Remanufacturing is extending the product’s life span by bringing a defective product to the same standard, as it was when it was first manufactured, letting it undergo a process that aim to recover most of the material - without compromising the quality. Though it might sound simple, the reman process is much more comprehensive.
To remanufacture automotive parts, used products, namely cores, should be retrieved. The collection of cores is a complex activity. At CPI we sell our remanufactured units with a deposit, which is returned to the customers if they send us the unit, they are replacing.
The core we are getting in exchange for a remanufactured unit is sent to our core warehouse in Poland; the largest core warehouse in Europe with more than 1 million units – ready for remanufacturing. Remanufacturing takes place in a large production site optimised for and adapted to the remanufacturing process. A quality assurance programme ensures that the right quality levels are met as the units pass through the various remanufacturing processes. At these production sites the cores undergo the remanufacturing process, which consists of six steps:
[ 1 ] Disassembly: Defective units undergo a complete disassembly process and parts that cannot be reconditioned are disposed of.
[ 2 ] Cleaning: Following the disassembly of the units into individual parts, they are given a thorough cleaning with several cleaning treatments, such as hot water and sand blasting, ultrasonic cleaning, etc.
[ 3 ] Inspection & sorting: Cleaned components are subject to an intensive inspection to determine if they are in a re-useable condition. This is done both visually and with test equipment measuring if the tolerances are within the acceptable limits.
[ 4 ] Reconditioning & replacement: At this stage re-useable parts are reconditioned, e.g. through galvanising and grinding of the parts. Parts that in the previous stages have been disposed are replaced with new parts.
[ 5 ] Reassembly: The remanufactured units are reassembled.
[ 6 ] Final testing: Each remanufactured unit undergoes a 100% performance test to ensure that the unit match OE standards.
Compared to the manufacturing process, the energy consumption is reduced with up to 79 % in the remanufacturing process.
Because of the energy consumption, the CO2 emission is reduced in the remanufacturing process.
Because of the numerous ‘lives’ added to the product, the use of natural resources are reduced.
The remanufacturing process reduces the amount of materials sent to scrap by keeping material in use for longer time.
Remanufacturing is a circular economy where resources are in a close loop in comparison to the linear economy where resources are consumed.