Rematec News | June-July 2019 by RAI Amsterdam

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June/July 2019

REMANUFACTURING INTERNATIONAL NETWORK | KNOWLEDGE | BUSINESS

ReMaTec 2019:

THE FUTURE IS NOW

Also Volvo at ReMaTec - first time ever Mahle: 'Don't be afraid of new technology' How driverless cars will change reman

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EDITORIAL

‘The waiting is nearly over. It’s time for ReMaTec 2019: enough said’

t’s almost here. Every two years, the remanufacturing world comes together to celebrate its triumphs, make new connections (and, yes, of course, to gossip) – plus, most importantly, to do business. Reman professionals know that ReMaTec 2019 is the global forum for an industry which feels this year as though it is on the cusp of something special. For three days in Amsterdam, 23-25 June, you will be one of thousands of visitors, looking at hundreds of exhibitors which are showing off more than a million parts and components. People from all over the world are making the trip to the Netherlands. All of your customers – current and future – and most of your peers will be there. So it makes perfect sense for you to be there too.

This is the ideal place to discover the latest trends and business models, to share best practice and to look to the future: what will remanufacturing look like in the next decade? It’s also a special anniversary: the 10th edition of the show. Birthday surprises are in store. Possibly. The aisles, stands and booths, thronging with people, represent the beating heart of the show. But outside of that, for example at the ReMaTec Theatre, there is a packed programme as usual: keynote speeches, presentations, discussions, round tables, expert sessions. They cover every section of this richly diverse sector – something for everyone. The three winners of the Remanufacturer of the Year 2019 Awards will also be announced at the opening ceremony on day one. There is a lot to look forward to. While commercial competition is the lifeblood of the industry, never forget that we have much more in common than that which divides us. The industry is gaining traction with politicians and policy makers. Worldwide environmental concerns are catapulting the issue of sustainable manufacturing to the fore. Reman is getting its message out to the world. And there’s no better place than ReMaTec 2019 to be a part of it… Adam Hill, Editor ahill@ropl.com

Published by RAI Amsterdam B.V. P.O. Box 77777, 1070 MS Amsterdam The Netherlands In association with Route2Market Editor Adam Hill: ahill@ropl.com Phone: +44 (0)7931 502947 US correspondent Denise Rondini: drondini@gmail.com Asia-Pacific correspondent Tim Maughan: tim@britishjournalistinjapan.com Route One Publishing Managing Director Andrew Barriball: abarriball@ropl.com ReMaTecNews: advertising manager Sara Clark Phone: +44 (0)1732 445302 sara.clark@talkmediasales.co.uk Contributors in this issue Ron Giuntini, Daniel Koehler, Volker Schittenhelm, Mathy Stanislaus, Tanya Tsui Marketing Communications & PR Evelien Feijen: e.feijen@rai.nl Phone: +31 (0)20 54915 81 ReMaTec & ReMaTec Asia: sales manager Yorien de Ruijter Phone: +31 (0)20 5493075 Fax: +31 (0)20 5491889 advertising@ReMaTecnews.com Publisher Evelien Feijen: (responsible under Dutch Press Law) e.feijen@rai.nl Design, Production & Printing Route One Publishing Ltd 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, photocopied, or otherwise, without the prior written permission of the publisher, RAI Amsterdam B.V. Subscription magazine & eNewsletter www.rematec.com Change of address info@ReMaTecNews.com ReMaTecNews online www.rematec.com/news Circulation Approx. 12,000 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.

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CONTENTS

Mahle: ‘Don’t be afraid of the future’ Remanufacturers should not be nervous about the technological challenges ahead - just prepared

Volvo revs up No vehicle manufacturer has taken to the stage at ReMaTec - until now...

COVER STORY ReMaTec 2019: let’s get started The waiting is over - reman’s biggest trade show is here and it’s time to

Robots: they’re not coming for your job Instead, automation can actually help to increase remanufacturing volumes, a symposium hears

News ATP is bought after 50 years; STS extends Scania deal; reman laptops hit Denmark; plus wind turbines are up for discussion at ReMaTec 2019

Viewpoint ‘Remanufacturers may have a once-in-a-century chance to become a major force in driverless cars’

Unlocking the potential Five ways in which the circular economy could be made to work for the world

Making history

APRA Europe is bringing its most comprehensive-ever contribution to ReMaTec 2019

Diary You may have heard there’s something going on in Amsterdam in June - but here are a few other dates for remanufacturers to bear in mind

On the right path A new education scheme from TU Delft could encourage more companies to explore the benefits of reman

The wealth of experience

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Companies must ensure that employees transfer knowledge to one another - or risk losing valuable expertise

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NEWS

KARDES LAUNCHES MEGA STARTER SOLENOID SERIES

STS extends Scania cooperation Scandinavian Transmission Service (STS) has extended its deal to remanufacture planetary gears for Scania trucks to include rear axle gears. These reman parts are sold via Scania Service Exchange. The move is significant for STS, which has been mainly known for the industrial remanufacture of transmissions and transmission components for passenger cars – the Scania contract gives STS a foot in the door of the heavy commercial vehicle segment.

“This is opening up a market to us with huge growth potential,” says Ola Stålebo, CEO of STS. “Naturally, we are thrilled that Scania has chosen to extend our cooperation. Since we began remanufacturing planetary gears roughly a year ago, our relationship has become stronger, and we truly feel that Scania appreciates our work and the expertise of the STS employees in the Scania team.” In practical terms, power train components for heavy

vehicles are larger and heavier than those for cars, requiring special lifting systems and tools. To fulfil the contract, STS needed to make changes at its Stenungsund facility, investing in the construction of production lines for Scania’s components. Stålebo adds: “There is an opportunity to increase the investment and become a strong partner for other manufacturers of heavy commercial vehicles.” STS was founded in 1969.

Turkish reman industry supplier Kardes Elektrik has extended its lines of automotive carbon brushes and brush holders with the MEGA Starter Solenoid series. In 1974, it started production of brushes under the MEGA brand. The company, which began business in the 1960s importing starter generators and DC motor carbon brushes, says the new line will “decrease lead times of European customers”. Its goal is “to provide a highquality product, favoured by key remanufacturing facilities throughout Europe”. Products are shipped after testing by a D&V solenoid tester.

RS AUTOMOTIVE CORE Q&A Following the Q&A with RS Automotive Core (ReMaTecNews April/May 2019), Autoenterprises has asked ReMaTecNews to make clear that it has no association with RS Automotive Core or its products. ReMaTecNews is happy to make this clarification.

MEET US!

