ReMaTecNews | October 2015 | Number 5 | Volume 15

REMANUFACTURING INTERNATIONAL

OCTOBER 2015 | NO 5 | VOLUME 15

Cummins – the fine art of remanufacturing

Learning new skills in Las Vegas

Universities move into online reman courses

Turbochargers: Boom times ahead www.rematecnews.com

CONTENTS

ReMaTecNews | 3

10 | Cummins ReCon: turning skills into art:

16 | Big R/ReMaTecUSA: Learning and innovation

17 | Facing up to the challenges

One of the world’s premier engine remanufacturers has many strings to its bow. Across a broad range of areas, remanufacturing is one of them.

ReMaTecNews reports from Memphis, Tennessee, where Cummins operates a state-of-the-art plant for turbos and DPFs.

Improve your business - that will be a key offer to attendees at this year’s Big R/ReMaTecUSA. Scheduled for October 31 to November 2, North America’s largest trade show for automotive and HD remanufacturing, the event features a broad range of tools for improving business methods.

The rapid development of vehicle technologies imposes significant challenges on remanufacturing.

The entire industry - from the motor industry to aerospace and medical remanufacturers - must adapt to enormous change. Mike Rayne, an industry veteran and Managing Director of FTI Consulting, sets the scene.

”We must invest in efficient tools and updated knowledge” Volker Schittenhelm, FIRM

www.rematecnews.com

Page 27

Editorial

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Reman courses online

5

New tester from D&V

7

BorgWarner strengthens reman team

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Ceramex to create European network

25

Remanufacturing: Invest or fail

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Europe’s new reman centre

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New horizons for remanufacturers

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Association News

34

International exhibitions

38

In 2014: 6 editions ReMaTecNews Magazine | Special pages on Transmissions in Editions 1, 3, 5 | Special pages on Heavy Duty/Trucks in Editions 2, 4, 6

EDITOR’S LETTER

ReMaTecNews | 4

ReMaTecNews October 2015 | Number 5 | Volume 15 Published by Amsterdam RAI B.V. P.O. Box 77777, 1070 MS Amsterdam The Netherlands In association with

Editor-in-Chief William Schwarck Phone +45 (0)20 55 84 42 editorial@ReMaTecnews.com US Correspondent Denise Rondini Office +1 (0) 773 334 5740 Cell +1 (0) 773 951 8563 drondini@gmail.com

The only constant is change “Change is the law of life. And those who look only to the past or present are certain to miss the future.”

President John F. Kennedy was not talking about remanufacturing when he spoke those words more than 50 years ago, but at a time when technological advances are sweeping the motor industry, his words are worth recalling in a remanufacturing context and it’s not hard to see how appropriate they actually are.

Anyone with an interest in the future of our industry would surely agree. The pace of such progress cannot be allowed to slow down.

Not long ago, remanufacturing was regarded as an oily, dirty and noisy subsection of the motor industry. Today it is accepted as the automotive industry’s green face. It has credibility at national and international government level. It has earned its place at their tables of discussion and its often hightech value proposals have begun to draw their attention and influence their decision making.

Accordingly, suppliers and remanufacturers must keep abreast of technological developments, continue to upgrade equipment and increase their knowledge, exchange views and in general, continue to raise our level of skill. That’s a pattern of progress reminiscent of early successes in the transmission sector, since replicated by many other sectors of our rapidly developing industry.

MERA is one such example. The organisers of the autumn’s Big R/ReMaTecUSA are another. Featuring a range of important seminars and lectures, the Las Vegas event reflects the ever growing need to keep pace with the changing face of the motor industry.

Articles on the subject later in this edition, by Mike Rayne, Managing Director of FTI, and Volker Schittenhelm of FIRM, make the point. They serve as further reminders of what remanufacturers need to accept, perhaps more than ever before.

That “Change is the law of life. And those who look only to the past or present are certain to miss the future.”

William Schwarck, Editor-in-Chief

Marketing Communications & PR Sanne van Dartelen Phone +31 (0)20 549 3061 s.v.dartelen@rai.nl Advertising Sales Ewoud Barink Phone +31 (0)20 549 1431 Fax +31 (0)20 549 1889 advertising@ReMaTecnews.com Publisher Niels Klarenbeek (responsible under Dutch Press Law) n.klarenbeek@rai.nl Production & Artwork Maaike van Dijk Phone +31 (0)20 549 1653 m.v.dijk@rai.nl Design Jenb, Graphic design, Hilversum, The Netherlands www.jenb-online.nl Printing SDA Print + Media Copyright RAI Amsterdam, Amsterdam, The Netherlands Reproduction No part of this publication may be reproduced, stored in a retrieval system, or transmitted, in any form or by any means, electronic, mechanical, photocopying, or otherwise, without the prior written permission of the publisher, RAI Amsterdam B.V. Subscription magazine and e-newsletter www.ReMaTecNews.com Change of address E-mail info@ReMaTecNews.com Website / ReMaTecNews magazine online www.ReMaTecNews.com Circulation Approx.13,500 readers per edition. The magazine is ­delivered on a controlled circulation basis to ­recipients in Western Europe, Eastern Europe, Africa, North America, South America and Asia.

NEWS

ReMaTecNews | 5

European universities in joint effort to promote reman skills A new collaboration between four European universities aims to boost the skills and knowledge of remanufacturing on a potentially massive scale.

The intention of the project, organised by the Technical University in Delft, the Netherlands, supported by Strathclyde University in Scotland, Bayreuth University in Germany and Linköping University in Sweden, is to set up a series of open online courses on remanufacturing.

These courses will enable companies and their employees to participate in so-called Small Private Online Courses (SPOCs) regardless of their location, size or industry. In the short to mid-term, the organisers hope to attract upwards of 1,000 participants. In the longer term the figure could be many times that.

“The Technical University of Delft has extensive experience with the so-called MOOC courses (Massive Open Online Course) which can be accessed by 100,000 participants or more, regardless of location or skills level,” explains Dave Peck, a Senior Research Fellow, Critical Materials and Circular Design, at TU Delft.

“The intention is now to offer SPOC courses in remanufacturing for companies already involved in the industry or companies that wish to acquire knowledge about reman. Once the SPOC courses have been successfully completed, they can easily be extended to the broader MOOC concept where thousands of businesses and people across the world can access it.”

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organisation, the initial part of the project is expected to run for 18 months. After that, Dave Peck believes that the opportunities for further development are huge.

“Delft has all the equipment and experience needed for producing the courses and Bayreuth, Strathclyde and Linköping will supply the technical reman knowledge together with representatives of the reman industry,” Dave Peck says.

“Remanufacturing is an important part of Europe’s industrial development and the future of the industry is dependent on getting new skilled people involved. We’re starting out on a small scale but I’m confident that this will grow strongly once we’re up and running.” n

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Testing times ahead much more expensive,” says marketing manager Michael Kelly.

He says companies like D&V are already working on test equipment for OE and will be well placed to provide test options for the aftermarket in the near future.

Marketing Manager Michael Kelly, D&V Canadian test equipment manufacturer D&V, in Ontario, says its latest ALT 198 alternator tester – a model that’s faster, more computerised and more energy efficient than its predecessor the ALT 98 – is designed to help remanufacturers cope with the increasing amount of on-board technology

in modern vehicles.

“It used to be all about starters and alternators in this market. Soon vehicles will be equipped with 48 volts technology, internal starter generators or belt starter generators. They will become one part on the vehicle instead of two – and they will be

Impact of legislation The impact of legislation to reduce vehicle emissions and the growth in sales of electric and hybrid vehicles is forcing a refocus among test equipment remanufacturers and having a significant influence on the market for remanufactured products.

Michael Kelly points to the Toyota Prius hybrid as an example of a model that has been on sale for several years with many of the early models now outside manufacturer warranty periods. Vehicle like the Prius will provide good opportunities for remanufacturers with the right procedures and the right kind of test equipment, he believes. n

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Toyota to invest millions in MIT/ Stanford projects The research and development of intelligent vehicle and mobility technologies will get a major boost in an ambitious new collaboration between Toyota, Stanford and Massachusetts Institute of Technology (MIT), AutomotiveNews has reported.

Toyota Motor Corp. announced that, over the next five years, it will invest approximately $50 million to establish joint research centers at each university.

Dr. Gill Pratt, former program manager at the Defense Advanced Research Projects Agency (DARPA) has joined Toyota to direct and accelerate these research activities and their application to intelligent vehicles and robotics.

Toyota said it believes the opportunities to improve everyday living through artificial intelligenceLitens7.5x5.236 2/5/15 9:37 AM Page 1

supported technologies are boundless, with significant breakthrough potential for the development of life-saving intelligent vehicles and life-improving robots.

Research at MIT will be led by Professor Daniela Rus, a professor of electrical engineering and computer science and director of the Institute’s Computer Science and Artificial Intelligence Laboratory.

