gas Legend: Gtou = Giga-ton Oil unity 1 Gtou = 1 billion tons Coal Oil Technische Universität Berlin Institute for Machine Tools and Factory Management Univ.-Prof. Dr.-Ing. Holger Kohl Source: [IEA-12] Page 9 Rising Raw Material Costs – Example of Crude Oil Price Development from crude oil price Public debt crisis Period 1960-2012 Bank crisis www.tecson.de Oil crisis Technische Universität Berlin Institute for Machine Tools and Factory Management Univ.-Prof. Dr.-Ing. Holger Kohl Page 10 Table of Contents  Global Resources  Product Life Cycle Perspectives  Remanufacturing Processes  Remanufacturing Cases  Chances for Implementation  Literature and References Technische Universität Berlin Institute for Machine Tools and Factory Management Univ.-Prof. Dr.-Ing. Holger Kohl Page 12 Product – Product Life Cycle Economic View  Economic product life cycle  Covers the duration of the presence of a product in the market  Product life cycles vary for different product types  Automotive: 7 years  Mobile phones: 6 month Product modification Product introduction Product life cycle new life cycle Product elimination Profit and Turnover Legend: Turnover: Product profit: + 0 - Development Introduction Technische Universität Berlin Institute for Machine Tools and Factory Management Univ.-Prof. Dr.-Ing. Holger Kohl Growth Maturity Saturation Decline Relaunch Recycling/ Disposal Source: [Pah-07] Page 13 Product – Product Life Cycle Technological View  Technological Product Life Cycle (≠ economic product life cycle)  Integrated model that covers all areas of a product‘s existence Recycling Raw material production •Selection of material •Make-or-Buy Production •Manufacturi ng •Assembly Distribution Remanufacturing Use Phase •Design •Usage •Maintenance Final storage Technische Universität Berlin Institute for Machine Tools and Factory Management Univ.-Prof. Dr.-Ing. Holger Kohl Re-use Valorisation Collection Incineration Transport (from product or part) Disposal Source: [Sel-00] Page 14 Business Approach Resources Cycles and “Selling Use Instead of Products”  Approach  Use of material and components of old/used products to manufacture new products  Primary raw materials (e.g. obtained by excavation) with the equivalent of € 3.7 Billion are substituted by secondary raw material (e.g. obtained out of used products or waste) in Germany, 2007  Elements of Cycle economies, including business opportunities Information Management Facility Management Product Development Production Distribution Service-engineering Logistics Pool Management Selling Utilization Use Reassembly Product data preparation Redistribution Cleaning, Control, Processing Reprocessing Disposal Disassembly Traditional material flow Product recycling flow Remanufacturing Product recycling Material Recycling flow Maintenance Repair Product data preparation Technische Universität Berlin Institute for Machine Tools and Factory Management Univ.-Prof. Dr.-Ing. Holger Kohl Cleaning methods Separation tools Source: [Bmu-09], [Sel-05] Page 15 Waste Hierarchy according the European Union Law Best solution Reduce  Waste hierarchy (EU-Directive 2008/98/EG from November 19th, 2008)  The waste hierarchy is valid in the EU as the standard for the correct waste management.  Introduction of extended producer Remanufacture Recycle Incinerate responsibility is one of the means to support:  the design and production of goods which take into full account and facilitate the efficient use of resources during their whole life-cycle including their repair, re-use, disassembly and recycling  without compromising the free circulation of goods on the internal market. Dispose Worst solution Technische Universität Berlin Institute for Machine Tools and Factory Management Univ.-Prof. Dr.-Ing. Holger Kohl  This directive should help move the EU closer to a ‘recycling society’, seeking to avoid waste generation and to use waste as a resource. Source: [Eup-08] Page 16 Disposal and Incineration Best solution Reduce  Incineration of both hazardous and harmless wastes causes emissions of substances which pollute the air, water and soil and have harmful effects on human health.  The European Union (EU) shall impose strict Remanufacture Recycle operating conditions and technical requirements on waste incineration plants and waste co-incineration plants. Incinerator Waste hopper Incinerate Bag filer www.gec.jp Waste crane Boiler Reception hall Dispose Worst solution Technische Universität Berlin Institute for Machine Tools and Factory Management Univ.