Stand no. 08.542 Hall 8 Explore our approach to manufacturing and remanufacturing of products

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NEWS

ATC Drivetrain acquires UK reman firm ATP Oklahoma City-based drivetrain component remanufacturer ATC Drivetrain has bought one of the UK’s best-known remanufacturing companies, ATP. No details of the transaction were disclosed. Alan Smart (pictured) founded ATP, headquartered in Cannock, half a century ago. “April 2019 marks ATP’s 50th year in business and I felt it was an appropriate time to secure the next phase of ATP’s continued growth,” Smart says. “I am confident that ATC is the right

permanent home for my life’s work and will continue to flourish under the leadership of ATC CEO Greg Heald and the rest of the ATC leadership team.” The acquisition sees ATP Automotive Transmission Remanufacturing Specialists, ATP Electronic Developments and ATP Holdings USA coming under ATC’s umbrella. Smart says the move will secure the future of ATP’s employees, “many of whom have over 30 years of service”. ATP specialises in remanufacturing automatic transmissions, including

Alan Smart (left) received the Queen’s Award for Enterprise in 2016 torque converters and automated manual transmissions, electronics and mechatronics, as well as manufacturing diagnostics systems. Heald says the companies “not only complement each other in the areas of technology, footprint and customer base, but also share common core values”. ATC remanufactures transmissions and engines

and related components for light-, medium- and heavy-duty vehicles. It was bought by private equity firm Crestview Partners in February 2018 and has since concentrated on “pursuing global expansion and technology diversification in support of ATC’s customers’ needs”. Heald praised Smart’s “decades of hard work” when announcing the sale.

The 1st International Forum on Wind Turbine Remanufacturing

25 June 2019 RAI Amsterdam, the Netherlands

Register your free visit now! 25 June 2019, ReMaTec welcomes wind energy professionals to attend the 1st International Forum on Wind Turbine Remanufacturing.

What to expect • Benefits and Terminology: What exactly is a remanufacturing process? • Installed Base Assessment: Which part of the current wind energy installed base qualifies for remanufacturing? • Business Opportunities: Which markets are adaptive to high quality pre-owned wind turbines? Find out more on our website: www.rematec.com/windpower. Register your free visit with the following code REM830010 online Organised by:

Co-located with: 23-25 June

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NEWS

Wind power reman conference at ReMaTec 2019 © Lovelyday12 | Dreamstime.com

The First International Forum on Wind Turbine Remanufacturing will be held at ReMaTec 2019. Taking place on Tuesday 25 June, the forum will present best practice from other sectors – including a presentation from APRA’s Joe Kripli on lessons from automotive reman - and offer thoughts on the benefits of reman. The oldest wind turbines have been in operation for more than 30 years as part

of a total installed global wind capacity of over 550,000 MW. “Remanufacturing offers new business opportunities, for

both new and replacement markets, in which Europe can lead the way,” the forum organiser says.

‘Carbon-neutral’ laptops for Denmark

Consolidation in the reman sector continues with diesel fuel injector and turbocharger maker Stanadyne buying US-based Pure Power Technologies, which remanufactures turbos in its facility in Blythewood, South Carolina. “Combining with Stanadyne affords Pure Power new opportunities for growth and the ability to continue to deliver the best quality and customer service,” says Pure Power CEO Jerry Sweetland (pictured). “Together we have an experienced, highly seasoned management and production team in place to drive the future growth of this new combined entity.” The companies say their “highly complementary product lines…will form a global company delivering broad fuel and air management systems directly to OEMs and OES/ aftermarket channels”.

UK-based computer remanufacturer Circular Computing has linked up with IT business Elitecom in Denmark to distribute remanufactured laptops. Jan Roedahl, CEO of Elitecom, says the collaboration will bring “sustainable, affordable and environmentally-friendly laptops to the Danish market”. In a statement, the firms say: “For the first time, IT procurement professionals, business managers and school headteachers in Denmark can now get great value for money enterprise-grade laptops, knowing that they are also the world’s most sustainable, ethically produced and eco-friendly computers available.” The move is part of Circular Computing’s plan to recruit a network of partners across Europe. The company says that 160 million new laptops are made every year, while 160,000 are disposed of every day in the European Union alone, “resulting in a million tonnes of e-waste”. It claims that over 70% of discarded laptops could be reused.

STANADYNE SNAPS UP PURE POWER

New hybrid platform ‘ideal for reman’ Researchers in Scotland have created a hybrid platform which combines additive manufacturing with machining. The University of Strathclyde’s Advanced Forming Research Centre (AFRC) has integrated laser metal deposition (LMD) technology within a CNC machine. In a statement, the AFRC says: “The LMD

hybrid platform is ideal for remanufacturing high-value components that would otherwise be scrapped due to failing in service, wearing over time or reaching the end of life”. It will be suitable for smaller companies, AFRC adds, providing “an affordable way” for them to embrace new technology.

The platform is designed to demonstrate that those with existing CNC technologies “can retrofit their machinery to accommodate additive manufacturing”, at a lower cost compared to buying it off the shelf. Integrated by Hybrid Manufacturing Technologies, the platform is being used in research projects including

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DigiTool, “which seeks to rejuvenate the UK tool and die sector through supporting the uptake of remanufacturing using digital technologies”. Stephen Fitzpatrick, machining and additive manufacturing team lead at the AFRC, called it “a significant addition to the overall offering of the centre”. ReMaTecNews

ROBOTICS

‘Automation does not mean job reduction’ A new symposium on the use of robots and automation in remanufacturing was a melting pot of bold ideas and lively argument on the future of the industry Pictures: Thomas Bartscherer/Jannick Scheer, Umwelt-Campus Birkenfeld

he future of remanufacturing was under discussion at a conference in Germany which the organisers hope will be the start of a new development in future remanufacturing. Organised by Wolfgang Gerke of Trier University and former APRA Europe chairman Fernand Weiland, the Symposium on Automated and Robotised Remanufacturing was endorsed by institutions such as ReMaTec, APRA and the European Remanufacturing Council. Current and former APRA board members Soren Toft-Jensen, Ian Buxcey and Rolf Steinhilper participated and contributed actively to the success of the meeting, said Weiland. At a panel discussion, together with Mike Hague-Morgan of Autocraft, they discussed what modern technology can bring to remanufacturing: larger volumes, higher quality and more efficient

production. Automation can best start at core collection, cleaning, painting and autonomous inspection, they suggested – and it does not mean job reduction but, on the contrary, elevated to bigger volumes, remanufacturing can continue to generate jobs. Steinhilper gave his expert thoughts on the automation of disassembly and cleaning, in particular the challenges and first solutions. Nigel Ramsden of Fanuc covered some of the issues around human-robot collaboration while Matthias Vette-Steinkamp of Zema Saarbrücken looked at possible applications of assistance systems for increasing flexibility in the assembly process. One of the biggest challenges – but one which carries the highest reward will be the future automation of those ‘not so clean’ and difficult jobs in disassembling. The universities present

Symposium co-organiser and former APRA Europe chairman Fernand Weiland

Reman legends Soren Toft-Jensen (left) and Rolf Steinhilper

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Automation could mean that reman volumes increase, generating more jobs at the meeting – including the host, Trier University of Applied Sciences, as well as Bayreuth University and the University of Birmingham - are all committed to work on this unique challenge. “The future of automation is a very attractive and exciting change in reman technology,” concluded Gerke. He insisted he is determined to continue to engage and encourage the reman industry to embrace it.

