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building a sustainable future through innovative technologies

Prof. Nabil NasrDirector, National Center for Remanufacturing & Resource Recovery

Rochester Institute of Technology (RIT)

January 21, 2007

Building a Sustainable Future Through Innovative Technologies

Presentation to:The APEC Market Access Group


NC3R is internationally-recognized as a leading center for applied research in remanufacturing.

NC3R’s mission is to deliver to industry advanced technologies and tools for efficient and cost-effective remanufacturing that have no negative environmental impacts.

Core Areas•Sustainable Design for Remanufacturing•Structural & Material Analysis•Clean Technologies•Intelligent Testing & Diagnostics•Life Cycle Engineering•Condition assessment and non-destructive testing•Enterprise planning for remanufacturing•Logistics & Policy


Examples of CIMS Sponsors


RecognitionAWARDS2006 Most Value National Pollution Prevention Award

2004 New York State Environmental Excellence Award

2004 NCAT Defense Manufacturing Excellence Award

2002 Governor’s Award for Pollution Prevention


Why Remanufacturing?


Net Use of Materials in the U.S.

Source: (Interagency Working Group for Industrial Ecology, Mater ials and Energy Flow, 1998)


The Natural Balance (Post-Industrial Revolution)


Sustainability Defined

EnvironmentalEnvironmental SocialSocial EconomicEconomic

Development that meets the needs of the present Development that meets the needs of the present without compromising the ability of future generations to meet without compromising the ability of future generations to meet

their own needstheir own needs

—— The World Commission on Environmental and Development, 1987The World Commission on Environmental and Development, 1987


Pathway to a Sustainable EconomySome key elements

Sustainable Production•Pollution Prevention•Safe & Healthy Workplaces•Environmental Management Systems•Workforce Engagement

Sustainable Products•Life-cycle Driven Product Design•Healthy Products•Product Labeling•Green Procurement

Closed-Loop, Sustainable Product Systems•Cradle-to-cradle Product Management•Reuse, Remanufacturing Recycling•Zero-to-waste•Transition from Products to Service

Sustainable Economy•Closed-loop, Sustainable Product Systems•Stakeholder Engagement•Renewable Energy•Dematerialized Economy•Green Chemistries•Biobased Products

The Path to a Sustainable Economy


3 Phased Journey to Sustainable Product Systems

Innovation Based Design Design for the Life-Cycle System/integrationProd. & Service Support Strategies

Sustainable Design Tools & MethodsClean ProcessesLife-Cycle DesignKnowledge Base

Life Cycle AnalysisTotal Cost of OwnershipSustainable MaterialsProcess TechnologyEducation & Certification

PHASE 1Sustainable Tools, Methodology, &

Education

PHASE 2Sustainable Design

Processes

PHASE 3Sustainable Product

Systems

DISCOVERY Opportunistic STRATEGIC

Marketing Logistics

Remanufacture Service

Product Disposition

TransportationElements of Product Life‐Cycle


Product Life Cycle

Design

Raw Material Acquisition

Earth & Ecosystem

Processing of Materials

Manu-facturing

Assembly

Use

Service

Upgrade

Retirement

Treatment & Disposal

Emissions

Closed-Loop Product Systems

Disassembly & Inspection

ReuseRemanu-facturing

Material Recycling


Disposition % by Weight

Fuser (Fixing) Assembly, 220V

Fuser (Fixing) Assembly, 220V Feeder Assembly

Laser/Scanner Assembly Cover, Delivery Cover, Delivery

Printer Drive Assembly

Guide, Separation, Upper Cover, Right Roller, Feed Duct, Scanner Spring Tension Hinge, Stopper Spring, TorsionPlate, Roller Holder Roller, Upper, Fuser Guide, Paper Cover, Coupler Cover, Front Plate, Hinge Plate, GuideClaw , Separation Roller, Low er Spring, Torsion Rail, Fuser (Fixing) Cover, Front, Engine Upper Cover Assy Coupler, FixingLever, Delivery Sensing, Fuser Cover, Fixing Roller Guide Feeder Spring, Leaf Cover, Front, Sub

Top Cover Assembly Gear, 42T/99T

Lever, Holding, Right, Fuser Cover, Upper Plate, Terminal Plate, Holder Label, Jam Removal Plate, Grounding Gear, 17T/57T

Lever, Holding, Left, Fuser Cover, Left Sheet, Insulating Plate, Duct, Front Latch Cover, Electrical Gear, 41TCrossmember, Separation Guide Guide, Entrance Block, Shaft Holding, F Mount, Fan Cover, Left, Low er

Open/Close Cover, Assembly Gear, 17T/75T

Spring, Tension Guide, Cable Block, Shaft Holding, R Arm, Lock, Inter Cover, Electrical Stopper. Delivery Gear, 73T