Led by Professor Fei-Fei Li, director of the Stanford Artificial Intelligence Laboratory (SAIL), the Stanford-based research center will collaborate with MIT and Toyota to develop advanced intelligent systems to recognize, understand and act in complex traffic environments.

across a broad range of mobility applications, the partners commented.

Rick Keister joins CDS Richard L. Keister, the former CEO of Keystone Automotive Industries, has joined Collision Diagnostic Services’ (CDS) board of directors as a financial partner in the company. A welll known figure in the US automotive aftermarket, Rick Keister, at various times, served as President of Remy International’s Aftermarket Division and as President of Delco Remy International Electrical Division.

Doug Kelly, CEO of CDS, said, “Rick’s extensive experience in the auto industry combined with his ability to champion significant strategic initiatives will be a huge addition to the company.” n

“The collaborative effort will open up new avenues for systems and product development

Decoupler Science

Consumer Demands

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Over the past 20 years, we have seen a revolution in engine design increasing the need for alternators equipped with a Litens OAD (Overrunning Alternator Decoupler) pulley.

Thanks to many upgrades such as direct injection and turbo charging, V8’s are continually being replaced with V6s and even inline 4 cylinders without any loss in performance and gains in fuel economy. Engine displacement and the rotating mass of the engine continue to be decreased dramatically. New electrical loads like heated seats, mirrors and infotainment systems are taxing alternators like never before. Drivers demand quiet and vibration free vehicles, however, these newer lighter weight engines have greater vibrations that need to be addressed.

It’s simple physics: Fewer cylinders make for fewer pulses during each 360 deg of crank rotation. These power pulses are much more pow-

erful than older engines thanks to the increased combustion pressures produced by the direct injection, cylinder eactivation and turbocharging strategies. These downsized engines have less mass to dampen vibration and therefore require special vibration absorbing devices.

The drive train can, in most cases, handle the increased vibration.

However the accessory drive pulleys at the other end of the crankshaft, have only limited capacity to dampen these vibrations created by the fluctuating changes in crank speed at sub idle and idle rpm. To do this the serpentine belt, tensioner and pulleys must work together as a system to dampen vibrations.

Increasing belt tension will make the belt wear out faster, accessories fail sooner, and will lead to poor fuel

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economy. To achieve harmony, most newer vehicles come equipped with alternators using a Litens OAD pulley. OADs are designed to be the sacrificial component of the belt drive system. The OAD will absorb the harmful vibrations and eliminate all the harmful side-effects. Alternators manufactured with a Litens OAD, allow for longer belt, tensioner, idler and component life while providing increased fuel economy.

Being the sacrificial component of the belt system, an OAD will require replacement during the life of the vehicle based on engine design and driving habits. Replacing the OAD when needed can maximize fuel economy and protect the other belt drive components – alternator, belt, tensioner, pulleys, etc…

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ReMaTecNews | 10

BorgWarner adds experienced executive to reman team When interviewed by ReMaTecNews earlier this year, Michael Boe, the recently appointed Vice President and General Manager of BorgWarner’s Global Aftermarket Turbo Systems, said that “in terms of warehousing, locations and remanufacturing facilities there are some areas where we will have to build a stronger platform.”

That process is gaining pace. With effect from October 1, BorgWarner has appointed one of Europe’s most experienced reman executives to the position of Senior Manager, Global, Remanufacturing in BorgWarner’s Turbo Systems business unit. In the new job, Ian Buxcey, until now head of Meritor’s European Reman operations, is tasked with strengthening BorgWarner’s remanufactured turbocharger business worldwide.

The appointment reflects BorgWarner’s increasing focus on remanufacturing as the company seeks to extend its global aftermarket presence.

Currently BorgWarner operates remanufacturing sites in the US, Germany, Brazil and China and the company believes that, over time, it will be able to substantially increase its current output of around 100,000 heavy duty and passenger car remanufactured units per year.

“The challenge of leading the implementation of the global remanufacturing strategy is something to which I’m looking forward immensely,” Ian Buxcey said. “BorgWarner is the leading global turbo supplier and the opportunity for doing more with remanufacturing within such a global player as BorgWarner, was too much to refuse.”

and seen some tremendous change,” he told ReMaTecNews. “Consistently more players and more products have entered the markets and external developments such as the circular economy and the need to preserve resources as well as the rising interest in remanufacturing shown by many governments, makes the industry a truly exciting place to be. There’s a lot of opportunities here and I’m looking forward to being part of it.” n

Buxcey comes to the job after five years as head of Meritor’s reman business in Europe, which covers the Trucktechnik unit in Liege, Belgium and Redditch in the UK. Earlier in his career, he worked for Lucas, Magneti Marelli and Denso as well as UK core dealer Premier Components.

“I’ve been in the industry for close to 30 years

Ian Buxcey

The 3D Revolution is Here and Now Sit back, relax and... go! The consumer is in the driving seat now more than ever as the 3D revolution in car retail has just started, says Frost & Sullivan, one of the world’s leading automotive consulting firms, in a research report.

“This is thanks to a next generation 3D car configurator solution, provided by IBM and ZeroLight,” the company explains in a White Paper which focuses on the new platform because of the way it allows customers to take a virtual test drive of a car at the touch of a button.

The platform allows prospective car buyers to open the doors, boots, and bonnets as well as activate features such as turning on the headlights, starting the engine, and taking a virtual test drive.

“As a result this virtual test drive can be taken to a new level of personalization by allowing the customer to select from a range of environments in which to see the car drive – such as virtually parking a city car in an urban environment or driving an SUV up a mountainside,” Frost & Sullivan explains.

Frost & Sullivan research predicts that in 2016 alone, OEMs will invest up to $5 billion in digitalization and unveil over 100 digital show rooms across the globe. “The technology now exists to overcome automotive retail barriers and transform automotive retail as the world knows it today.

The next generation 3D car configurator solutions provided by IBM and ZeroLight, delivers an experience so “real” that time-poor, urban-based

customers no longer need to travel to an outof-town car dealership,” stated Frost & Sullivan Consultant Catherine Hutt.

“Car makers and dealers recognize that there will be tremendous disruption in the retail process over the next 10 years and are embracing the retail revolution by considering the cost of technology as an investment, not as an expense,” Hutt says. n

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Dependability. Every Time. ™

Looks may change, but the message has always been the same. Since 1919, Cummins has proven the dependability of its products. You own the best engine. Keep it running for years to come by using only the best parts. Choosing Genuine Cummins parts means less downtime, lower operating costs and better engine performance. For more information on Genuine Cummins parts available for your Cummins engine, contact our Customer Assistance Center today.

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COVER STORY

ReMaTecNews | 12

Cummins: RECONizing the true value of remanufacturing

Cores – old, rusty, dirty and near-obsolete parts – are the lifeblood of the remanufacturing industry. Much like newly mined diamonds, they have to be cut, cleaned and polished so that at the end of the process, you have a shining new product of considerable value.

Not as easy as one might think. To succeed requires care, dedication and substantial technical skills.

That’s why people with the relevant qualifications are in short supply in the automotive and heavy

duty remanufacturing industries. Once you have them, you try to hang on to them and professional remanufacturers are well aware of this.

Rarely, however, is this illustrated to such an extent as at an industrial facility off Pershing road in Memphis, Tennessee. Here, in a 150,000 sq. ft. plant, a workforce of 200 remanufactures turbochargers and DPFs for Cummins, the manufacturer of the legendary diesel engines and other technology products for the global motor

industry. Behind the facade, the plant provides an apt illustration of Cummins’ long-standing commitment to sustainability in general and its remanufacturing operations, Cummins ReCon, in particular.

Commitment A visit to the Cummins ReCon plant leaves little doubt that its commitment to remanufacturing extends all the way from top management to local plant management and to the operations on the

Cummins Cummins Inc., one of the world’s largest engine manufacturers, designs, manufactures, and distributes engines, filtration, and power generation products. Cummins also services engines and related equipment, including fuel systems, controls, air handling, filtration, emission control and electrical power generation systems. Headquartered in Columbus, Indiana, United States, Cummins sells in approximately 190 countries through a network of more than 600 company-owned and independent distributors and approximately 6,000 dealers. Cummins’ sales were around 1,6 billion dollars in 2014.

Cummins is organised into four business units: • Cummins Engine Business manufactures diesel and natural gas-powered engines for on-highway and off-highway use. Cummins Engine Business also provides a full range of new parts and services and remanufactured parts and engines.

• Cummins Power Generation Business is a global provider of power generation systems.

• The Components Business Segment consists of four businesses: Cummins Filtration, Cummins Turbo Technologies, Cummins Emission Solutions and • • Cummins Fuel Systems .

COVER STORY

ReMaTecNews | 13

Mark Nugent Mark Nugent is Director of Strategic ReCon New Business Development, with responsibility for worldwide new business initiatives and implementation for the Cummins New and ReCon Parts organisation.

factory floor. Throughout, work processes, from salvage and cleaning to assembly and testing, reflect strict compliance with Cummins ReCon’s own guidelines.