Mike Hague-Morgan, Autocraft

Nigel Ramsden of Fanuc

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NOTES & COMMENT

ReMaTecNews

VIEWPOINT

“Remanufacturers may experience a once-in-a-century opportunity to become a major force in the AV ecosystem” Ron Giuntini

he current worldwide annual production value of light vehicles (LVs) is estimated at more than $2 trillion, which is joining an installed base whose replacement value is thought to be more than $20 trillion. With an estimated $30 billion annual global spend on remanufactured parts, the reman industry remains a relatively ‘small’ player. The current business model of original equipment manufacturers (OEMs) has remained basically the same for over 100 years: build for efficiency and quality, sell to dealers and support the dealers. But with the introduction of autonomous vehicles (AVs), the OEMs will require a new business model. Why? Because AVs will most likely never be owned by the passenger, but by enterprises that will provide subscriptionbased, on-demand mobility services employing large fleets of AVs. If so, AVs will be employed eight to 12 hours per day to optimise return on investment, versus that of the current private-ownership legacy LV employment of one to two hours per day. As a result, either the subscription-based providers will be required to replace assets every one or two years - or a new AV design will be created with a longer

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economic and operational life. This is where remanufacturing comes into play. It is quite apparent that by remanufacturing an entire $150,000, designed-fordisassembly/modifiable AV (that would enter a reman process two or three times during its five-to-six-year life) the asset cost per passenger mile would be less than 50% of a subscription service business model employing a legacy LV. In lieu of manufacturing new AVs to meet demand, supply would be replaced by remanufactured AV asset exchange pools, with reman spend equivalent to 50-60% of the cost of building a new LV. Given my estimates, the reman

Ron Giuntini Founder of G35 Software

community would experience a five- to ten-fold increase in demand for their services. One canary-in-the-coal-mine that suggests others foresee the same future is the acquisition of reman enterprises by private equity firms. So, all enterprises and associations engaged in the LV remanufacturing community should carefully follow the AV sector, and especially how OEMs will be driven by the ultimate buyers of AVs - the subscriber service providers. The manufacturing world may be unrecognisable in the next 30 years and remanufacturers could experience a once-in-acentury opportunity to become a major force in the AV ecosystem.

ReVisits... Once more we travel blindly into the ReMaTecNews time tunnel – only to find ourselves in June, 14 years ago. Blink and look around and there is something familiar about the place. We were all younger then, perhaps slimmer and with more hair, but some things don’t change. It’s striking that APRA Europe and FIRM were active at ReMaTec 2005 – in much the same way as they will be at ReMaTec 2019, once more as valued partners.

There is a list of some of APRA’s highlights at this year’s show on p26. FIRM is also heavily involved as one of the prime movers in the first-ever European Engine Reman Championship, which is a brilliant innovation. Interesting that mechatronic reman was on the agenda back then, as well as evergreen subjects like cleaning. There was also a session on European regulation BER 1400/2002, which sounds dry until you see that it involved access to technical information by independent repairers. No doubt there was lots to discuss at the cocktail reception. Plus ça change and all that…

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REMATEC 2019: VOLVO

For the first time, a vehicle manufacturer is taking to the stage at ReMaTec

The first time Volvo has been involved in remanufacturing since World War Two – but it is now looking far into the future. And the Swedish group becomes the first automotive OEM to take the stage at ReMaTec

eMaTec 2019 is going to be memorable for a number of reasons – but a keynote speech in this edition of the show could mark a sea-change in the way that automotive original equipment manufacturers (OEMs) are viewed in the remanufacturing industry. A number of OEMs have for many years been a little coy about the extent to which their operations include reman. But the rising profile of environmental concerns, plus legislation which prioritises sustainable manufacturing – and a growing acceptance by customers that not everything has to be bought new – means that vehicle manufacturers in particular are seeing the commercial sense of offering reman options. In his ReMaTec 2019 keynote address, Dick Cruslock, Volvo Cars strategy and programme manager, global customer service, will present an outline of Volvo’s commitment to remanufacturing, explaining how reman fits with the company’s core values. He will include an overview of Volvo’s long reman history that stretches back to World War Two, when the company first began renovating gearboxes in the town of Köping in southern Sweden. Shortages of raw material made reman a sensible investment choice.

Carbon saving Cruslock will also offer some insight into current practices, highlighting the position of remanufacturing in the new era of sustainable mobility. Last year its remanufacturing programme saved approximately 420 tonnes of steel and 210 tonnes of aluminium, the company says. This corresponds to a carbon dioxide emission reduction of 4,700 tonnes a year, Volvo adds.

Volvo’s manufacturing operations are well-known, but it is also committed to reman

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Volvo’s appearance at the world’s premier reman trade show is a sign that big OEM names are now starting to push remanufacturing. Niels Klarenbeek, director, remanufacturing at ReMaTec organiser RAI Amsterdam, is delighted by what this marquee speech from a major auto maker represents for the remanufacturing industry. “We’re excited with the Volvo keynote address,” says Klarenbeek. “The 10th edition will be the first time a vehicle manufacturer literally takes the stage at ReMaTec. This not only underlines the importance of the ReMaTec platform, it also emphasises the commitment from vehicle manufacturers like Volvo Cars towards the circular economy. They take responsibility to resource efficiency and carbon emissions; remanufacturing is a crucial enabler of their sustainability objectives. Remanufacturing as a process has become mature and well-accepted.”