Label, Caution Holder Bushing Spring, Leaf ShutterTray, Face-Dow n Output Tray, Delivery Gear, 27T/30T

Diode Holder Assembly Holder, ThermostatArm, Registration, Paper Sensor Fan Cover, Pow er Sw itch

Cover, Right Door Assembly Gear, 26T/39T

Fixing, Cable, 2 Lever, ControlCover, Static Charge Eliminator Spring, Tension Spring, Compression Cover, Right

Heater, Halogen, 110V Plate, Thermosw itch Frame, Transfer Cable, Laser Cover, Right RearCover, Open/Close, Right

Heater, Halogen, 220V Ring, Grounding Eliminator, Static Charge Cable, Scanner Motor Guide Cover Guide, CoverSurface Temp. Sensor Unit Plate, Grounding Plate, Terminal Cable, BD Spring, Torsion

Stopper, Open/Close

Thermosw itch Plate, Right Cable, Paper Sensor Cable, ILS Panel, Control Front Lever

Gear, 29T Plate, LeftCompression Spring, Front Cover, Cable Control (Display) Panel

Gear, 25T Guide, SeparationCompression Spring, Rear Support, PCB

Panel, Control Front (WX)

Gear, 18TScrew , Stepped, W/Washer, M3 Varistor Spring, Tension Label, Jam Removal

Gear, 14T Frame, Fixing IC, Photo, TLP1230 Spring, Compression Cable AssemblyGear, 48T Guide, Separation Clip, Cable Tray, Face-Up OutputSpring Compression Roller, Delivery Cover, Cable, DC Gear, 20TBearing, Ball Bushing Mount, Control RollerLabel, Caution Gear, 20T Plate, Shield Plate, Guide

Plate, Compression Guide Spring, Torsion Spring, CompressionFixing, Cable, 3 Guide, SeparationLabel, 110V Holder, HeaterLabel, 220V Roller, Delivery, FixingBushingRoller, Cold Offset

building a sustainable future through innovative technologies*National Safety Council

The Gold Mines


What is Remanufacturing?

An industrial process in which non-functional or retired products are restored to like-new conditions.


What is Remanufacturing?A more detailed definition of remanufacturing:

A product is considered remanufactured if:

• Its primary components come from a used product.

• The used product is dismantled to the extent necessary to determine the condition of its components.

• The used product’s components are thoroughly cleaned and made free from rust and corrosion.

• All missing, defective, broken or worn parts are either restored to sound, functionally good condition, or they are replaced with new or remanufactured parts.

• To put the product in sound working condition, such machining, rewinding, refinishing or other operations are performed as necessary.

• The product is reassembled and a determination is made that it will operate similar new product in reliability, life cycle, and operational cost.


Remanufacturing SectorsRemanufacturing Sectors• Defense• Aerospace• Automotive• Medical Equipment• Electrical Apparatus• Compressors• Machinery• Office Furniture/Equipment• Tires• Toner/Inkjet Cartridges• Valves• Consumer electronics

• Other


Remanufactured Products AreasRemanufactured Products AreasOffice Furniture

Plastic Products

Saw Blades

Iron & Steel Forgings

Chrome Plating

Armament Support Equip.

Valves

Steam Turbines

Diesel Engine Components

Farm Equipment

Construction Machinery

Mining Machinery

Oilfield Equipment

Machine Tools:

- Metal Cutting

- Metal Forming

- Welders

Fork Lifts

Power-Driven Handtools

Textile Machinery

Woodworking Machy

Printing Trades Machy

Food Processing Equip.

Shoe Making Machy

Semiconductor Machy

Large Diameter Bearings

Air and Gas Compressors

Indust. Furnaces, Ovens

Mech. Power Transm. Eq.

Computer Parts

Computers & Components

Toner Cartridges

Vending Machines

Refrig. Compressors

Refrig. Components

Hydrostatic Transmissions

Calculating, Accting Mach.

Office Machines

Industrial Machinery

Transformers, Switch Gear

Elec. Motors, Generators

Electronic Controls

TVs & Component Parts

Cellular Telephones

Electron Tubes

Automotive Elec. Equip.

Video Cassettes

Industrial Lasers

Motor Vehicles

Truck and Bus Bodies

Automotive Components

Truck Trailers

Airplanes & Helicopters

Aircraft Engine Components

Aircraft Parts

Railroad Equipment

Radar, Surveillance &

Communication Equip.

Lab Apparatus & Furniture

Industrial Instruments

Fluid Meters & Countg Dev.

Surgical and Med. Apparat.

