The remanufacturing of auto parts is the use of advanced cleaning technology, repair technology and surface treatment technology to make used parts meet or exceed the performance of new products and extend the service life of products. This not only makes full use of the secondary resources contained in used parts and components, saves the energy, water, and raw materials needed for manufacturing new products, reduces the exploitation of primary resources, but also reduces costs and facilitates maintenance.
As an emerging industry, auto parts remanufacturing can not only enhance the competitiveness of traditional industries, but also provide a large number of job opportunities. Therefore, the research and development of auto parts remanufacturing industry has significant economic, environmental, and social benefits, and is of great significance to the development of recycling economy, building a resource-saving, environment-friendly society. However, compared with foreign countries, China's auto parts remanufacturing industry is still at an exploratory stage.
A. Concept: Main contents of remanufacturing processing and product performance upgrade
Differences between domestic and foreign experts and scholars on the definition of remanufacturing mainly focus on two points: one is the processing process, and the other is the performance and quality of the product. Industry experts believe that the remanufacturing of auto parts includes two main parts, namely the remanufacturing process and the performance upgrade of obsolete products.
The definition of remanufacturing has been widely disparate in various countries. The remanufacturing of auto parts as a new industry has no uniform definition.
Boston University remanufacturing experts define the remanufacturing as a technical specification: in the factory, through a series of industrial processes, the disused product is disassembled, and the unusable parts are repaired through reprocessing technology, making the repair process. The expected performance and life expectancy of the subsequent parts are at or higher than those of the original parts.
The chairman of the International Remanufacturing Industry Committee and the president of the American Automobile Parts Remanufacturing Association, Ka Ke, defined remanufacturing as: Remanufacturing is a process that restores waste products to the same performance as new products. It can save energy and natural resources, fill the space, and reduce the air pollution caused by the recycling process by reducing material remelting...
The German remanufacturing engineering center defines remanufacturing as: Remanufacturing is the process of reusing a used product into a remanufactured product that is as good as new products.
Xu Binshi, pioneer and advocate of China's remanufacturing project, academician of the Chinese Academy of Engineering and director of the National Defense Key Laboratory of Equipment Remanufacturing Technology, defined remanufacturing as the guideline for the design and management of life cycle of electromechanical products and the performance of used electromechanical products. The general term for a series of technical measures or engineering activities for repairing and renovating used mechanical and electrical products by means of advanced technology and industrialized production, with the goal of leap-forward improvement as the guideline for high quality, high efficiency, energy conservation, material saving, and environmental protection. Simply summarized, remanufacturing is the industrialization of high-tech restoration and transformation of used products.
Domestic remanufacturers define engine remanufacturing as: Engine remanufacturing is the process of returning an engine that has entered a certain life cycle to a new machine in accordance with the remanufacturing process. Some companies are also defined as: Engine remanufacturing is the process of returning an overhauled engine to a new machine in accordance with the remanufacturing process.
Combining the different viewpoints of experts and scholars at home and abroad, combined with the reality of China’s remanufacturing, the industry defines the remanufacturing of auto parts as follows: Based on the analysis of performance failure analysis and life assessment, the old auto parts are used as roughs. Remanufacturing engineering design, and then through the repair and technological transformation, so that the quality and performance of the old auto parts reach or even exceed the processing of prototype products.
Industry experts believe that the remanufacturing of auto parts includes two main parts, namely the remanufactured processing and the performance upgrade of obsolete products. Among them, remanufacturing processes are mainly products that are scrapped to achieve physical life and economic life. On the basis of failure analysis and life assessment, used spare parts with remaining life as remanufactured blanks are processed using advanced technologies such as surface engineering to restore their performance and even exceed new products.
The performance upgrade of outdated products is mainly aimed at products that have reached the technical life, or products that do not meet the requirements for sustainable development. Through technological transformation and partial renewal, especially through the use of new materials, new technologies, new processes, etc., the technical performance of the product is improved, the service life of the product is prolonged, and the environmental pollution is reduced. Outdated mechanical and electrical products are often only some of the key indicators behind, not all parts can not be used again, the use of new technology inlay partial transformation, you can make the original product performance to meet the new use requirements.
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Bã€Characteristics: outstanding effect of energy saving, emission reduction and product life extension
Although the remanufacturing of auto parts in China is still in its infancy, China’s auto ownership has exceeded 50 million at present, and the huge amount of ownership has made the industrialization of parts remanufacturing an inevitable trend. The two major characteristics of energy conservation and emission reduction and the extension of the life cycle have gradually brought China's auto parts remanufacturing industry to scale and mature.