“Cummins manufactures some of the world’s finest engines, turbochargers and other components, so it’s essential that our remanufactured versions meet the same standards as the original product”, as Mark Nugent, Director of Strategic ReCon New Business Development, explains. “We never forget that 85 per cent of an engine can be remanufactured and that a product can be remanufactured can be remanufactured using 85 per cent energy compared to a new one.”

Sustainability report Hardly surprising that Cummins 2015 sustainability report states that not only are Cummins ReCon engines and parts good for business, they also benefit the environment. Instead of sending tons of metal to landfills, the company recycles and reuses resources, significantly reducing the need to mine new raw materials. This conserves natural resources and minimises greenhouse gas emissions associated with excavating, refining and machining. In total, Cummins ReCon products currently generate greenhouse gas reductions totaling 200 million lbs.

He has worked at Cummins for the past 7 years including his current role in the New and ReCon Parts organization. Prior to working in the ReCon business at Cummins, Mark Nugent was in Corporate Mergers and Acquisitions (M&A) where as Director, M&A Support, he was responsible for enabling Cummins’ inorganic growth plans including acquisitions, divestitures, and joint ventures.

Before working in M&A, Mark led the strategic finance function and commodity risk management strategy for the Cummins Emission Solutions business.

Prior to joining Cummins, Mark worked in the finance function at Intel Corporation in Oregon. Prior to Intel. Mark was a Civil Engineer in Los Angeles.

Mark Nugent has a degree in Civilan MBA in Finance from Brigham Young Universityagree in Civil Engineering and MBA in Finance from Brigham Young University.

“Increasingly, remanufactured products are “upcycled” to include design, emissions, fuel economy and quality upgrades.”

The figures bear this out. Backed by half a century of remanufacturing expertise, the 3,000 employees who work at Cummins ReCon’s nine plants across the world were responsible for sales of no less than USD 600 million apportioned across 4,500 part numbers last year alone.

Mark Nugent and Gary Johnson

COVER STORY

ReMaTecNews | 14

some slower, some faster. Currently, the focus on sustainability issues and reman is as strong as ever, perhaps even more so, as this engineering giant responds to the numerous influences that impact on the motor industry – and on the global landscape in general. As a result, in recent years, Cummins’ reman specialists have become involved in the design stage of a product’s development much earlier than before. This means that, increasingly, remanufactured products are “upcycled” to include design, emissions, fuel economy and quality upgrades.

Lighter, more compact engine designs combined with new materials (compact graphite and aluminum) and special coatings are changing Cummins’ approach to remanufacturing and making engines more fuel efficient.

Remanufacturing is Cummins’ “green business.”

By planning and designing Cummins’ products to have a long and increasingly more fuel-efficient life, remanufacturing maximises benefits for customers and the environment,” the report points out. “Through the common application of salvage technology, component re-use guidelines and remanufacturing-specific policies and

procedures, the company has become increasingly sophisticated in what it can remanufacture and for how long it can extend a product’s life.”

50 years of reman With 50 years of remanufacturing behind it, remanufacturing at Cummins has obviously gone through different periods in its development -

“We’re all part of the discussions. All the stakeholders are there to communicate what is important to the customers”, explains Plant Manager Gary Johnson, the man in charge of the 300 people working at the Memphis plant. “Sometimes these criteria are conflicting, sometimes they line up perfectly. In the end,

COVER STORY

ReMaTecNews | 15

the goal is to ensure that the product meets the customer’s requirements.”

Gary Johnson

Clearly this is paying off. In recent years, Cummins has strengthened its reman focus across the world – and across product lines. One advantage is the nearby global distribution centre which makes it easy to ship Pershing Road’s remanufactured products to world-wide markets.

“Over the last several years, the Memphis plant has gone through much of a transformation, where we have gone from making multiple products to having focus on turbochargers and getting these products out to our customers via our distribution centre here in Memphis,” Gary Johnson explains.

As Director of Strategic ReCon New Business Development with responsibility for new business initiatives, Mark Nugent, a 29 year old Civil Engineer, links customer requirements to the technical side of ReCon’s business. In keeping with the expansion of the reman operations, the task is becoming a key component of Cummins’ reman ambitions.

Gary Johnson, an electrical engineer, is responsible for operations and strategic planning for remanufacturing of Cummins turbochargers and diesel particulate filters and DPF’s . The Memphis remanufacturing plant is Cummins center of excellence for turbocharger remanufacturing globally.

“At the end of the day, we believe that remanufacturing is good for the environment.

That’s one of the key reasons why we do it. It’s also good for customers when it comes to the economy of the product because it gives them an option for more affordable replacement parts. So these voices (from the reman side) have become louder over the years as it has become much more apparent that being able to remanufacture a product impacts on profitability. This has not always been the case but it’s becoming a very robust part of the development process.” n

He has worked for Cummins Inc. for over 20 years, including positions as Director of Laboratory Operations at the Cummins global technical center and Quality Director at Cummins’ San Luis Potosi Mexico remanufacturing site.

Prior to joining Cummins Gary Johnson worked for the Dow Chemical Co in their Global Process Control organisation and for Eaton’s Research and Development Center in Michigan.

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BigR/ReMaTecUSA moves ahead Exhibitors from more segments and more countries than has been the case in the past 20 years - from October 31 until November 2 the second edition of Big R/ReMaTecUSA will be bringing together the remanufacturing community of North America and beyond.

“We believe that the new Big R/ReMaTecUSA turned a corner last year,” says Joe Kripli, President of the Automotive Parts Remanufacturers Association, APRA. Together with one of Europe’s leading show-organisers, RAI Amsterdam, APRA is hosting the year’s largest remanufacturing event in North America – and the two partners have high expectations.

“America needs a high-quality reman show and the 2015 Big R/ReMaTecUSA is clearly it. Floor space and exhibitor numbers are significantly up on the inaugural edition last November and repeating our co-location with ATRA’s Powertrain EXPO means that the automotive and HD reman industries exhibit under one roof for their premier event.”

Once again located at Las Vegas’ RIO Hotel & Convention Center, the show, which runs from October 31 to November 2, showcases a wide variety of remanufacturing companies and their suppliers world-wide. Altogether around a dozen countries are expected to display products, processes and methods to an audience from over 50 different countries worldwide. The 2014 event recorded over 1.300 visitors and 92 exhibitors.

This year the show expects well over a hundred exhibitors to cover a total floor-space of 50,000 sq feet.

“One difference from last year is that in 2015 the show is taking place in one large hall against two last year,” Product Manager Kim Schotborgh at RAI Amsterdam says. “We know that this appeals to most exhibitors because everybody will now be together in the same place.“ The view is shared by Dennis Madden, CEO of ATRA, the Automatic Transmission Rebuilders Association, which runs the annual Powertrain Exhibition, the transmission rebuilders’ annual Mecca. In 2014 Powertrain attracted a record number of attendees and Madden expects the show to do even better this year.

“The trend that was clearly noticeable last year, is set to continue,” Madden told ReMaTecNews.

“In 2014 we had more attendees than for several years and indications are that 2015 will be even better. Many transmission rebuilders are experiencing considerable growth and I’m confident that this will be reflected on the show floor in Las Vegas.” n

New exhibitors BigR/ReMaTecUSA Ajax Tocco Magnethermic Atlantic Automotive Enterprises, Inc CRP Industries Inc. DAH KEE Co., Ltd. Diesel Core Dorman Products G2 Diesel Products, Inc. GEEVO Automobiles Parts GMA Industries, Inc. Hebei Yinghui Herm-Archer Turbochargers Jiangsu Suotepower Engineering Co., Ltd. Mylex International, Inc. Paul Automobiles Rozrusznik.eu Safe Guard La. Co., Ltd. Selex Automotive INC. Turbo International TurboPark UNIFAP Indústria Metalúrgica Ltda.

Qiyuan Auto Parts Wah Seng Industry Sdn. Bhd. Youtech Group

Big R/ReMaTecUSA

ReMaTecNews | 17

Remanufacturing: From a cottage industry to a global juggernaut

By Mike Rayne Managing Director, FTI Consulting Remanufacturing has grown from a cottage industry to a global juggernaut that embraces a broad cross section of businesses from aerospace to medical. The industry has significantly impacted the aftermarket and replacement parts sectors, driving down cost and providing customers with a wide range of options.

The United States is the largest remanufacturer in the world with revenue in excess of $43 billion and employment 180,000+. But the remanufacturing industry operates within a commercial landscape which is rapidly changing and nowhere is this more evident than in the automotive sector.

Automotive is currently facing significant change and disruption in a number of key areas: Distribution Model: Radical Change creating winners and losers!

• Manufacturers using proprietary technology to secure market share.

• Channel Compression – Two step distribution and the internet challenging traditional three step distribution models.

• Franchise models emerging which challenge the traditional parts store model.