Design4reman Four years ago, in May 2015, Volvo Cars gave an exclusive interview to ReMaTecNews in which Cruslock and Gunnar Magnusson discussed Volvo’s 50 years of heritage in remanufacturing and spoke about the (then newly-introduced) Volvo XC 90 II SUV. This was the first model created in such a way that reman expertise was integrated into the product design. One of the crucial questions in the design phase was how to maximise opportunities for remanufacturing when it became time for overhaul (without compromising on safety and quality). Now, Volvo says, 95% of materials used in its car design can be recovered, either through re-use or recycling. Volvo Cars has comprehensive exchange systems through its network of authorised dealerships worldwide, offering a wide range of parts. Coming back to ReMaTec 2019, having such a major brand name taking the stage says a lot about where remanufacturing is headed as it gains greater acceptance, Klarenbeek concludes. “We are confident that this keynote will drive attendees from many OEMs’ aftermarket suppliers and other stakeholders in the supply chain.” Remanufacturing from an OEM perspective: the Volvo approach Monday 24 June 10.30, ReMaTec Theatre ReMaTecNews

REMATEC 2019: MAHLE

Huge changes in the way we move around – and in how vehicles are powered – are coming: but Christoph Dutschke of Mahle Aftermarket insists this is exciting, not frightening, for workshops

‘DON’T BE AFRAID OF THE FUTURE’ Dutschke: don’t be nervous – be prepared instead

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REMATEC 2019: MAHLE

hristoph Dutschke is excited. The future is challenging and unpredictable but he isn’t bothered by that. As technical service Europe coordinator of training for Mahle Aftermarket, he sees only opportunities. But the trick to grasping them, he insists, is to be ready for what’s coming – even if you don’t quite know exactly what it is. “You need to be prepared, educated and you need to have the tooling for these different technologies,” he says. “From the workshops of today, only those will survive who are wearing running shoes: investing in new technology, new toolings, to be prepared for all repair jobs that will come.” Dutschke has been with German group Mahle for 30 years. It specialises in engine systems and components, filtration and thermal management, covering off all aspects of powertrain and air conditioning technology. He started work with Mahle as a student and returned in 1992 after a degree in mechanical engineering at university to jump straight into sorting out warranty claims and developing technical training for customers. He is in good company: Mahle has nearly 80,000 employees worldwide – and 6,500 of them are mechanical engineers (“every 11th person,” he laughs).

Every second vehicle This makes sense: many automotive original equipment manufacturers (OEMs) are not really ‘making’ cars anymore – at least not in the way that most people would understand the term. “No-one is taking the scissors and cutting out cylinder head gaskets,” he goes on. Instead, OEMs are increasingly turning to suppliers such as Mahle. The company positions itself as a specialist in drivetrain systems, “internal combustion engine (ICE) and everything around it”. OEMs might plan a launch in five years’ time and want elements such as filters, pistons and bearings for their new product; they would visit a company such as Mahle to explain what they want. “We’re not buying parts from China,” points out Dutschke. “We are a developer and manufacturer of these parts.” The company says its products are “fitted in at least every second vehicle worldwide”. But into what sort of vehicles will these parts be put in future? And therefore what skills will the industry need? His keynote address to ReMaTec 2019’s audience will look at a broader issue and examine how things are changing for automotive: the 2016 Paris Agreement was signed by nearly 200 countries and pledged to keep global warming to under 2 degrees Celsius. “Relating to the global goal of climate change, the near future will be very exciting,” Dutschke says. “Everybody is working very hard to follow these targets and reduce CO2 emissions.” The ICE is under threat, and alternative power sources, such as electric vehicles (EVs) and hybrids are gaining in popularity. So what will be the drivetrain of the future? “There are more and more alternative vehicles on the market, but the biggest share is vehicles with ICEs,” he continues. “Slowly, slowly, EVs et cetera are coming on to the road. But how will it be in 2030?” Put simply, figures ➤ ReMaTecNews

REMATEC 2019: MAHLE

➤

suggest that penetration of alternative vehicles will be a maximum of 30% in the next decade. “So more than 70-80% will still be cars with ICE. My clear message to workshops is that ICEs will be on the road for many, many years,” Dutschke says firmly. “They need to be serviced and maintained for the next 1015 years. On the other hand, more and more EVs are coming onto the road. So mechanics need to be educated for EVs as they are coming, piece by piece.”

Reducing emissions Mahle knows all about the importance of adaptability. “Five to 10 years ago, Mahle was a specialist for ICEs,” Dutschke recalls. Then, in 2008, the company developed a new engine, just to get a feel for what was possible. It came up with a three-cylinder, 1.2-litre engine which had the same power as a six-cylinder, 2.4-litre engine. “The target was to reduce fuel consumption by 25%,” he explains. Other manufacturers, including Ford and Mercedes-Benz, have followed suit. “You get nice power and excellent fuel consumption, with low CO2 emissions.” Given the drive systems available already, it is by no means clear what the future will hold. That is why Mahle has put in place what it calls the ‘dual strategy’. “If you ask three really good specialists what will be the future drive systems, you will get five different answers,” Dutschke says. He says he prefers to discuss all the options: ICE, hybrid, EVs, battery electric vehicles (BEVs) and so on. “Electric cars – which I personally like very much – the number of gas stations is a problem. In Germany in 2017-18 we doubled the number from 20 to 40 –

it’s nothing! It’s not enough: we will kill these cars. But it’s a really nice concept.” In 2017, Mahle introduced MEET, a 48-volt concept vehicle, combining two electric motors, the transmission and a 48-volt electronics system, which the company said could do seven days’ worth of inner city trips on a single charge. Thermo-management of hybrids and BEVs is a sophisticated job. “The electric motor is much more sensitive than the ICE when it comes to overheating,” suggests Dutschke. “Thermomanagement is going to be much, much more important. The mechanic has to be trained.” Looking ahead, he is enthusiastic about the changes that are surely coming to the aftermarket. “We don’t want mechanics to be afraid of the future,” Dutschke concludes. “Should I have to close because of EVs? All mechanics worldwide are nervous about what will happen in the future. I want to cool them: be prepared – embrace new technology.”

“From the workshops of today, only those will survive who are wearing running shoes: investing in new technology”

BELOW: Batteries are going to be an increasing part of garage work BELOW RIGHT: Mahle introduced the MEET 48-volt concept vehicle in 2017

Mahle’s view: drive systems Internal combustion engine With the help of improvements to components it is possible to reduce emissions. Fewer emissions are generated in the internal combustion engine (ICE) as less emission has to be cleaned in exhaust aftertreatment. Temperature management is key for the best performance of drive systems. Using compressed natural gas (CNG) as fuel for the ICE also presents big opportunities. Hybrid With the help of an intelligent combination of combustion engine and electric motor - using the respective optimal speed- and load range of both drive systems - there is big potential for reducing emissions. Battery electric There is big potential for battery electric vehicles (BEV). But there are still open issues, including production of CO2-neutral infrastructure electricity, infrastructure chargers, charging time, capacity and price of batteries, production and recycling batteries. Fuel cell Fuel cell vehicles are a variation of BEV. This type of EV uses compressed hydrogen and a fuel cell to produce electricity. Challenges are CO2-neutral production and the infrastructure of hydrogen gas stations.