Product cost is lower than new product 50%
Industry experts believe that one of the most important advantages of auto parts remanufacturing is energy saving, consumption reduction, and emission reduction. Since remanufacturing is based on the use of scrap parts as the processing object, the cost of remanufactured products is lower than that of new products by 50%, which can save energy by 60% and save materials by 70%. Environmental benefits are very prominent.
Taking Jinan Fuqiang Engine Remanufacturing Company to manufacture 10,000 more Steyr engines per year as an example, consumers can save 290 million yuan in investment, recover 359 million yuan in added value, directly use 0.85 million tons of metal, and save 16 million kilowatts of electricity. Time.
According to a research team study conducted by the United States, the average energy consumed to manufacture a new engine is 11 times that required for remanufacturing, and the energy consumed to manufacture a new alternator is more than seven times that of remanufacturing.
According to data provided by Shanghai Volkswagen Ruibeid Powertrain Co., Ltd., the company currently produces more than 13,000 engines and saves 872 tons of steel, 240 tons of aluminum, and 1.68 million kilowatt-hours of electricity; it also reduces carbon dioxide emissions by 8,475 tons and carbon monoxide. Tons, nitrogen oxides 15 tons, solid waste 4330 tons; remanufactured engine prices are 55% of the new machine, single engine users can save about 7,000 yuan. If the old machine is returned to the furnace, its recycling value is only equivalent to 3% of the original machine, and the engine remanufacturing can make more than 80% of the value of the original machine recycled.
Extend product life cycle features
The normal product life cycle refers to the three stages of product manufacturing, use, and disposal. After the birth of the remanufacturing industry, the product life cycle has more than three stages. Instead, product design is fully considered during product design, and advanced technologies including remanufacturing are used to repair and reconstruct the end-of-life products. Performance and value continue. In other words, after remanufacturing, products that should be scrapped can be used again, and the product's life-cycle chain is therefore extended to the manufacture, use, scrapping, remanufacturing, reuse, and scrapping of the product.
In addition, remanufacturing is a kind of high-tech repair. Its raw materials or components have been reborn. It is a brand-new product. Therefore, the lifespan of some remanufactured products will exceed that of new products. According to statistics, after remanufacturing, scrapped equipment, especially petrochemical, power generation and other large-scale mechanical equipment can extend the service life of 20 to 40 years. In the United States, the B-52H bombers produced in 1961 and 1962, after undergoing two technical transformations and remanufacturing in 1980 and 1996, the original 20 to 30-year service period has doubled and is expected to be used until 2030. .
Cã€Origin: profitable growth drives the rapid growth of the industry
The foreign remanufacturing industry is relatively mature. The lucrative profits have prompted the rapid development of auto parts remanufacturing, making this industry the “industrial giant†behind the steel industry.
Lack of funding and resources
Compared with domestic, foreign remanufacturing industry is relatively mature, and the origin of foreign auto parts remanufacturing can be traced back to the 1930s. At the time of the Great Depression, the United States, due to the lack of funds and resources, some repairers had to try to use remanufacturing measures in vehicle maintenance to save money and resources.
During the World War II, the parts remanufacturing industry got a certain development. At that time, all automobile manufacturers and parts manufacturers in the United States turned military products to meet war needs, resulting in a serious shortage of domestic auto parts supply in the United States. Many types of vehicles could not continue to be used because of lack of spare parts. This forced some auto repairers to dismantle scrapped and defective parts and continue using them, thus gradually forming a new industry. At the same time, the U.S. military used a large number of vehicles on the battlefield for combat. The damage rate was very high. They were eager to repair and began to try to use the spare parts that were repaired in the country to quickly replace the auto parts on the battlefield, which greatly improved the speed of vehicle maintenance.
All participants in the industrial chain have considerable economic benefits
After the end of World War II, parts and components remanufacturing companies survived and developed rapidly over a period of time, mainly due to the lucrative profits generated by this industry.
In the whole industry chain of auto parts remanufacturing, from the collectors of the old parts to the users of the remanufactured products, all the participants obtained considerable economic benefits without exception. This led to the rapid development of the auto parts remanufacturing industry, which quickly covered the entire North American continent and became the “industrial giant†behind the steel industry in the United States.