Sectors: New players entering the market creating growth, opportunity and threats • Alternate Fuel Technology OEMs and Distributors (Natural Gas, EV and Hybrid) entering the market for the first time.

• “Connected Vehicle” Integrators and Back Office Companies (Telematics) struggling to make the channels work for them.

• “All Makes” applying significant pressure on OEMs and the legacy model, disrupting channels to market with both price and incentive models.

Global Markets: Risk and Opportunity • EMEA – Saturated distribution in Western Europe, opportunity in Eastern Europe • AP – Rapid Aftermarket model evolution including development of discreet platform models • NA – Internet evolution, WD’s and OEM channels fighting for turf

While there are many drivers, Technology has been a front runner in the Automotive On Highway sector. Engine management systems have evolved from hydro mechanical and electro electronic to full authority electronic systems that are integrated with powertrain and emission systems. The introduction of stop/start is changing the vehicles basic electrical starting and charging system.

Challenges for remanufacturers Telematics and predictive failure analysis are changing the way the service industry interacts with its customer base. The same step changes in technology are taking place across most of the vehicle. This creates new challenges for remanufacturers as they grapple with information access, test equipment, tooling and increased capital investment, technology has also created change in the distribution model and the market players.

“Over 50% of consumers who purchase automotive parts use the internet for price comparison and point of sale searches.”

In response to these changes, large global autocenter groups have entered the market to create a service and support structure that aligns with the technological complexity of current vehicles. Several global players have entered the US market over the last few years, aiming to participate in this fast growth sector and taking market share from traditional players.

Internet - In 2014 online automotive parts sales reached approximately $3.2 billion. While this is still a small portion of the overall aftermarket, it is also one of the fastest growing segments. Over 50% of consumers who purchase automotive

Mike Rayne parts use the internet for price comparison and point of sale searches, the web is becoming an integral part of the automotive service industry and its influence is increasingly more significant in shaping the future.

Telematics Telematics – Customer retention and market penetration are key areas of concern for OEMs, Independent Aftermarket Distributors and Remanufacturers where a key strategy being used by vehicle manufacturers is the increasing integration of telematics systems in new vehicles.

Industry estimates place in service telematics devices at over 4 million units.

With the growth of telematics systems, OEMs have direct communication to vehicle owners which creates a competitive market advantage.

Telematics can notify the vehicle owner of regular service requirements from oil changes to emission components which must be changed. OEMs can provide wireless software updates creating value for the motorist strengthening brand bond.

Telematics will also be the basis for predictive maintenance, where the driver is warned of pending component or systems failure, and can be directed to a service provider.

Continued on next page

Big R/ReMaTecUSA

Summary Looking forward, the independent after market and remanufacturers must address the changes taking place in the industry both from a product technology standpoint and the options that end users have to access product and service.

The remanufacturing industry will grow and

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companies that adapt to market changes and embrace new technology will share in that growth.

Big R/ReMaTecUSA on Monday November 2 at 09.15AM. See page 21 for the full speaker programme. n

Keynote Mike Rayne and colleague Ramesh Subramoniam will give a presentation on this subject at

Remanufacturing - Taking the next step, critical thinking at a critical time Mike Rayne Mike Rayne has over 35 years’ experience in the Automotive industry, most recently serving as Global Vice President for Delphi DPSS. Mike is a Chartered Engineer a Fellow of the Institute of Road Transport Engineers and a McFarlen and Ortner award recipient. During his career Mike has served in North America, Asia and Europe leading business transformation and new technology introductions. Mike is currently a Managing Director for FTI Consulting a $1.8B multinational corporation.

Ramesh Subramoniam Ramesh Subramoniam is a Managing Director in FTI’s Performance Improvement practice and is based in Dallas. Mr. Subramoniam holds a PhD in remanufacturing and is responsible for the implementation of performance improvement and enterprise value realization engagements. He is also a member of the industry advisory board of the Center for Intelligent Supply Networks, University of Texas, Dallas and in the board of directors of the Remanufacturing Industries Council.

Turbochargers – Boom time ahead The turbocharger industry – and its remanufacturing partners – is set to experience a significant upturn going forward. On the horizon is an unprecedented turbocharger boom as car makers introduce ever smaller and more fuel efficient engines in greater numbers.

“The application of turbocharger technology has accelerated hugely in recent years and the trend is likely to continue for the foreseeable future,” says Bob German, a former RIT expert who will deliver an important presentation on past, present and future turbocharger developments. Bob German is currently working as Senior Project Manager for Flight Systems Group, the US-based turbocharger remanufacturer with an operating subsidiary in the Czech Republic.

“We’re getting into a stage where consumers can choose from multiple turbocharged four cylinder vehicles that have as much power as the high performance eight cylinder vehicles from 15 years ago. These smaller engines operate at 20 to 40 per cent lower rate of fuel consumption when compared to a larger, naturally aspirated eight cylinder engine so the prospects for the turbocharger segment are indeed bright,” Bob German says.

Golden Age One recent comment on the outlook for the industry comes from Nitin Kulkarni, Vice-President of North America, Japan and Korea at Honeywell Transportation Systems, one of the world’s top turbocharger manufacturers.

“We’re in the golden age of turbos,” Kukarni said.

“Turbochargers are a no-compromise solution because they can be applied to all kinds of vehicle sizes, fuels and engine strategies.”

“As the turbo market in Europe is well established, much of the growth will come from China and North America,” Bob German explains.

“Honeywell estimates that North America’s turbo market will grow by 14 per cent per year for the next five years. By 2019, this growth will result in annual North American sales in excess of 8 million turbocharged vehicles or 38 per cent of the global market. No doubt, there is plenty of room for radical expansion in the turbo market – and for remanufacturers operating in it.” n

The claim is backed up by recent trends for this year’s Big R/ReMaTecUSA where Sales Manager Ewoud Barink reports rapidly growing interest from exhibitors. “We’re seeing more interest this year than ever before and it’s clear that the segment will be a significant component of the show,” Barink says. “We see the development as an important pointer towards the future and expect to see even more turbocharger-activity over the coming years.”

Global Turbo Forecast Earlier in 2015, Honeywell Turbo Technologies released a Global Turbo Forecast showing that, by 2019, the industry will generate USD 12 billion in revenue by equipping 49 million vehicles with turbochargers annually.

Bob German, Flight Systems Group

Big R/ReMaTecUSA

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Learn better business at Big R/ReMaTecUSA Never has the global motor industry’s development proceeded so rapidly as today.

This applies to global car makers, Tier 1 and Tier 2 suppliers as well as to the entire supply chain. The automotive and Heavy Duty remanufacturing segments are no exception.

“3D printing is a relatively new technology that has got a large amount of attention recently,” Haselkorn says. “Using industrial case studies we’ll look at how these technologies are currently used in remanufacturing and the future growth opportunities for additive manufacturing and 3D printing in the remanufacturing industry”.

More than ever remanufacturers at all levels are subject to market forces, new technological challenges, the need for extending services to customers and, not least, the ever rising environmental, energy saving and CO2 reduction demands from authorities and, indeed, consumers.

Gain insight into online strategies One way of combatting this enormous array of challenges is constant upgrading of skills and learning.

“In many respects learning is perhaps the single most important parameter for today’s remanufacturers,” says APRA president Joe Kripli, one of the organisers behind the Big R/ ReMaTecUSA show. “This is why this year we have placed such emphasis on learning during Big R/ReMaTecUSA. By presenting such a range of expert speakers and in-depth seminars, we’re giving attendees a unique possibility to learn new business skills while, at the same time, participating in the most important networking event of the year.”

term Technical Advisor for APRA, speaks on how to address rebuilding issues regarding commonly used newer alternator and starters and explains how to maximize testing techniques for such units.

3D printing Speed Traps, Pot Holes & Idiots Under this somewhat provocative headline, Jay Gubrud, the well-known catalyst for performance improvement, will provide a number of guidelines for improving business performance in the remanufacturing industry as well as personal performance.

“Speed Traps, Pot Holes & Idiots is designed to maintain a winning mindset,” Jay Gubrud says.

“Attendees will learn how to establish rewarding new mindsets and overcome fears that get in the way of change as well as how to get along with difficult people and build powerful connections with others.”

Joe Kripli at last year’s event Among the speakers at the show is Rochester Institute of Technology’s Mike Haselkorn.

Haselkorn who has, over the years, lectured extensively on the technological advances taking place in remanufacturing, will present two seminars – on 3D printing and Innovations in Cleaning.

“The details and updated information regarding newer alternators as well as testing them, using various affordable aftermarket test boxes and adaptors will be highlighted”, Mohammad Samii says. “We will show how systems such as Mitsubishi D-P, GM’s RVC, Ford PCM, Toyota RLO, and various BSS, and LIN systems work, and how their related units that are showing up more and more for rebuilding, can be tested to validate their proper operation.”