MAHLE FACTFILE Founded in

1920 €12.8 billion sales in 2018 78,000 employees 170 production locations 16 R&D centres 16

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RESEARCH

Finding the right path Getting companies involved in reman is vital for the future of the industry. Tanya Tsui, researcher in climate design & sustainability at TU Delft, explains how the new Remanpath project will help

emanpath aims to give courses that introduce and promote remanufacturing to companies. Currently, European remanufacturing activity is only around 2% of equivalent manufacturing activity - even though this number could be significantly increased in the future. To make that increase possible, the competence of companies needs to be developed, particularly with small‐ to medium‐sized manufacturing firms. The Remanpath project therefore aims to develop, pilot and hold educational courses for employees of those sorts of companies. The aim of the course is for people to identify their firm’s own competence development paths, and devise innovative business models, in order to start remanufacturing products into something new and valuable. The Remanpath course is a half-day event which includes lectures, company case presentations and exercises, allowing participants to work together and share ideas. The target participants are manufacturing firms who do not yet remanufacture their products, industrial sector bodies and Tanya Tsui: The idea of reman isn’t spreading to other industries

Remanpath participants at TU Delft discuss the way forward

consultants. The learning material is built not only to be used individually but also as the basis for collaborative activities, and allows participants to imagine solutions their company could use to apply remanufacturing to their business. Pilot courses have been held in five countries: Finland, Germany, UK, Netherlands and France. The courses were well received, and participants came from a diverse set of industries – from automotive to construction and product design. Currently, the learning materials are being refined in the light of comments from the participants and key findings at the pilot courses. More courses will be held later in 2019 using the improved learning material.

skills to solve the technical problems of remanufacturing, they lacked the business and management skills needed to start remanufacturing activity in their own company. During a pilot course, a manufacturing SME (small and medium-sized enterprise) found out that remanufacturing is technically possible for their company, but is much more challenging in terms of business and management. Although the employees of this company have the skill to remanufacture cores to an as-new quality, they do not have knowledge or skills in reverse logistics and information management – two important skills for remanufacturing.

What we learned

Participants in the pilot courses also found that the design of their product was a barrier to remanufacturing. Components of products are often bound together by adhesives, which makes them difficult to disassemble. The different versions of products often use different dimensions, making them difficult to upgrade and modify during the remanufacturing process. Incorporating the objectives of remanufacturing directly in the design process would greatly increase the ease of remanufacturing products at their end of life. It was also surprising to find that remanufacturing is a mostly unknown ➤

The most important insight that was gained from the Remanpath workshop is that most participants were interested in knowledge related to business and management for remanufacturing. From our questionnaires, we found that the majority of participants were interested in learning more about the business of remanufacturing - such as business models, marketing, pricing, managing competition - and the logistics and management of remanufacturing, such as reverse logistics and information management. During the pilot courses, participants commented that, while they could have

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RESEARCH

More workshops: autumn 2019 and beyond The Remanpath project will be organising more workshops at the end of the year in Finland, Netherlands, France, Germany and the UK. • For more information, please visit the website https://eitrawmaterials. eu/course/Remanpath/or email Remanpath project manager Heikkilä Jouko at: Jouko.Heikkila@vtt.fi

Design ‘boot camp’

Remanpath: getting together

In response to the design issues identified in previous remanufacturing research projects, the European Institute of Innovation and Technology has funded the CARED project (Catalyse Remanufacturing Through Design Boot Camp), which will hold courses on design for remanufacturing in late 2019 or early 2020. • For more information, please email Heikkilä Jouko at: Jouko.Heikkila@vtt.fi

Remanpath is funded by the European Institute of Innovation and Technology Raw Materials. The project partners are: Technical Research Centre of Finland (lead partner), Coventry University (UK), Grenoble Institute of Technology (France), Oakdene Hollins (UK), Delft University of Technology (Netherlands) and Wuppertal Institute (Germany). The European Remanufacturing Council is also committed to support this initiative.

The workshop experience Dr Helen Roby, assistant professor, FBL, Centre for Business in Society, Coventry University

Companies wanted to know about the logistics and management of remanufacturing

➤

subject in many industries, despite its economic and environmental benefits. In the Delft pilot course in the Netherlands, participants were mainly from the façade manufacturing industry. Most participants in the course were unaware of the term ‘remanufacturing’ before they joined the course, even though they were interested in how their companies could position themselves within the circular economy. Even though façade products are very suitable for remanufacturing (long lifetimes, high value, produced in high quantities), the participants in the pilot course were unaware of the option of remanufacturing their own products. It seems that the idea of remanufacturing is stuck in the automotive and aerospace industries, and isn’t spreading to other industries as well. Finally, what has pleasantly surprised and impressed us as a team of academic researchers in the Remanpath project is the enthusiasm of our corporate

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“We had very good feedback from the workshop, with most of the participants saying how much they enjoyed the morning. The workshop included a good mix of participants including managing directors, business development managers, industrial designers and sales managers. There was plenty of interaction from the participants, asking lots of questions and sharing their experiences of remanufacturing. All but one participant was from the automotive industry, but this was not surprising based on the case studies and choice of location. It was clear from the feedback received that the case studies and networking opportunities were the most interesting aspects for participants. Many of these companies work in isolation - and knowing others were experiencing the same issues as them and being able to discuss these was an important aspect of the morning. At the end, participants specifically asked if they could have each other’s contact details so that they were able to stay in

participants. They were open, enthusiastic and eager to share their ideas. They appreciated working with academics, and creating more opportunities for exchange. As researchers working in an academic

touch. Recruitment was a challenge for this workshop. The response was slow and mailings and personal approaches had to be sent out several times to get a reasonable number of participants. However, it was felt by the participants that a smaller group with an informal approach to the workshop was beneficial, facilitating a greater opportunity for discussion and networking. Although the content of the workshop was important in attracting participants, the location was also a critical factor. RDM Automotive is a leading manufacturer in autonomous vehicles. The opportunity to gain insights into their work and to see the vehicles in operation were definitely a draw to the workshop. Having an interesting location or including the workshop in other activities is a good way to encourage attendance. The case studies from SMEs already established in remanufacturing generated greatest interest from the participants. They gave the opportunity to understand the process of remanufacturing and to learn from others’ experiences. One participant commented that he had not realised he was actually already remanufacturing until listening to the presentations.”

environment, it is inspiring to see that companies are interested and willing to collaborate with academia on topics of sustainability, circular economy and remanufacturing.