Medical Sterilizers

X-ray Apparatus and Tubes

Photographic Equipment

Electromedical Equipment

Computer Equip. Repair

Tire Retreading

Remanufacturing is Diverse

building a sustainable future through innovative technologiesUnited Kingdom


Remanufacturing Firms, Industry Sales and Employment*

Sector TotalNum ber of

Firm s

Total Sales(M illions)

TotalEm ploym ent

Autom otive 50,538 $36,546 337,571Com pressors 155 $249 2,878ElectricalApparatus

13,231 $4,633 47,280

M achinery 120 $434 3,155O ffice Furniture 720 $1,663 12,148Tires 1,390 $4,308 27,907Toner C artridges 6,501 $2,475 31,872Valves 410 $589 4,577O ther 250 $2,009 14,372

Total 73,315 $52,906 481,760*”The Remanufacturing Industry: Hidden Giant”, Robert Lund


Industry Vision


The Remanufacturing Industries Council

• Recycling Industries– $ 7.2 Billion– 103,000 Jobs

• Remanufacturing Industries– 73,000 Companies– $53+ billion in sales– 481,760 Jobs


Remanufacturing Technology Challenges


Health Monitoring Development ProcessExpanded RCM

Feature Design

Fault Progression

Sensor Placement

Testing:- Seeded fault- Transitional

Feature Design

Fault Progression

Sensor Placement

Feature Design

Fault Progression

Sensor Placement

Feature Design

Fault Progression

Sensor Placement

Testing:- Seeded fault- Transitional

Prognostic Engine

Diagnostic Engine

Optional

Diagnostic -Inference Model

(Tests and Observables)

Expanded FMECA

FMECA Analysis

Fault / Damage Indicators

Usage Indicators

Expanded FMECA

FMECA Analysis

Fault / Damage Indicators

Usage Indicators

Components

Expanded RCM

RCM Functional Analysis

System Performance & Condition Indicators

System Context Indicators

System

Signature Analysis & Feature

Identification

Fault Detection and Isolation

Analysis

Feed

back

loop

s

Diagnostic Cost / Benefit Assessment

PARETO Analysis

Prognostic ModelOptional

Sensor Set

Signal Proc

Feedback

Feedback

DRV_SGTo Workspace12

DRV_theo_dischargeTo Workspace11

PmfbTo Workspace10

DRV_max_closeTo Workspace1

DRV_max_openTo Workspace

TheoreticalDischarge

Spool Stroke

SG60SG60

f(u)Pilot Window Flow f(u)