See page 21 for the full program. n

Online Strategies & Reputation Management Dennis Jacinto, a former Chairman of APRA, will discuss how technology is changing the way businesses market products and interact with customers. “The internet provides powerful tools that were previously unavailable or unaffordable to all but the largest organizations. So why do so many of us not take advantage of these ways of saving time and money while better serving existing customers and finding new ones?”

Jacinto asks.

Affordable testing of starters/alternators Mohammad Samii, Alternator Specialist and long

Big R/ReMaTecUSA 2014

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ReMaTecNews | 21

Better Your Business Seminar Program Saturday, October 31 8:45 AM - Noon

Thrive & Survive Electrical Clinic

Mohammad Samii, Sammy’s Auto Electric

9:30 AM - 11:00 AM

Innovations in Cleaning

Mike Haselkorn, Rochester Institute of Technology

11:30 AM - 12:30 PM 2015 Employment Regulations: What Are We Required To Do?

Jamie Hasty, SESCO Management Consultants

Sunday, November 1 10:00 AM - 11:00 AM

Additive Manufacturing and 3D Printing –

Hype or the Future of Reman?

Mike Haselkorn, Rochester Institute of Technology

11:15 AM - 12:00 PM

Online Strategies and Reputation Management

Dennis Jacinto, You Tech Group

12:15 PM - 1:00 PM

Turbocharger Remanufacturing Today and Tomorrow

Bob German, Flight Systems Automotive Group

Keynote Speakers Seminars by the keynote speakers are free for all visitors and exhibitors.* Sunday, November 1 8:30 AM - 9:45 AM

Speed Traps, Pot Holes & Idiots –

Eliminating Roadblocks to your Success

Jay Gubrud

Monday, November 2 9:15 PM - 10:00 AM

Taking the Next Step, Critical Thinking and Critical Time

Mike Rayne, FTI Consulting * Content, dates and times are subject to change

&

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CV-411 The Motoplat CV-411 test bench has a 380V 3 phase power supply and tests both 12 and 24 volt alternators.

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VC-09 ST The Motoplat VC-09ST is the world’s first aftermarket tester/calibrator for Valeo ST-series alternators. These are start/stop reversible alternators which also have the function of charging the battery and starting the engine.

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VC-17F The Motoplat VC-17F DFM alternator tester, can test the load signal from the alternator to the car ECU.

ReMaTecNews | 23

Cost effective turbo testing The BenchFlow 2000 is a bench-top turbo unit test machine designed for small to medium remanufacturing businesses. It delivers accurate, efficient and cost effective recalibration at a competitive price, says the company.

Manufactured and supplied by British test equipment manufacturer Turbo Synthesis, it is a compact VNT calibrator supplied with eight turbo mounting adapters and four electronic actuator cables.

The machine is easy to use and expected to become especially popular with ambitious remanufacturing enterprises emerging from Eastern Europe, such as Slovenia and Poland, where large volume brands have yet to become dominant, the company says.

“It is a small affordable recalibration machine that delivers quality assurance and reduces potential warranty claims. It ensures that small remanufacturing companies can continue to grow with confidence, without being concerned that their products will be returned,” says the Birmingham-based manufacturer. n

Managing Director Gareth Cole, Turbo Synthesis, with the BenchFlow 2000

Faster alternator test bench French test equipment manufacturer TMA has introduced a new test bench for starter and alternator remanufacturing specialists that TMA claims is one of the most powerful tabletop testers on the market.

Designed and manufactured at its factory in Lyon, the Onyx Tester is a smarter 12/24V tester, with simple unit and belt mounting procedures, capable of identifying most communication protocols from a wide range of units fast and accurately, often within a minute.

TMA Onyx starter and alternator tester

Users follow a series of intuitive onscreen procedures designed to achieve accurate results,

Vietnamese trade The EU and Vietnam have reached an agreement in principle in the negotiations for a Free Trade Agreement (FTA), after two and a half years of intense talks. This agreement will remove nearly all tariffs on goods traded between the two economies.

“It sets a new, better and modern model for Free Trade Agreements between the EU and developing countries, and establishes a good standard for the trade relationship between the EU and South East Asia as a whole.” said EU Trade Commissioner Cecilia Malmström. The deal has still to be approved by the Council and European Parliament. n

while an inbuilt thermal printer delivers proof of performance that helps to eliminate inappropriate warranty returns.

Unit identification is easy. For example, the onboard database includes over 190,000 different alternator units that can be identified automatically, either by OE reference number, vehicle manufacturer or OE manufacturer.

Future-proof, online updates ensure that data about additional models can be added as they become available to ensure that remanufacturers stay in touch with developments and remain at the cutting edge of the reman business. n

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Pan-European DPF network on the planning board DPF Renu of Northern Ireland, last week became the first member of a new international network of Diesel Particulate Filter remanufacturers.

It’s the first move in the development of a new concept for the automotive remanufacturing industry, one that appears to offer its network members significant profit opportunities from their local automotive markets.

That’s because OE replacement DPFs typically cost over 1,200 euros per unit. DPF Renu and other members of the new network are expected to be able to deliver a reliable DPF remanufacturing service with big savings for garage customers.

Ceramex, the British company behind the move, announced its intention to develop a Pan-European network at the ReMaTec 2015 show, held in Amsterdam at the beginning of June. Network members are not franchisees, but licensees that remain independently run. Many are expected to be ‘experienced remanufacturers with good automotive connections’ and with either spare capacity or an eye for an opportunity.

within three days.”

DPF Renu is part of a group that also includes a parts distributor and two vehicle service centres, which were already users of the Ceramex UK service. “We can already vouch for the quality of the DPF equipment,” he adds.

“Our DPF remanufacturing business for passenger cars is already increasing by between 20-30%, month on month”

than 430,000 cars built to Euro 4 classification.

Many of these vehicles are already outside their vehicle warranty periods, with units due for replacement.

As a remanufacturer with plans to export, DPF Renu will also be able to call on support from the Government agency, Invest Northern Ireland, which can assist with marketing campaigns, for example.

Ceramex has experience in managing international partnerships. Its joint venture with Springfiedbased US company, SRC, has already secured a significant share of the DPF remanufacturing market among the heavy duty fleets of North America.

Although the passenger car market for DPF remanufacturing is likely to grow quickly, Ceramex says nobody can forecast how big it will eventually be - or how wide the new DPF remanufacturing network will have to become. n

Euro 4 classification Located close to the Irish border, the business is well placed to export its new remanufacturing service to the Republic of Ireland, which has more

Flexpurge DPF cleaning system Each network member will be equipped with a Flexpurge DPF cleaning system, a machine that Ceramex says is based on the heavy duty version that’s already satisfying the OE service DPF remanufacturing requirements of commercial vehicle and construction vehicle manufacturers worldwide. The adapters supplied ensure that almost any passenger car DPF can be remanufactured from the word go.

Demand for credible DPF remanufacturing services is increasing and sales figures from Ceramex suggest that network members should prosper.

“What we can say is that in the UK alone, our DPF remanufacturing business for passenger cars is already increasing by between 20-30%, month on month,” says account manager Marcus Beament.

Mark Gilmore, Managing Director of Newry-based DPF Renu says: “Until now, garages on both sides of the Irish border were unable to gain access to a satisfactory local aftermarket solution to clogged DPFs, without turning to the dealers. Well, now they can. They are received, processed, fully tested and sent back to repair garage customers

Mark Gilmore’s DPF Renu is the first in the network.

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The reman industry must focus more on investment Since the early 1980s, the development of electronic components and processes within the motor industry has proceeded at an astonishing pace. Driven by issues concerning car pollution and rising demand for driving comfort and safety, modern vehicles now contain hugely complex interrelated systems. Moreover, most of them communicate with each other.

Besides the new opportunities for the motor industry, this also poses some real challenges to the automotive remanufacturing industry. Unless remanufacturers face up to them, they could face serious threats to their survival.

The warning comes from long-standing reman expert, Volker Schittenhelm, a former CEO of Germany’s Association of Engine Remanufacturers, VMI, and currently working for

the global Schaeffler Group.

“Today’s cars have a minimum 40-50 CPUs installed, controlling, regulating and documenting nearly every process, sensor, data management or security relevant system. As the share of E/E-components continues to rise, this trend is set to increase,” Schittenhelm says. “If our industry wants to offer a complete repair and service programme, we have to face the fact that we must invest in efficient tools and updated knowledge. Businesses which fail to do this will, in all likelihood, consign themselves to niche areas such as mechanical repairs, veteran cars, rallies etc. That, I believe, is not what most of them want to do.”

Legal issues Schittenhelm emphasises he is not merely referring to technical and technological skills and

knowledge. Dealing appropriately with legal issues is also vital for workshops. Such issues include: - Clear agreement and common understanding of end-users’ orders – in writing - Open communication about costs and invoices - Transparent terms and conditions - The effective fixture of the general terms and conditions of business into contracts - Clear understanding of the difference between warranty (as required by law) and guarantees (voluntary) - All insurance policies required for covering risks relating to doing business with private/commercial customers.