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CIRCULAR ECONOMY

Unlocking the potential Sustainability is on the political and business agenda: Mathy Stanislaus highlights five ways in which the value of the circular economy – of which reman is a key part – can be unlocked

overnments and businesses are sitting on a massive opportunity to lessen their climate impact and drive up revenue and consumer satisfaction by moving toward a circular economy. A circular economy is one that can: • Be regenerative by design, retaining as much value as possible from products, parts and materials • Mitigate the climate impact of continually manufacturing new products • Recoup the $4.5 trillion wasted in the current ‘take-make-waste’ consumer model The concept of a circular economy has begun to go global. Over the last year, it has featured prominently at many major conferences, demonstrating its growing currency. Yet the gears of the global economy - from finance and business models to consumer behaviour and law - still embed waste as a necessary if unfortunate by-product of a successful economy. Here are five ways governments, working with the private sector, can begin shifting their economies toward this more sustainable model.

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1. Shift from a waste hierarchy to a circularity hierarchy

the utilisation of materials as a resource, such as by extending the life of products and recovering valuable materials Beginning in the 1970s, governments - in for new products. For example, the their role as stewards of public health current system of electronics recycling and environmental protection - adopted inadequately recovers metals for reuse. the concept of a waste hierarchy to Governments need to replace their set preferences for managing waste. waste hierarchies with a circularity This hierarchy, centred on public hierarchy, which would maximise the health and environmental protection, utilisation of materials by extending the resulted in policies life of products and infrastructure and extracting focused on diverting optimal value once waste from landfills they’re discarded and creating value REMANUFACTU RING INTERN ATIONAL NET WORK | KNOW LEDGE | BUSIN to turn them into through recycling ESS new products. and energy capture. Under this new For example, wasteparadigm, all to-energy facilities policies, including create value from taxes, would materials that be required to would otherwise HOW REMA be landfilled. CAN (HELP) S N A But the waste THE PLANETVE hierarchy UN research hi sector’s susta ghlights optimises a bad The recent report inable role situation without from the United addressing root Nations International Also issues; it focuses Resources Panel Continental: ‘We have to explain ED reman ever y day’ MERA and RIC-RIT ON IS conference repo M OT G rts Netflix and Spotify on managing highlighted the IU ROB RIN 9 are changing rem S O & TU 1 anufacturing MP D AC , 20 SY ATE NUF -21 SIDE waste rather importance of reman M A 20 S IN O T M h IL AU RE MarcDETA than maximizing for sustainability www.ReMa

Tec.com

December 2018

/ January 2019

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demonstrate, through a lifecycle-based analysis, achievement of the highest possible level of circularity. Implementing this hierarchy requires governments to enable industry innovation without being overly prescriptive (which would hinder innovation) or lowering public health standards.

2. Update national climate plans to incorporate the circular economy The flow of materials from mining to manufacturing to use is responsible for 50% of greenhouse gas emissions. National climate plans under the Paris Agreement - known as Nationally Determined Contributions (NDCs) should be updated to incorporate three key levers of the circular economy: value-retention processes, secondary materials and the supply chain. Value-retention processes extend products’ lives through reuse, repair, refurbishment or remanufacturing. A recent report from the UN International Resources Panel (IRP) looked at three industrial sectors in the United States,

For the circular economy to work, governments must switch from a ‘waste hierarchy’ China, Brazil and Germany. It found that extending the life of products through value-retention processes could reduce raw materials by as much as 80-99% and decrease greenhouse gas (GHG) emissions in some sectors by 79-99% (see ‘How reman can [help] save the planet’, ReMaTecNews December 2018/

January 2019). But a circular economy doesn’t stop there. Once a product’s life is maximised through value-retention processes, recovering and reusing its materials in a new product can also have significant climate benefits. A recent study concluded that reusing aluminium, steel and plastics in Nordic economies could reduce emissions by 96%, 86% and 37%, respectively, compared to emissions when products use raw materials. Finally, the supply chain offers an overlooked opportunity to link these circular economy levers. A recent study concluded that emissions in a company’s supply chain are around four times as high as those from direct operations but only about a quarter of companies engage their supply chains to reduce emissions. If governments send a signal through their NDCs to business and align them with policy enablers to focus on these three levers - value-retention processes and secondary materials linked in the supply chain - they can drive circularity and reduce emissions. ➤

ReMaTec Asia 2019 24 - 26 September 2019 Guangzhou, China

Join us in Guangzhou for the first edition of ReMaTec Asia: Reasons to participate: • There are an estimated 93.2 million passenger vehicles in China that are out of warranty. • Remanufactured parts are a reliable middle way between expensive original parts on one side and cheap inferior imitation on the other side. • ReMaTec Asia is located in the heart of the automotive industry: Guangzhou. • Benefit from value added services such as pre-arranged matchmaking appointments, an industry dinner, translation services and excursions to local remanufacturing companies. Find out more on our website: www.rematec.com/asia

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CIRCULAR ECONOMY

The Basel Convention is an international treaty designed to reduce the movement of hazardous waste between nations, particularly from developed to less developed countries, due to concerns regarding the public health consequences of dumping. Countries’ adoption of laws implementing the Basel Convention serves as a critical check against problematic cross-border flows of waste. However, the convention can impede remanufacturing of post-use products and recovering secondary materials from manufacturing and used products. So, while electric vehicle lithium batteries can be repurposed, some countries treat them as hazardous waste, which has the effect of hindering circularity. In this author’s opinion, comprehensive reform of the convention to incorporate circular principles is unlikely in the foreseeable future. But countries can accelerate circularity by streamlining implementing requirements with rigorous transparency to encourage remanufacturing and secondary materials use. France, the Netherlands, the UK and Flanders have established a cross-border framework to harmonise administrative requirements to recover materials from used electronics for use in new products while adhering to existing legal requirements and public oversight. Similarly, as recommended by the IRP, governments can also reclassify certain eligible products for remanufacturing as ‘non-waste’ while remaining vigilant against dumping. Some countries treat electric vehicle lithium batteries as hazardous waste

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4. Reform recycling regulations to promote closed-loop manufacturing Re-examining existing national regulations for opportunities to promote closed-loop manufacturing and remanufacturing can result in environmental and economic benefits. Governments should amend recycling regulations to incentivise comprehensive use of materials, helping manufacturers recognise how to minimise loss of materials and maximise value. The US EPA enacted one such rule that removes from the ‘waste’ category manufacturing residuals returned in a closed loop to production. The EPA also strengthened requirements on recyclers to safely manage against risk of fires, explosions, accidents and release of hazardous materials. The changes are projected to save $59 million in materials and reduce emissions by 344 kilotonnes of carbon dioxide equivalent per year.

