Production Engineering Flashcards
Why is additive production good?
(3D printer)
—> save time, material, money, taste and transport
- Distribute localised products
- Process control and quality
- efficiency and waste minimization
- Spare part production
- change for consumer
What is remanufacturing?
- the process of rebuilding a product, during which, the product is cleaned, inspected and disassembled; defective components are replaced; and the product is reassembled, tested and inspected again to ensure it meets or exceeds newly manufactured product standars
What is the core for remanufacturing?
Used/broken down products (or components) aimed for reman.
core -> steps -> reman. prod.
What are the steps in remanufacturing?
Inspect > Clean > Disassemble > Store > Reprocess > Reassemble > Testing
- order can vary depending on product/manufacturor
Describe step “Inspection” in remanufacturing:
- Identify the malfunction/errors
- base the inspection from a failure report
Describe step “Clean” in remanufacturing:
- Choice of cleaning technology
- which cleaning liquid does the product withstand?
- Various products have various cleaning difficulties: type of product and user behaviour
Describe step “Disassembly” in remanufacturing:
- Valuable parts/components are put in storage
- Broken parts/components are sent to material recycling or EOL treatment
- Use of special tools
- Disassembly instructions
Describe step “Storage” in remanufacturing:
- products/parts/components stored until reassembly
- registration in storage database
- Storage costs money
Describe step “Reprocess” in remanufacturing:
- Cutting and grinding of metal
- refill with new material
(when necessary)
Describe step “Reassembly” in remanufacturing:
- choice of fasteners
- condition of parts and components
- upgrading product parts
- upgrading software
Describe step “Final test” in remanufacturing:
- function
- safety
- Quality
What are the drivers for remanufacturing?
Profit
- cost reductions
- costumer demands
- new product sales, eg product service systems
Environment:
- Legislations, follows for less waste and min material use
- Moral and ethical
Policy
- protecting the aftermarket
- protecting brand
- providing additional aftermarket solutions
What does PSS mean?
PSS means change in material flow
How can PSS be helpful for remanufacturability?
Traditional mindset: supplier -> customer/user ->
Traditional + new (PSS) mindset: supplier customer/user ->
PSS as a driver for reman.?
- Reduce the uncertainty of when and how many cores that arrive to remanufacture
- give possibilities of condition monitoring that can provide useful data for reman.
- Facilitate OEM remanufacturing with much product data and knowledge from reman + good feedback loop to producer
- PSS and full core knowledge is an approach to overcome tough remanufacturing challenges.
In what ways are reman. good for the env.?
- Less operational steps in production chain (can eliminate material extraction, mat. manufacturing and component manufacture, to only do product manufacturing)
- More studied product with leasing and sytem services
Why remanufacture for the env.?
- calculations show that reman. is a preferred option in comparison with new manufacturing
- alleviation of depletion of resources
- reduction of global warming potential
- chances to close the loop for safer handling of toxic material
What does the European Remanufacturing Network (ERN) do?
- encourages business to take up remanufacturing
- help existing remanufacturers to improve their operation
- improve competitiveness of reman. domestically and internationally
What does the customer get for values of reman.?
- price worthy options in comparison to new products, because of price reductions 10-90%
What are the economical challenges with remanufacturing?
- staying competitive/profitable
- core access/management
- lack of customer awareness
- product design issues
- process efficiency issues
What are key resources for remanufacturing?
- technical staff
- access to cores
- facilities, machinery and equipment
What env. benefits for a company is there for remanufacturing?
- reduced material consumption
- reduced CO2 emissions
- reduced energy consumption
What social benefits for a company is there for remanufacturing?
- job creation
- more access, higher access to products
- events and charity
What should the business model for reman. describe?
- value chain
- reman process
- sutomer value
- economic benefit
- ecenomical challenges
- key resources
What is ecodesign?
Optimization of life use/end-of-life
What is there to do for optimization of EOL?
- Reuse/remanufacturing of products
- Reuse/remanufacturing of components - ease through disassembly
- Recycling of material
- safe incineration
Describe what to do for “Reuse/remanufacturing of products” for optimization of EOL in ecodesign.
- a classic design makes the product more attractive for the next user
- a good technical design makes the product not grow old in advance
Describe what to do for “Reuse/remanufacturing of components” for optimization of EOL in ecodesign.
Make disassembly easier through:
- modularization
- use few fastenings
- use fastenings that are possible to disassemble, eg screws
- standardize screw types
- plan the product so disassembly can be made from one direction (one worker)
Describe what to do for “Recyscling of material” for optimization of EOL in ecodesign.
- Ease disassembly
- use material that have a recycling market
- use few materials
- avoid hazardous materials that complicate recycling
- try to achieve recycling made by machines
- label materials in the product according to standards
- do not combine materials that contaminate each other in recycling
- avoid stickers on plastics
Describe what to do for “Safe incineration” for optimization of EOL in ecodesign.
- label the product if it contains hazardous materials
- put hazardous materials together so one disassemble in prior to incineration
What can be done in production for design for life-time extension?
- tech development - product upgrade so product doesn’t become dated/obsolate
- avoid/change components being outdated - some faster that others
- products that are easy to repair and maintain have generally longer tech life-time
Guidelines for joining methods:
- use joining methods that facilitate a non-destructive disassembly
- use joining methods that facilitate disassemby with few tools, preferably standard tools
- make joints in the same materials as the ones that are assembled, integrate joints in component if they are of the same material
- minimize nr of joints and place them where they are easy to access