“Adhering to legal rules and regulations is becoming far more important than before when shop operators tended to trust customers when agreeing contacts.

Continued on page 30

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ReMaTecNews | 28

Think factory, not just Think Tank Three years of planning and millions of euros spent, but Bavarian students of the future and the world in general stand ready to benefit from the investment in a new home for remanufacturing, research and science in Europe.

Spread over five floors and covering 3,000 m2 of floor space, the Fraunhofer Projektgruppe Process Innovation Centre is the latest offshoot of the Fraunhofer Institute. It is a glass-clad, ‘think factory’, set behind steel facades that house up to 44 scientific staff and 60 engineering students.

“Innovation needs space, good ideas need fresh air to breathe,” said Bavarian deputy minister for business and industry, Franz Josef Pschierer in his keynote speech at the opening ceremony (August 2015). He said that the 8.5 million euro building (which is adjacent to Bayreuth University in Northern Bavaria), will strengthen the links between sustainability and remanufacturing on one hand and industry on the other. It will also serve as a focus for engineering students for generations to come. Pschierer added: “Fraunhofer takes ownership of technologytransfer as no other institution in our country and, therefore, through world-class research, contributes to value-creation in Bavaria and to the success of Bavarian industry. The new building and its team of top-class scientists, researchers and advisers to business offer a new, future perspective for our region and its people.”

100 Industrial partners Since its inception in 2006, the Fraunhofer Project Group has worked with more than 100 industrial German and international companies to find innovative solutions to technical issues, including process optimization as well as energy and material saving measures. To date, it has

Bavaria’s Deputy Minister for Business and Industry Franz Josef Pschierer represented the Bavarian government. achieved average cost savings of between 30 and 50 percent for its partners.

“In view of the ever increasing competition in international markets, the need for high-tech solutions is greater than ever,” says Professor Rolf Steinhilper, who together with Dr. Stefan Freiberger has been responsible for leading the project. “The new building, which could be described as ‘Green Factory Bavaria’ will significantly strengthen the potential for delivering such solutions to businesses, including remanufacturers, across Europe.”

organization, the Fraunhofer Institute operates a series of research centres across Germany.

It employs a total of 23,000 people, of which the majority are scientists and engineering staff, undertaking research dedicated to the improvement of people’s needs, health, security, communication, energy and the environment.

Its activities include advice and consultation services, product design, the development of new technology and the improvement of industrial processes. n

The Fraunhofer Institute Europe’s largest application-oriented research

The opening of Bayreuth’s new research center attracted a significant number of scientists, officials, politicians and industry representatives.

ReMaTecNews | 29

British treasurer FIGIEFA Australian move Wendy Williamson, chief executive of the UK’s Independent Automotive Aftermarket Federation, has been appointed to the board and made treasurer of FIGIEFA, the association representing the needs of the European independent automotive aftermarket to governments and legislators of the European Union.

The IAAF and FIGIEFA enjoy a very close working relationship, promoting the contribution of the independent automotive aftermarket in order to achieve the EU’s goals for a competitive European economy. n

One of the largest distributors of new and remanufactured power steering products for the heavy duty vehicle market in Australia has extended its national market coverage with the help of a new warehouse in Brisbane, Queensland.

New FIGIEFA Treasurer Wendy Williamson

Bosch extends coverage Bosch has extended coverage of the remanufactured starter and alternator market in North America with the addition of 13 SKUs, this month (September 2015).

These SKUs cover late-model Domestic, Asian and European applications from as early as the 2003 model year right up through 2014. n

Melbourne-based Hydrosteer, which also provides regular services to customers in New Zealand and South East Asia, is the authorized service agent for systems produced by equipment manufacturers such as RH Sheppard and Z. Brands supplied include Aisin Seiki, Koyo and JKC. n

TRANSMISSION world

ReMaTecNews | 30

Russian show gets on the road AutoTransTech, Russia’s largest provider of services and equipment for automatic transmission rebuilders, has celebrated its first decade of international seminars.

The intention is to expand further over the coming twelve months including a roadshow in collaboration with renowned US transmission specialist Sonnax.

For the first of an extended series of 2015/2016 events AutoTransTech gathered a number of expert lecturers from Transtar, Sonnax, Kinergo, Raybestos, Alto and LuK in Moscow on August 21 for an “Advanced Torque Converter Rebuilding” seminar. A follow-up seminar the following day on “Structure, Repair and Diagnostic of Automatic Transmissions” featured speakers from Precision. Transmatic, Exedy, Bluereach, Raybestos and HYDRA-TEST.

“The event marked the start of a major effort to extend our services to other part of Russia and neighbouring countries, where we see a rapidly expanding market,” AutoTransTech owner, Slava Bakalov explained. “It’s clear that knowledge about automatic transmissions is in great demand.

We intend to run several more seminars during the coming year.”

Recent AutoTransTech seminars have attracted more than 200 participants from Ukraine, Moldova, Kazakhstan, Belarus, Latvia, Lithuania as well as most regions inside Russia itself.

Slava Bakalov – organizing a country-wide series of transmission Seminars in Russia

In addition to its original role as a transmission parts supplier, AutoTransTech has, over the past decade, built a substantial business comprising seminars and exhibitions, diagnostic equipment and technical support for companies, specializing in diagnostics and repair of automatic transmissions. n

UK bus operators go Direct UK bus and truck parts remanufacturer Direct Group has now added transmission parts to its product portfolio. The move follows favourable responses to the supply of some remanufactured differential units to a number of major bus operators earlier in the year, as part of an introduction to the product line.

Group managing director Roy Kendrick says it’s an exciting development for the company: ‘A major fleet operator has now come back to us and asked for more, which demonstrates satisfaction with the quality of the products that we were able to produce.’

New contracts The move extends a successful summer period for the company, which has increased its share of the heavy duty service exchange parts market to bus operating companies. In August, the company renewed two remanufacturing contracts with fleet operator Stagecoach. The first continues a

Continued from page 27 Investment focus Today the reality is that you have to make sure that all potential disagreements are accounted for,” Volker Schittenhelm says. “The workshops

reman parts supply connection on power steering products that has been unbroken for 20 years.

The second extends an agreement to supply remanufactured hydraulic fan equipment that has been in place for five years.

In July, the company announced it had won a new contract to remanufacture front axle beams and rear axle casings for Arriva, another of the UK’s large fleet owners. The two-year contract, which carries an option for a third, should provide Arriva with major savings on vehicle maintenance. n

really need to be careful with these things.”

As for engine remanufacturing in particular, Volker Schittenhelm points out: “Since faults are no longer confined to single components, a whole range of issues has to be considered during diagnostic processes. With engines, this

has created a need for a new definition of ‘the engine’s periphery’ because in terms of repairs/ remanufacturing, engines cannot be viewed as isolated units any longer.” n

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ReMaTecNews | 32

Profit opportunities in new markets

Inspecting rebuild electrical windings at Sulzer facility in Falkirk ( Scotland) Industrial equipment manufacturers supply many different markets but there are strong arguments to suggest that, when considered collectively, it is comparable in size with the equipment manufacturing market for the automotive sector.

Accordingly, it can be assumed that the size of their respective markets for remanufacturing are of similar sizes, an assumption that suggests very substantial opportunities for remanufacturing specialists who wish exploit opportunities outside the automotive or heavy duty reman sectors.

A segment of the industrial manufacturing market that might well draw their attention might be the electric and electronic technologies that lie at the heart of many industrial components. Consider the wide-ranging applications such as electrical motors/generators, electronics for industrial automation, robots and wind turbines, for example. The opportunities for remanufacturers would appear to be wide-ranging – both in the mid-term and in the longer term.

Extending the operational life span of electrical motors/generators is, typically, achieved in a

variety of ways: 1) Repair – service of existing unit 2) Overhaul – rebuild the unit with serviceable parts 3) Remanufacture – original part re-engineered, updated and fitted with OE quality key components For example, in the rotating electrics market, remanufacturing is likely to involve the replacement of copper wires and bearings and the replacement of some key components. The issues are whether to exchange the component for a new one, use a remanufactured unit from stock or simply repair or rebuild.

for decades. One wonders why some industrial sectors have so far failed to follow suit. Costly downtime for electrical machines must be a serious problem. One would have thought that reducing these costs through instant replacement with a remanufactured exchange unit, was an obvious solution, or at least one worthy of serious consideration.

In the industrial equipment sector, on the other hand, end users will ask either their original equipment manufacturer or an independent repairer to ‘process’ their equipment. Typically, this means the replacement of the original unit with a new one. Too often, the idea of exchanging the non-functioning component for a remanufactured unit from stock is an exception to the rule.

“It seems illogical that all manufacturers of servo motors and medium size motors, have so far failed to (make use of exchange systems)”

An obvious solution The service exchange system has been used with great success by the automotive industry

Manufacturers of wind turbines have realised that stocking units and simply exchanging generators

ReMaTecNews | 33

due for service is a far more rational approach than refurbishing an operator’s existing units one by one. The remanufacturer will simply supply an exchange unit at a remanufactured price ex-stock, with the provision that the old unit is received as part of the deal – and that it is, of course, repairable.