5. Incentivise design for circularity

“The Basel Convention can impede remanufacturing of post-use products and recovering secondary materials from manufacturing and used products”

Our current take-make-waste economy doesn’t reward making products that last, or that are easily reused, repurposed, repaired or recycled. Governments should nudge companies to design products that retain their value or that enable recovery of materials as secondary feedstock. This can be done through tax policies that favour remanufactured goods. Currently, such products are largely taxed as new, which effectively penalises them since they were previously taxed during the original manufacturing. China, for example, has reduced taxes on products that include ‘waste resources’, such as industrial metal waste.

➤ 3. Reform cross-border regulations

Design for circularity needs to be built in to the economy

Governments can also set goals for minimum recycled content. China’s Producer Responsibility Extension System Implementation Program targets 20% recycled content in new products in electronics, batteries and automobiles by 2025. Similarly, the European Commission is currently evaluating ecodesign rules to foster circularity.

The promise of the circular economy When carefully measured, designed, and integrated, the circular economy holds promise for the environment, consumers, businesses and governments, as it can: • Reduce unnecessary waste • Derive even more value from products • Reduce damaging emissions Currently the circular economy is generating considerable interest in many sectors. These are five concrete, nearterm actions that governments and the private sector can take to realise reduced material intensity and improved GHG outcomes. This article originally appeared on WRI’s Insights blog: www.wri.org/blog/2019/04/5-waysunlock-value-circular-economy

ABOUT THE AUTHOR Mathy Stanislaus is a circular economy fellow at World Resources Institute. Prior to this he served in the Obama Administration as assistant administrator for US Environmental Protection Agency’s Office of Land and Emergency Management

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REMATEC 2019 SCHEDULE

The ReMaTec Theatre will be the scene of many insightful presentations

Full participation APRA Europe is playing a significant role in ReMaTec 2019 in Amsterdam, with speakers from the association taking part in sessions across the three days in a variety of different subject areas

Daniel Koehler: automotive trends

Peter Bartel: expert session

Sunday, 23 June 2019

Monday, 24 June 2019

Tuesday, 25 June 2019

11:30 – 12:00 Trends in automotive remanufacturing: how APRA members tackle challenges and opportunities Place: ReMaTec Theatre Dr. Daniel C. F. Koehler Chairman APRA Europe

11:30 – 12:00 Remanufactured parts: business opportunity for warehouse distributors and wholesalers Place: ReMaTec Theatre Dr. Daniel C. F. Koehler Chairman APRA Europe

14:00 – 14:30 Next generation of core management: from reverse logistics to business intelligence Place: ReMaTec Theatre Peter Bartel Vice chairman APRA Europe

16:30 – 18:30 APRA Europe General Assembly Place: Room F001 (members only)

11:20 – 11:50 Automotive remanufacturing: history, best practices, business models, opportunities What could the wind energy industry learn from the automotive sector? Place: At co-located First International Forum on Wind Turbine Remanufacturing Joe Kripli President APRA

17:00 – 19:00 Reman industry reception Place: Park Foyer Co-hosted by APRA Europe

The reman industry reception is a great networking opportunity

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11:30 – 12:00 Remanufacturing and reuse options for composites: status of the FiberEUse project Place: ReMaTec Theatre Professor Marcello Colledani Department of Mechanical Engineering Polytechnic University of Milan 13:15 – 14:00 Optimised reverse logistics Place: Expert Table Peter Bartel Vice chairman APRA Europe

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Making history APRA Europe is ready for ReMaTec 2019 in Amsterdam – and is bringing its most comprehensive-ever contribution to the show, says association chairman Dr Daniel C F Koehler Following the renewed strategy of APRA Europe, our association has come up with the most comprehensive ReMaTec contribution in history. It is not by chance that this coincides with APRA Europe’s 30-year celebrations (reported in ‘The story so far’, ReMaTecNews April/ May). Not that APRA Europe has not been active in the past - but this time we are even more focused on bringing value to both our members and the remanufacturing industry. It is our goal to raise more awareness of the positive contributions made by our association to the business environment of remanufacturing in general - as well as the manifold benefits of being a member.

Expert speeches Therefore, we have prepared six experts’ speeches ranging from business opportunities to latest reverse logistics trends. Four different speakers, all renowned experts in the remanufacturing field and dedicated to APRA, are presenting their views on the industry and bring interesting insights on technology and market developments (see p16).

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Industry reception Being one of the founding members of ReMaTec (celebrating its 10th edition in 2019) and having the anniversaries in common, we joined forces for a co-hosted industry reception between ReMaTec and APRA Europe. This is going to be an unprecedented event and exceptional networking opportunity with all leading experts of the industry. Take the opportunity to make new contacts and grow your business!

General Assembly Due to our newly-constituted Brusselsbased association APRA Europe AISBL, we are going to hold the first General Assembly of our members during ReMaTec. This is the optimal time and place which facilitates participation of our members so that you have a chance to actively contribute to the future and success of the association. One of the highlights will be the election of two new board members (members receive a list of candidates up front) where as many votes as possible are desired. All members have already received their invitations. We kindly invite you again to take this opportunity and be

present at the General Assembly. For more information and registration, email: europe@apra.org

New booth location and stand concept For the first time, APRA Europe is going to have its booth (P.03) in the Foyer, right in front of the entrance to the RAI Amsterdam exhibition hall. This brings us much more presence and the opportunity to interact more intensively with our members and industry experts. The highlight of our stand will be a column on which you may write your thoughts on the question: Why remanufacturing is important to me. This, in fact, is not just a nice feature. We want to use your comments as a basis for further improvements in our positioning and services. You are invited to be very (inter-) active at our booth!

APRA European Symposium 2020 In addition to our ReMaTec activities, we have already initiated plans for the next edition of our APRA European Symposium. After a very successful event in Budapest last year, with many top-class speakers and an exciting plant visit to Remy, we are eager to exceed the previous edition. In 2020 we are going to hold the symposium in Prague, Czech Republic, from 24-27 March. Please save the date now in your calendar for this unique networking event. Highlights will be the plant visits to Knorr-Bremse in Liberec and ZF in Frýdlant. Talks with proven experts have already started so that we are very confident to present you with another high-quality agenda of speeches.