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D. Development: Social benefits have become an important driving force for industry prosperity
In the early stages of industrialization, people have not fully understood the limited supply of natural resources and environmental capacity. Manufacturing has become the largest resource user in all industries and is one of the largest sources of pollution. Remanufacturing, as the most direct and effective means to improve this evil, has become an important way for the sustainable development of society.
Social benefits have drawn more and more attention
While mankind has created tremendous wealth through the industrial revolution, it has also paid a huge resource and environmental cost. With the progress of society, the social benefits brought about by remanufacturing have increasingly attracted the attention of the society. At present, there are more than 73,000 remanufacturing companies worldwide. In terms of 2000 statistics alone, the scale of the automobile remanufacturing industry in North America is approximately US$36 billion, the scale of industrial equipment remanufacturing is US$12 billion; the scale of European automobile remanufacturing is approximately US$20 billion, and the scale of industrial equipment remanufacturing is approximately US$4 billion. . In 2005, the global remanufacturing industry output value exceeded 100 billion U.S. dollars.
The size of the US remanufacturing industry is the largest in the world, reaching 75 billion U.S. dollars, of which automobiles and construction machinery and other fields account for more than two-thirds of the total, about 50 billion U.S. dollars. The scope of U.S. remanufactured products covers automotive parts, machine tools, construction machinery, railway equipment, medical equipment, and some electronic products. Among them, the remanufacturing of auto parts has advantages in terms of technology maturity, economy, and industrial scale. It covers engines, transmissions, steering gear, generators, motors, clutches, pumps, oil pumps, air-conditioning compressors, and rain. Scrape motor, brake master cylinder, cylinder, starter, tires and other parts.
Remanufacturing parts into important parts of the maintenance industry
In the automotive maintenance and spare parts industries, parts remanufacturing is an important part, and spare parts for auto parts produced through remanufacturing account for 45% to 55% of the automotive aftermarket market share. According to the different types of parts or components, this ratio is also different, and some of the remanufactured parts accounted for even 100% of the market share. For example, in the spare parts of starters and alternators, the share of remanufactured parts has exceeded 90%; the share of remanufactured parts of engines and automatic transmissions has reached more than 70%; of every 10 cars on the US highway, there is 1 Taiwan uses a remanufactured engine; North American engine remanufacturing has reached an annual output of 5 million units.
Since companies with per capita output below 100 yen per minute have no vitality in Japan, and remanufacturing is a relatively labor-intensive industry, this has become an important reason for the underdevelopment of Japan's remanufacturing industry.
E. Patterns: Countries have mature industries but different patterns
In Europe and North America, after several decades of development, the auto parts remanufacturing industry has formed a relatively complete operating model and a mature market environment, but the development models of various countries are different.
North America's management policies ease market environment
In North America, the scale and speed of development of the auto parts remanufacturing industry exceed that of Europe. This is mainly due to the U.S. government's management policy on remanufacturing easing and a favorable market environment.
In the United States, remanufacturing companies have three modes of operation: The first is an independent remanufacturing company. Such a company does not rely on any of the original manufacturing plants, and solely manufactures remanufactured products according to the needs of the automotive repair market. It is only responsible for the quality of the remanufactured products produced.
The second is a remanufactured enterprise that is invested, controlled or authorized by the original manufacturer. Such enterprises only produce their own products, and the remanufactured products directly circulate in the spare parts and service system of the original manufacturing enterprise, and use the original manufacturer's logo, such as the Caterpillar Remanufacturing Group.
The third type is tens of thousands of small remanufacturing factories. They provide customers with comprehensive remanufacturing services in a variety of flexible ways. Customers remanufacture them and the ownership of the old parts does not change. In recent years, these small remanufacturers have begun to take the road of chain operations and intensification in order to adapt to more and more severe market competition. For example, the United States NAPA has formed a scale of 7,000 companies including remanufactured parts and components. Chain Group.
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European companies dominate industry development
In Europe, the development of remanufacturing in Germany, Britain, and France is the most mature. Its main characteristic is that the development of the remanufacturing industry is basically under the control of automobile manufacturers and auto parts manufacturers. Among them, the German Volkswagen Company, France's Citroen Corporation and other auto manufacturers represented. Most of the remanufactured enterprises or original manufacturing enterprises in Europe that have invested or established their holdings, and remanufactured products that have been authorized by the original manufacturing enterprises, mostly circulate in the after-sales service network of the original manufacturing enterprises, and rarely flow to the social maintenance market.