Wind turbine manufacturers have successfully introduced a service exchange system into the market, so it seems illogical that all of the manufacturers of all servo motors and medium size motors, for example, have so far failed to do so.

Exchange systems While it is true that some independent remanufacturers in the sector have begun to operate exchange systems on some medium sized units, it is certainly not (yet) the norm.

Equally, some OEMs are beginning to offer a service exchange on some remanufactured parts, although this mainly applies to sub-components for larger equipment. There is a trend, but the speed with which it will grow remains a question without answer.

supply remanufactured units for those parts now out-of-production.

When it comes to electronics or converters for transfer and conversion of currents, voltages and control frequencies, some wind turbine operators - such as Zopf (see photo) - have set up exchange systems in order to reduce downtime, in conjunction with equipment remanufacturers.

Original and independent remanufacturers of electronics replace semiconductor components, capacitors and interface boards for instance.

Some independent remanufacturers also offer special services for out of production units.

Electronics components are increasingly used in industrial automation systems and that’s one area where independent remanufacturers have become very active. For example, several offer to

Robotics industry The robotics industry is a sector that offers some significant remanufacturing potential. In Europe alone, there are more than half a million robots in active service, requiring regular servicing and overhauls. Independent remanufacturers are not only supplying remanufactured units, they also have the capacity to upgrade or convert to newer models. In general, however, rather than running exchange systems, they simply rebuild the operator’s robots. To reduce downtime, they may also lease short-time replacement units or even do rebuilds on site for customers.

Original manufacturers, of course, do the same but with a few worthy exceptions, do not offer

Quality check of electrical wiring at Sulzers Falkirk facility: exchange programs - except on robot arms.

OE remanufacturers either have either central workshops or rely on appointed service agents.

Operators using several robots may stock rebuilt units for rapid exchange. Remanufacturers hold stocks of old and remanufactured units, but not in large quantities. The total number of electrical equipment remanufacturers is significant.

In Europe, a conservative estimate is that there are at least 1000 rebuilders/remanufacturers that, between them, account for billions of Euros.

When it comes to the bigger units, the market is dominated by remanufacturing programmes from original equipment manufacturers. The lion’s share of the smaller motors market is dominated by independents.

Electrical reman – a good option While there are other segments of the industrial equipment manufacturing market where committed automotive remanufacturers could benefit, electrical remanufacturing looks a particularly good option. Remanufacturing in this segment is neither as transparent, nor as well organised as the automotive remanufacturing sector.

As political interest in the circular economy grows and as lawmakers around the world begin to lend serious support towards remanufacturing programmes, there has never been a better time to seize the moment and, as they say, think outside the box. n

Repair of frequency converters at ZOPF Energieanlagen in Leipzig, Germany

NEWS FROM OTHER ORGANISATIONS

ReMaTecNews | 34

APRA names new Technical Manager APRA has appointed Wes Grueninger to the newly-created role of APRA Technical Manager, with particular responsibility for the APRA website.

that I looked at was either too expensive or did not have the features that we needed. So I decided to create my own.”

Before joining APRA, Grueninger served as Website Director, Trade Show Director and Production Manager at the ERA, the Electrical Rebuilder Association. n

Having run his own rebuilding operation for 35 years, Grueninger is no stranger to the automotive remanufacturing industry where, during his career, he ran an auto salvage business, a car lot, a complete auto repair facility and an alternator/ starter rebuilding company. “I became interested in computers in the mid-1980s when I was looking for a software system to manage cores.

At that time, we were manually maintaining a “core bank” for each customer,” Grueninger explained. “The amount of bookkeeping time was overwhelming, and it seemed to me that a properly designed software system could do the job better and cheaper. However, every system

Wes Grueninger

Design4Reman Earlier in the year, Berlin-based VDA, the Association of German car manufacturers, launched a working group called Design4Reman. The aim is to create a position paper on the benefits of incorporating the potential for remanufacturing of components at a very early stage in their development.

A member of the group, FIRM, The European Federation of Engine Remanufacturers, has expressed strong support for the move. “This would certainly ease the remanufacturability of

future combustion engines and their sophisticated technologies such as materials, surfaces, production processes,” says FIRM’s Volker Schittenhelm.

EU position paper In a position paper, the environmental committee of the EU Parliament has set out its demands relating to the circular economy to the EU Commission. Among other things, the committee demands guidelines for improving recycling and repairs relating to extending product life cycles. n

George Davis leaves APRA After four years, George Davis, a former Chairman of APRA, is leaving his position as Technical Director of APRA to join consumer goods giant Rubbermaid. George Davis will take up the position as Senior Quality Manager.

A well known face in the US remanufacturing industry, George Davis said: I began in 1978 and have been employed in the industry full-time since then. I say “leaving”, but as a few of us have observed, you never really leave reman. It is almost a type of addiction. We change jobs, do other things, but we tend to drift back. At least to

a clinic or trade show. I think that’s because of the wonderful people in this industry. I believe that no one leaves remanufacturing forever.”

President of APRA, Joe Kripli commented: “It is with great sadness that I have to announce the resignation of George Davis. Although I am extremely happy for George and wish him great success with his new job, he will be truly missed.

I can honestly say I have never seen anyone give more to their position with a company/ organisation than George has given us over the past couple of years.” n George Davis

NEWS FROM OTHER ORGANISATIONS

ReMaTecNews | 35

APRA President undertakes additional responsibilities Portland, Oregon-based Instrument Sales and Service (ISS) have appointed APRA President Joe Kripli as Vice President, Remanufacturing.

He will be responsible for leading the company’s remanufacturing operations, distribution, order fulfilment and new business development as well as extending ISS’s role in automotive electronic component remanufacturing.

1990s and today is one of the largest suppliers of remanufactured replacement electronics for automotive instrumentation, audio/radio and navigation units for original equipment manufacturers and Tier‐1 suppliers in North America. n

Joe Kripli will continue in his post as President of APRA. ISS has remanufactured electronic and electromechanical products since the early

Joe Kripli

PAACE Automechanika in Mexico to strengthen Strategic Partnership Believing that the move will strengthen their strategic partnership, the organisers of Latin America’s largest motor show, PAACE, have decided to move their annual event to new dates. With effect from 2016, the show will take place on April 13-15 at the Centro Banamex in Mexico City with approximately 600 exhibitors covering 30,000 sq. m. floor space.

PAACE Automechanika in Mexico City is currently produced in partnership with Messe Frankfurt, and U.S.-based associations: APRA, MEMA and SEMA. “Paace has been important for APRA throughout its 17 year existence and we’re delighted to

MERA moves office The Motor & Equipment Remanufacturers Association (MERA) has relocated to Riverside Centre in Southfield, Mich., USA. In addition to combining space with its sister association, the Original Equipment Suppliers Association (OESA), the new space includes a state-of-the-art conference centre. The centre – which will serve as a venue for MERA meetings

and small events is centrally located and easily accessible from major roads in the Detroit area.

MERA’s new office and conference centre address: 25925 Telegraph Rd., Ste. 350 Southfield, Mich. USA 48033-2553 The MERA main phone number remains the same at +1 248 750 1280. n

be part of an even stronger event,” said APRA President Joe Kripli, who attended the signing of the new agreement between the participating organisations at the end of August. “The move means that we now have greater opportunities to promote remanufacturing in Latin America.”

New model The closer partnership between the organisers, Industria Nacional de Autopartes (INA) and Automechanika Mexico, aims at increasing the number of exhibiting companies and visitors, showcases a new model for exhibition, communication and integration with buyers, distributors, retailers, mechanic shops and students. n

MARKET PLACE

ReMaTecNews | 36

Balancing machines

Schenck RoTec GmbH Landwehrstr. 55 64293 Darmstadt | Germany P +49 6151 32 2311 E rotec@schenck.net W www.schenck-rotec.com

Cleaning

ARMEX Church & Dwight Co., Inc. 469 North Harrison Street Princeton, NJ 08543 U.S. W http://www.armex.com

Cores

Autoenterprises Ltd. Units 5,6,14,15 Pembroke Centre, Gardiners Lane South Basildon, Essex, SS14 3HX, United Kingdom P +44 (0)1268 285888 E john.snr@autoenterprises.co.uk W www.autoenterprises.co.uk

Gobbi Spare Parts Spa Via Capannaguzzo 3681 47521 Macerone di Cesena (FC) Italy P +39 0547 311146 E info@gobbisp.com W www.gobbisp.com

SDA Import - Export BV Duizeldonksestraat 7, 5705 CA Helmond The Netherlands P +31 (0) 492 524463 E tony@sdaim-export.nl W www.sdaim-export.nl

Test Equipment STP-Parts GmbH Otto-Hahn-Str. 7, D-40721, Hilden Germany P +49 (0) 2103 978 66 10 E info@stp-parts.de W www.stp-parts.de