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STP-Parts GmbH

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

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

CONSORZIO ARMEC Via Ruvo, Km. 1 9, 70033, Corato, Italy P +39 (0) 80 872 44 17 E support@turbo.it W www.turbo.it

Diagnostic Equipment

Turbo Parts

CONSORZIO ARMEC Via Ruvo, Km. 1 9, 70033, Corato, Italy P +39 (0) 80 872 44 17 E support@turbo.it W www.turbo.it

Cores

MSG Equipment 18 Biolohichna str, Kharkiv, Ukraine

CONSORZIO ARMEC

P +38 05 7728 0171 E info@msgsteering.com W www.servicems.eu

Via Ruvo, Km. 1 9, 70033, Corato, Italy P +39 (0) 80 872 44 17 E support@turbo.it W www.turbo.it

Transmission Parts

RS Automotive Core Unit 3, Brunel Road, Manor Trading Estate, Benfleet, Essex SS7 4PS P +44 (0) 1277 822806 E enquiries@rsautocore.co.uk W www.rsautomotivecore.co.uk

EXEDY Clutch Europe Limited Unit 2, Rokeby Court, Manor Park, Runcorn, Cheshire, UK, WA7 1RW P +44 (0) 1928 571850 E enquiries@exedy.co.uk W www.exedy.co.uk

YOUR COMPANY DETAILS HERE For more information please contact the ReMaTecNews Sales team. Sara Clark Advertising Manager P +44 (0)1732 445302 E sara.clark@talkmediasales.co.uk

513-771-8000

WE KEEP YOU RUNNING

email: info@jnelectric.com

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ReMaTecNews

DIARY

June 2019 03.Jun - 05.Jun

WORLD CIRCULAR ECONOMY FORUM Helsinki, Finland 04.Jun - 06.Jun

AUTOMECHANIKA BIRMINGHAM Birmingham, UK 18.Jun - 20.Jun

CIRCULARITY19 Minneapolis, USA New circular economy event, supported by the Ellen MacArthur Foundation. 22.Jun

CHOICE TECH SEMINAR Amsterdam, Netherlands

23.Jun - 25.Jun

ICoR 2019

Amsterdam, Netherlands Co-located with, and supported by, ReMaTec, the University of Strathclyde and Linköping University host the fourth International Conference on Remanufacturing.

Amsterdam, Netherlands The largest remanufacturing event in the world, bringing the whole supply chain of reman together. New features in this edition include wind turbine reman.

24.Sep - 26.Sep

REMATEC ASIA Guangzhou, China First edition of ReMaTec Asia, co-located with AAG Auto Aftermarket, bridging east and west in remanufacturing.

10.Nov - 16.Nov

AGRITECHNICA Hanover, Germany

December 2019 03.Dec – 06.Dec

AUTOMECHANIKA SHANGHAI Shanghai, China

24.Jun

APRA EUROPE Amsterdam, Netherlands General assembly 24.Jun

EUROPEAN REMANUFACTURING COUNCIL

24.Sep - 26.Sep

AAG AUTO AFTERMARKET Guangzhou, China Includes the Remanufacturing Forum, organised by China Parts Remanufacturing Association (CPRA).

Amsterdam, Netherlands Annual meeting

October 2019

July 2019

MERA SUSTAINABLE MANUFACTURING CONFERENCE

23.Jun - 25.Jun

REMATEC 2019

September 2019

17.July - 19.July

LATIN AUTO PARTS EXPO

Panama City, Panama

July/August 2019 30.July - 2.Aug

ADS INTERNATIONAL CONVENTION & TRADE SHOW Orlando, USA

01.Oct

Metro Detroit, USA

March 2020 24.Mar – 27.Mar

APRA EUROPEAN SYMPOSIUM Prague, Czech Republic

Meet the team! Contact us to make an appointment. rematec@rai.nl June 2019

15.Oct - 19.Oct

EQUIP AUTO Paris, France

November 2019

23.Jun - 25.Jun

REMATEC 2019 Amsterdam, Netherlands

September 2019

05.Nov – 07.Nov

AAPEX 2019 Las Vegas, USA

24.Sep - 26.Sep

REMATEC ASIA Guangzhou, China Yorien de Ruijter sales manager ReMaTec & ReMaTec Asia

To advertise in Contact Sara Clark sara.clark @talkmediasales.co.uk Tel. +44 (0)1732 445302 Sara Clark advertising manager ReMaTecNews

www.ReMaTec.com

Send your remanufacturing diary events to editorial@rematec.com

The wealth of experience Your employees have a treasure trove of knowledge so make sure they pass it on, insists Volker Schittenhelm – it is the only way to maintain skills in the reman industry going forward Some weeks ago, I was asked for technical information and spare part sources for a very old honing machine. The former machine operator, who had been with the company for many years, died before training other colleagues on that special machine and sharing his knowledge with them. Now, honing skills are not available anymore at that garage - even though honing is one of the key competences for an engine reman garage. In addition - and making the problem even worse - the machine is so old that it is impossible to find technical information, or even someone who knows the machine manufacturer. I don’t know what the garage’s solution will be: to invest in a new machine is only one part of the solution. Our industry field needs very special equipment and very skilled people. These machines do not – in contrast to transfer lines in big industrial engine reman facilities – do their job after pushing the start button and achieve a honing quality and honing angle automatically! Not at all! The machine operator in a representative small- or medium-sized

engine reman garage has a lot of years of practical knowledge and a honing background which encompasses the machine itself plus the honing tools. Because he has this knowledge and experience, he is able to achieve a final honing result of the cylinder surface to a quality which is similar to a new cylinder surface, with no difference in surface roughness and all the other relevant parameters affecting engine performance, emissions, fuel and oil consumption and reliability. And this is independent from the block/cylinder material, size and geometry. What a skill…which is gone now forever. And this real-life example goes for every technical process within an engine reman garage: from cylinder honing to grinding of crankshafts, from cylinder head surfacing to valve seat grinding, and all the other processes in between. Have you ever imagined the huge knowledge pool that you have in your garage, in your company? Have you

documented all that? Do you have access to machine-related data like specifications, drawings and electrical wiring diagrams as well as spare part sources and technical service contacts? Do you organise internal training sessions where skilled machine operators and skilled employees transfer their long-standing knowledge, acquired over years, to their colleagues? Never say: “It’s going just fine as it is,” but always ask: “What if a colleague leaves, retires or (see above) dies. Am I prepared?” Well, are you prepared? Having everything documented and under control in your database has another advantage which is not to be underestimated: you cannot be put under pressure by an employee because they are the only skilled operator for that special machine or process, who wants more money or is threatening to leave. Transferring skills is about tradition the handover and delivery of expertise means you will continue to be a market player in the future. Remember: tradition is keeping the fire burning, not praising the ashes.

“Tradition is keeping the fire burning, not praising the ashes”

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