One of the related links: The difference between remanufacturing and manufacturing
The difference between remanufacturing and manufacturing is mainly reflected in four aspects: First, different processing objects. Manufacturing is the processing of uniformly mass-processed cast-forged blanks or parts, while remanufacturing uses various shaped parts that have been scrapped for a long period of service.
The second is that the initial state of the blank is different. The initial condition of the manufactured blanks or parts is relatively homogeneous, single, and clean. Most of the remanufactured blanks suffer from surface failure caused by wear and corrosion, residual stress due to fatigue, and internal cracks, and deformation of parts due to shock and impact. , due to complex conditions caused by the difficulty of parts dirt removal and other issues.
The third is different quality control methods. The life assessment and quality control of manufactured products have matured, and the rough and damage conditions of remanufactured products are complex and varied. The residual stress, internal cracks, and fatigue layers lead to life assessment and service cycles that are complex and unpredictable. Parts after remanufacturing Quality control is relatively difficult.
Fourth, different processing techniques. In the manufacturing process, size and force properties are easy to control and are suitable for large-scale production. Remanufacturing is based on the premise of keeping the quality and shape of used zero parts and components unchanged. Exceeds the original product's performance index, realizes the original product's function promotion, simultaneously also uses the normalization, the scale of the processing method, therefore the processing craft is more complicated.
Related links II: The difference between remanufacturing and maintenance
Maintenance is a technical measure taken to maintain its good technical condition and normal operation during the use phase of the product. It often has randomness, in-situ, and emergency. Maintenance is mainly based on replacement parts, supplemented by single or small batch zero (part) repairs.
Remanufacturing is the collection and demolition of a large number of similar waste products. It is collected and tested according to the type of parts and components. Remanufactured products with remanufactured value are used as remanufactured blanks, and they are repaired and upgraded with high technology. The remanufactured products obtained have reached or even surpassed new products in technical performance.
The essence of remanufacturing is repair, but it is not simple maintenance. Remanufactured cores are manufactured using the manufacturing model, which is a high-tech repair technique, and it is an industrialized repair. Therefore, remanufacturing is an advanced stage of maintenance and development, and it is a kind of traditional maintenance concept. Promote and rewrite.
Related links: Overview of major foreign remanufacturers
Caterpillar Remanufacturing Corp.: Caterpillar has established 14 manufacturing/remanufacturing facilities in 7 countries including the U.S., UK, France, Mexico, and China, and has well-established logistics in more than 200 countries around the world. The system has basically achieved "global logistics." At the same time, the company's independent development of advanced technologies for remanufacturing has resulted in more than 100 patents for remanufacturing alone.
In 2005, the company’s remanufactured output value exceeded US$1.5 billion, and remanufactured 2.2 million pieces of used and used spare parts, of which 85% of the parts can be remanufactured or reused, saving 135 million pounds of metal; 2005 , registered in China's Shanghai Remanufacturing Industry Co., Ltd., plant occupies 4,000 square meters.
Lister-Petter Remanufacturing Company: Lister-Petter is the UK's largest specialized engine remanufacturing company. The company has established manufacturing in five countries including the United Kingdom, the United States, France, China and India. The manufacturing company, in cooperation with CNHTC, established an engine remanufacturing company, Jinan Fuqiang Power Co., Ltd., and established a remanufacturing technology production laboratory in cooperation with the China National Key Laboratory of Remanufacturing Technology and the University of Birmingham, UK.
Volkswagen remanufacturing company: Volkswagen began to remanufacture five kinds of auto parts in Wolfsburg in 1947, and relocated to Kassel in 1958 to start mass remanufacturing, and gradually established it on a global scale. Perfect old recycling logistics system and remanufactured parts sales network system, recycling 2.5 million pieces of original old parts each year. As of 2004, the company has re-built 7.48 million engines and 2.4 million transmissions. In recent years, due to the application of high technology in remanufacturing, the ratio of remanufactured engines, accessories and new machines sold by the company reached 9:1.
BMW: BMW Germany has established a complete national chain of recycling products. During the remanufacturing process, 94% of the recovered old machines were repaired by high technology, recycled by 5.5%, and only 0.5% by landfill. The company's remanufactured engine costs 50% to 80% of the new engine.
Peugeot-Citroën (PSA) and Renault (RE鄄NAULT): Peugeot-Citroën combined with the French steel company and cement company to establish a car remanufacturing plant near Lyon, and Renault also established a corresponding automobile scrap recycling center.
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