Lizarte S.A. Polígono Agustinos C/B 31013 Pamplona, Navarra (Spain) P +34 (948) 303436 E info@lizarte.com W www.lizarte.com

Remaned Pol. Ind. Morea Sur, 41. 31191 Beriáin - Navarra, Spain P +34 948 368 775 E contacto@remaned.es W www.remaned.com

Pos Service Holland­­ Stichtse Kade 47c 1244 NV ’s-Graveland The Netherlands P +31 (0)35 6563180 E psh@psh.nl W www.psh.nl

RECICLANOVA METAL S.L. C/ Rosa de los vientos nº40 Polg. El viso, 29006 Málaga P +34 952240970 E adreciclanova@gmail.com W www.reciclanovametal.com

Parts & Engines

Vitobello Ricambi Srl. Via Luciano Lama, 28 47020 Longiano (FC), Italy P +39 0547/52839-56209 E info@vitobello.it W www.vitobello.it

Remanufactured Products

BU Drive GmbH Friedrich-Ebert-Straße 125 Lingen (Ems) | Germany P +49 (0) 5 91 / 71 050 E info@bu-drive.de W www.bu-drive.de

ROBARCKO B.V. Markerkant 1306a 1314 AN Almere Stad The Netherlands P +31 ( 0 )36 530 46 02 E info@robarcko.nl W www.robarcko.nl

Diesel Line Srl Via Verona 7 31046 Oderzo (TV) Italy P +39 0422 717572 E info@diesel-line.it W www.diesel-line.it

Starters & Alternators

Arrowhead Electrical Products, Inc. 3787 95th Ave. N.E. Blaine, MN 55014 United States of America (USA) P (763) 255-2555 E info@arrowheadep.com W www.arrowheadep.com

Emmetec S.r.l.

Sede operativa-Headquaters: via Stazione, 8 - 21020 Ternate (VA) Italy P +39 0332 9618.86 / 96 E info@emmetec.com W www.emmetec.com

Transmission parts

Ganzeboom Transmissies Planthofsweg 45 7601 PH Almelo, The Netherlands P phone +31 (0)546-819510 E info@ganzeboom.net W www.ganzeboom.net

GFX Corp.

4810 NW 74 Ave. Miami, FL. 3166 United States of America (USA) P 305-499-9789 E www.gfxcorp.com W dios@gfxcorp.com

Turbo Parts

Melett Limited Unit N, Zenith Park Whaley Road, Barnsley S75 1HT, United Kingdom P +44 (0) 1226 320939 E sales@melett.com W www.melett.com

INFORMATION For more information please contact the ReMaTec Sales team phone +31 20 549 14 31 advertising@rematecnews.com www.rematecnews.com

ReMaTecNews | 37

For further news about

The material for this page has been supplied by APRA, the Automotive Parts ReManufacturers Association

Apra ­Europe, please visit ­www.apra-europe.org

Remanufacturing Associations Meeting Peter Bartel, Chairman of APRA Europe invited other remanufacturing associations to attend a meeting during the ReMaTec exhibition in Amsterdam.

The objective was to discuss common challenges and opportunities as well as individual activities in remanufacturing.

Many sectors like automotive, heavy duty vehicles, engines, industrial machinery, aviation, information technologies, health care etc. are all active in remanufacturing but have not yet joined forces to promote their businesses Europe- wide.

APRA, Automotive Parts Remanufacturing Association, is one of the associations leading the continuous development of remanufacturing in Europe and supporting a joint approach with Governments and Institutions worldwide. n

Remanufacturing

Benchmark Sample bitkom Global ICT »Original Equipment Manufacturers« (OEMs) are committed to remanufacturing. They are actively engaged in the effective reuse of ICT products in the Business-to-Business sector.

Manufacturers of computing equipment, printers, networking and communications products are also amongst them. They see remanufacturing and resale of such products as part of their core activities and as an important contribution to circular economy. bitkom – the German based Digital Association – has now published a questions + answer brochure titled „ICT Remanfucturing in the European B2B market“ what shows how the ICT sector is communicating the benefits of remanufacturing. Download: www.apra-europe.org/ bitkom. n

Remanufacturing

Trade Mark Rights and Remanufacturing For many in our industry, remanufacturing related trade mark rights are still unclear. We are missing easily understandable guidelines.

Hence, this situation is often exploited in order to create trading barriers by aggressively claiming trade mark infringements. Most of the time these claims are obsolete and misleading. As association we can provide guidelines to avoid trade mark infringements and we therefore recommend to clearly label all remanufactured units/parts.

www.apra-europe.org/remanflyer In addition, APRA provides comprehensive knowledge and advice on trade rights and remanufacturing in the European Community with special emphasis on automotive parts remanufacturing. Specialist knowledge provides your advocates with solid background information and allows them to offer in-house guidance. For further information and to order these expertise documents, please contact APRA Office Europe. n

Products in question should be clearly identified as being remanufactured and the remanufacturer should also be stated. By doing so the company is taking responsibility for the product in the market.

See also the definition for remanufactured parts, supported by all major European automotive associations involved in remanufacturing business.

NEW APRA Europe MEMBERS since last issue of ReMaTecNews Vol. 4-2015:

• OWS Auto Spare Parts Trading LLC, United Arab Emirates • PSS Steering & Hydraulics Division, UK renewed

Kick off to implement G7 declaration

The German Federal Ministry for Economic Affairs and Energy assumes leadership for this task. The German Government will host a high-level event to mark the establishment of the G7 Alliance for Resource Efficiency in Berlin on 2nd October 2015. APRA, as worldwide voice for the remanufacturing industry will follow up and will keep you informed. n

INTERNATIONAL EVENTS & TRADE FAIRS

ReMaTecNews | 38

01/10 - 04/10/2015

20/10 - 24/10/2015

AUTOSHOW NITRA

BedrijfsautoRAI

International Exhibition for Passenger and Commercial Vehicles and Accessories NitrA | Slovakia

(TERTS - The European Road Transport Show) The European Road Transport Show Amsterdam | Netherlands

01/10 - 04/10/2015 COMMCAR

22/10 - 25/10/2015 Auto e moto d’epoca -

Commercial Vehicle Exhibition Chemnitz | Germany

Classic Car and Motorbike Exhibition Padua | Italy

02/10 - 04/10/2015

23/10 - 24/10/2015

AUTOCLASSICO

Tbilisi Auto Show/Caucasus AutoShow

International Classic and Vintage Automobile and Motorcycle Exhibition Porto | Portugal

International Specialized Fair of Automobiles, Auto Business, Spare Parts, Auto-cosmetics Tbilissi | Georgia

08/10 - 11/10/2015 MOTORWORLD Classics

24/10 - 26/10/2015

Oldtimermesse Berlin | Germany

PS Show und Autosalon Wels Wels | Austria

13/10 - 17/10/2015

27/10 - 29/10/2015

EQUIP AUTO

SAECCE / CAEMEX - SAE

Trade show of automobile equipment, garage equipment and after-sales networks Paris | France

China Congress & Exhibition / China Automotive Engineering and Manufacturing EXPO Shanghai | China (PR)

14/10 - 25/10/2015

27/10 - 30/10/2015

Johannesburg International Motor Show

AutoService.Mechanics.

Autocomponents

Johannesburg | South Africa

Classic Expo

International Automotive, Garage Equipment, Automotive Spare Parts and Accessories Exhibition Minsk | Belarus

International Classic Car Exhibition Salzburg | Austria

28/10 - 08/11/2015

16/10 - 18/10/2015

Tokyo Motor Show

16/10 - 21/10/2015

Tokyo | Japan

BUSWORLD Europe European Coach and Bus Exhibition Kortrijk | Belgium

19/10 - 21/10/2015 CIAPE China International Auto Parts Expo Shanghai | China (PR)

28/10 - 30/10/2015 AUTOCOMPLEX International Trade Fair for Filling Stations and Equipment, Car Equipment and Maintenance, Garage and Parking Moscow | Russia

28/10 - 30/10/2015 20/10 - 22/10/2015

AUTOMOTIVE & AUTOTECHNIKA -

Testing Expo

International Automotive Maintenance Industry Budapest | Hungary

Automotive Testing Expo North America Novi | USA

31/10 - 02/11/2015 20/10 - 22/10/2015

Big R/Rematecusa

eCarTec Munich 2015

North America’s most comprehensive remanufacturing trade show Las Vegas | USA

International Trade Fair for Electric & Hybrid Mobility/ Munich | Germany

Las Vegas NV, October 31 - November 2, 2015

The No. 1 reman show in North America you can’t afford to miss!

• Strong focus on automotive remanufacturing • Network and grow your business • Keep up-to-date with trends and developments • Educational ‘Better your Business’ seminar program • Enjoy exciting Las Vegas!

Register visit now!

Early Bird Rates endyour September 15! www.BigRReMaTecUSA.com Organized by:

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