-Prof. Dr.-Ing. Holger Kohl Ash Induced draft fan discharger Electric room Ash storage Example of municipal waste incineration facility: Mitsubishi stoker incineration system Waste storage Source: [Eup-00b] Page 17 Recycling End-of-Life (EOL) Products Best solution Reduce Remanufacture  The objective of recycling is to recover and reuse the material of the products.  In recycling the identity and functionality of the product is lost and the goal is to return the product to a raw material form to be used in future manufacturing process. Metals collection Recycle Old mobile phone Dispose Metals recycling Valuable metals source www.umicore.com Incinerate Worst solution Example of recycling: precious metals in old mobile phones Technische Universität Berlin Institute for Machine Tools and Factory Management Univ.-Prof. Dr.-Ing. Holger Kohl Source: [Eup-08] Page 18 Targeted Recycling Percentages in the EU WEEE Directive Waste electrical and electronic equipment (2002/96/EC) Large electrodomestical appliances Vending machines IT and telecommunications appliances Entertainement electronics Small electrodomestical applicances Lightening devices Electric and electronic tools Toys, sport and leisure devices Surveillance and controlling devices Gas discharge devices 0% 20% 40% 60% 80% 100% Weight percentage blau = Reutilisation Technische Universität Berlin Institute for Machine Tools and Factory Management Univ.-Prof. Dr.-Ing. Holger Kohl rot = Valorisation grün = Disposal Source: [Bun-05] Page 19 Remanufacturing EOL Products Best solution Reduce Remanufacture  Remanufacturing is the rebuilding of a product to specifications of the original manufactured product using a combination of reused, repaired and new parts.  The purpose of remanufacturing is providing the used products the same level of quality than a new original manufactured product.  There is a total disassembly of the product and several Recycle Incinerate inspections of the components of the product allowing remanufactured products to offer the same guarantee as the new manufactured products.  The components are reprocessed but keep their original form all along the process, thus keeping encapsulated value added. mercedes-benz.ca Dispose Worst solution Technische Universität Berlin Institute for Machine Tools and Factory Management Univ.-Prof. Dr.-Ing. Holger Kohl Mercedes-Benz Canada – Remanufacturing Centre Source: [Joh-14] Page 20 Remanufacturing preserves the product‘s embedded value Product value retained in a product 85% 8% Source of value in the product: Percentages show in this chart are illustrative only. Actual percentages vary with product type Technische Universität Berlin Institute for Machine Tools and Factory Management Univ.-Prof. Dr.-Ing. Holger Kohl Source: [Hau-12] Page 21 Reducing Waste Best solution Reduce Remanufacture  The best strategy for waste management is to design products using less materials alongside their lifecycle.  Packaging is a great example in how companies can manage to reduce waste without altering product characteristics. Recycle Dispose Worst solution Technische Universität Berlin Institute for Machine Tools and Factory Management Univ.-Prof. Dr.-Ing. Holger Kohl www.wasteawarenesswales.org.uk joswinson.org.uk Incinerate Over packaged bananas Example of packaging reduction Page 22 Technical Approach End-of-Life Strategies Within Product Life Cycle  Remanufacturing is typically a more efficient means of material recirculation than recycling.  Remanufacturing retains more of the energy associated with the original conversion of raw materials to finished product.  Similarly, component reuse will typically result in lower overall material and energy use than component remanufacturing. Technische Universität Berlin Institute for Machine Tools and Factory Management Univ.-Prof. Dr.-Ing. Holger Kohl Source: [Nas-06] Page 23 Table of Contents  Global Resources  Product Life Cycle Perspectives  Remanufacturing Processes  Remanufacturing Cases  Chances for Implementation  Literature and References Technische Universität Berlin Institute for Machine Tools and Factory Management Univ.-Prof. Dr.-Ing. Holger Kohl Page 24