Pilot Window Areau[1] / 0.04

Pilot Spool Stroke

PWFl

PWArea

f(u)Orifice Area

61.33Nominal SP Offset

MuxMux

MuxMux

Mux

MuxMux

Mux

Mux

Mux

Mux

f(u)Leakage

f(u)Gain Damping

Orifice dp0.006

Gain DampingOrifice Dia

0.0647DRV min Area

DRV dp

f(u)DRV Valve

Opening Area

DRV VPdp

DRV SetpointOffset

f(u)DRV SP Offset

u[5] - u[1]DRV Pressure

Drop

DRV PilotLeakage Flow

f(u)DRV Outlet Temp

DRV Outlet Press

DRV OutletTemperature

f(u)DRV Max Open

f(u)DRV Max Close

f(u)DRV Heat Rejection

f(u)DRV Discharge

Pressure

CEXCEX

f(u)Average SG

f(u)Average

Specific Heat

5EFP Tout

4EFP Outlet Press

3TPF

2A/C Boost Press

1Manifold Press



PmfbTo Workspace10




Spool Stroke

SG60SG60



Pilot Spool Stroke

PWFl

PWArea

f(u)Orifice Area


MuxMux

MuxMux

Mux

MuxMux

Mux

Mux

Mux

Mux

f(u)Leakage

f(u)Gain Damping

Orifice dp0.006


0.0647DRV min Area

DRV dp

f(u)DRV Valve

Opening Area

DRV VPdp

DRV SetpointOffset

f(u)DRV SP Offset


Drop


f(u)DRV Outlet Temp

DRV Outlet Press


f(u)DRV Max Open

f(u)DRV Max Close


f(u)DRV Discharge

Pressure

CEXCEX

f(u)Average SG

f(u)Average



PmfbTo Workspace10




Spool Stroke

SG60SG60



Pilot Spool Stroke

PWFl

PWArea

f(u)Orifice Area


MuxMux

MuxMux

Mux

MuxMux

Mux

Mux

Mux

Mux

f(u)Leakage

f(u)Gain Damping

Orifice dp0.006


0.0647DRV min Area

DRV dp

f(u)DRV Valve

Opening Area

DRV VPdp

DRV SetpointOffset

f(u)DRV SP Offset


Drop


f(u)DRV Outlet Temp

DRV Outlet Press


f(u)DRV Max Open

f(u)DRV Max Close


f(u)DRV Discharge

Pressure

CEXCEX

f(u)Average SG

f(u)Average

Specific Heat

5EFP Tout

4EFP Outlet Press

3TPF

2A/C Boost Press

1Manifold Press

Specific Heat

5EFP Tout

4EFP Outlet Press

3TPF

2A/C Boost Press

1Manifold Press



PmfbTo Workspace10




Spool Stroke

SG60SG60



Pilot Spool Stroke

PWFl

PWArea

f(u)Orifice Area


MuxMux

MuxMux

Mux

MuxMux

Mux

Mux

Mux

Mux

f(u)Leakage

f(u)Gain Damping

Orifice dp0.006


0.0647DRV min Area

DRV dp

f(u)DRV Valve

Opening Area

DRV VPdp

DRV SetpointOffset

f(u)DRV SP Offset


Drop


f(u)DRV Outlet Temp

DRV Outlet Press


f(u)DRV Max Open

f(u)DRV Max Close


f(u)DRV Discharge

Pressure

CEXCEX

f(u)Average SG

f(u)Average

Specific Heat

5EFP Tout

4EFP Outlet Press

3TPF

2A/C Boost Press

1Manifold Press



PmfbTo Workspace10




Spool Stroke

SG60SG60



Pilot Spool Stroke

PWFl

PWArea

f(u)Orifice Area


MuxMux

MuxMux

Mux

MuxMux

Mux

Mux

Mux

Mux

f(u)Leakage

f(u)Gain Damping

Orifice dp0.006


0.0647DRV min Area

DRV dp

f(u)DRV Valve

Opening Area

DRV VPdp

DRV SetpointOffset

f(u)DRV SP Offset


Drop


f(u)DRV Outlet Temp

DRV Outlet Press


f(u)DRV Max Open

f(u)DRV Max Close


f(u)DRV Discharge

Pressure

CEXCEX

f(u)Average SG

f(u)Average



PmfbTo Workspace10




Spool Stroke

SG60SG60



Pilot Spool Stroke

PWFl

PWArea

f(u)Orifice Area


MuxMux

MuxMux

Mux

MuxMux

Mux

Mux

Mux

Mux

f(u)Leakage

f(u)Gain Damping

Orifice dp0.006


0.0647DRV min Area

DRV dp

f(u)DRV Valve

Opening Area

DRV VPdp

DRV SetpointOffset

f(u)DRV SP Offset


Drop


f(u)DRV Outlet Temp

DRV Outlet Press


f(u)DRV Max Open

f(u)DRV Max Close


f(u)DRV Discharge

Pressure

CEXCEX

f(u)Average SG

f(u)Average

Specific Heat

5EFP Tout

4EFP Outlet Press

3TPF

2A/C Boost Press

1Manifold Press

Specific Heat

5EFP Tout

4EFP Outlet Press

3TPF

2A/C Boost Press

1Manifold Press

Phys

ical

/ Si

mul

atio

n M

odel

Operating Modes for detection

Fault Progression Pattern

Historical Knowledge (maint/failure histories)

System Operating Modes


Remanufacturing in mainstream retail markets


OPC Drum Life-Cycle Analyzer

Solution: OPC Drum Life-Cycle Analyzerthe OPC Drum Life-Cycle Analyzer detects how many times the drum can be reused

15 million drums represent used annually in the US

tons of materials are diverted from landfills


Wiper Blade Edge AnalyzerProblem

2.6M pounds of sheet metal from unrecycled wiper blades end up in landfills annually

Solution: Wiper Blade Edge AnalyzerOver 1,000,000 wiper blades successfully reused in the global remanufacturing of toner print cartridgesSub-licensed to 8 remanufacturing companiesDiverted over 260 ton of steel and plastic from landfill

Awarded2004 NYS Environmental Excellence Award


Office Furniture RemanufacturingSponsor:Davies Office Refurbishing, Inc.

FindingsCosts 25–75% less than new furniture

Natural resources, such as wood and aluminum, as well as steel, plastics, and fiber, may be reused over and over to the fullest extent possible

Conserves labor and manufacturing energy

Reduces global warming, acid rain, photochemical smog, and other forms of air pollution


Examples of Remanufacturing


Case Study: Office Furniture

Fabric is cleaned; desk tops are re-covered; dents in metal are hammered out

Small parts are replaced; all movable parts are tested

Furniture style is updated

Avoids disposal costs - $93 million in U.S. annually

30 to 50% cost savings for businesses

Conserves one tractor trailer worth of material for every 40 cubicles remanufactured


Case Study: PhotocopiersXerox Document Center 265*

designed to include easily removable subassemblies and more durable parts

Xerox takes back the used copiers.

80% of the parts are remanufacturable

designed to be upgraded

Remanufacturing diverted 4 million cubic feet of material from landfill in one year company-wide.

Xerox saves several hundred million dollars per year by designing parts for remanufacture and recycling.

*Environment Health and Safety Progress Report. Xerox Corporation. Available through: www.xerox.com