ReMaTecNews | rem05-2012

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ReMaTecNews REMANUFACTURING INTERNATIONAL

• Impressive line-up at Reman Summit

• CLEPA – a new force in reman

• Remanufacturers at Automechanika

Germany’s RG a true family firm • APRA News • FIRM News • International events www.rematecnews.com

2012 - NO 5 - VOLUME 12

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CONTENTS

NO 5 • AUGUST 2012 • VOLUME 12

Major German CLEPA commits Reman at core dealers 10 to reman 14 Automechanika 24 Some twenty years ago, RG in Northern Bavaria, Germany, started out as a small, local remanufacturer of starters and alternators.

The business concept did not last long.

Instead RG chose another path. Today, the company is Germany’s largest independent core dealer. ReMaTecNews paid a visit.

CLEPA, the influential European Association of Automotive Suppliers is backing automotive remanufacturing in a big way. Josef Frank, an important part of the drive, explains the reasons.

This year’s Automechanika, the world’s largest aftermarket event, is once again set to be a meeting place for automotive and heavy duty remanufacturers. We provide a preview of what to expect.

‘Consolidation in the reman industry will offer opportunities for large remanufacturers who wish to extend their product portfolio by acquiring specialised firms’ Fernand Weiland, Vice Chairman of APRA Europe

4 Editorial 5 Melett expands in the US 18 World Remanufacturing Summit 19 ReMaTecNews’ award ceremony 20 Cleaning for remanufacturers 26 Transmissions World

30 Electronics & Mechatronics 33 News from other organisations 34 APRA News 36 FIRM News 38 International events and trade fairs www.rematecnews.com

Eight issues in 2012: February, March, May/June, June/July, August, Sept/Oct, Oct/Nov, December Special pages on Transmissions and Electronics & Mechatronics in edition 1, 3, 5, 7 Special pages on Heavy Duty/Trucks in edition 2, 4, 6, 8

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EDITOR’S LETTER

ReMaTecNews Volume 12 – Number 5 – August 2012 ReMaTecNews, the only international news magazine and website dedicated to automotive and heavy duty remanufacturing worldwide, is an independent channel for news, views and developments within the remanufacturing industry.

Welcome back

Published by: RAI Langfords B.V. P.O. Box 10099 1001 EB Amsterdam The Netherlands In association with

With a short – and often wet – summer behind us, the reman community is now returning from the holiday season. Ahead lies what is set to become a busy half year with plenty of interesting opportunities in addition to the industry’s normal day-to-day challenges.

Since ReMaTecNews is the media partner for September’s World Remanufacturing Summit at the University of Bayreuth in Germany, you will understand that much of our attention is currently devoted to this unusual event. For the first time (at least as far as we’re aware) the World Remanufacturing Summit is attempting to build a bridge between the reman industry and the world of research and science upon which much of the industry will rely for its future progress. In terms of technological advances, the automotive industry has, in recent years, moved forward at breakneck speed and if anything is certain in a changing world, it is that this is bound to accelerate. Already attracting a stellar list of speakers and attendees the summit represents a rare opportunity to look into the future of remanufacturing. At the same time, it allows its participants to obtain fresh insight into the day-to-day aspects of automotive and heavy duty remanufacturing. The present and the future all in one package.

This edition of ReMaTecNews also contains a review of a new book, European Automotive Remanufacturing – Technical Trends and Market Development. With particular focus on the growing role of electronics and mechatronics, the book (by APRA Vice-Chairman Fernand Weiland and a group of academics and specialists from the industry) sets out future scenarios for remanufacturing in Europe and guides the reader through the labyrinth of pitfalls and opportunities through which the reman industry must navigate over the years to come.

The summit and, indeed, literature such as ‘European Automotive Remanufacturing’ illustrate the need for closer links between theory and practice in remanufacturing, between leading-edge technology and an industry which, by its very nature, has been somewhat conservative in outlook.

For those remanufacturers who wish, or need to, stay at the forefront of their professions, the World Remanufacturing Summit in Bayreuth is undoubtedly a good place to begin.

Editor-in-Chief William Schwarck Phone +44 (0)1865 340 435 Fax +44 (0)8704 215 681 editorial@rematecnews.com Advertising Sales Eva Barten Phone +31 (0)20 504 28 00 Fax +31 (0)20 504 28 88 advertising@rematecnews.com Managing Director RAI Langfords B.V. Ron Brokking Publisher Luuk Aleva (responsible under Dutch Press Law) l.aleva@rematecnews.com Editorial Advisory Board Niels Klarenbeek Production Niels Zwan, Sebastiaan Dekker, Christiaan van Goens Phone +31 (0)20 504 28 00 traffic@railangfords.nl Design & Art Van Munster & Bos, Amsterdam Printing MediaCenter Rotterdam, The Netherlands Copyright RAI Langfords B.V., Amsterdam, The Netherlands Reproduction Permitted, providing ReMaTecNews is credited Subscription magazine and e-newsletter 8 editions 1 73 See www.rematecnews.com Change of address Phone +31 (0)20 504 28 00, Fax +31 (0)20 504 28 88 E-mail info@rematecnews.com

William Schwarck, Editor-in-Chief

Website www.rematecnews.com ReMaTecNews magazine online www.rematecnews.com Circulation 13,230 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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NEWS FROM THE INDUSTRY

Melett crosses the Atlantic UK turbocharger replacement specialist sets up subsidiary in the US The UK’s Melett in Barnsley in Yorkshire, a specialist in replacement turbochargers, recently opened a new sales and distribution centre in North America. The new facility will be managed by Kenny Taylor, formerly with Cummins Turbo Technologies.

The opening of the new centre follows Melett’s move to larger premises in 2011 and the opening of Melett’s representative office in China earlier this year.

“The plan is to launch the new business at the ADS show and be operational by the beginning of August,” says Kenny Taylor, General Manager of Melett North America Inc. “The new centre will be a sales, warehouse and distribution point acting as a distributor for the US and Canada and a shipping point for customers in Mexico or South America if shipping from the US is preferred.”

A familiar face in the turbocharger segment, Kenny Taylor has worked with

Cummins/Holset for the past 10 years. As General Manager, he was responsible for the sales and distribution of turbos and parts to the entire Holset dealer network in the US and Canada.

Melett’s presence in North America allows the company to build up stronger business partnerships within the US, the company says.

“The American market is Kenny Taylor becoming stronger,” says Managing Director and Owner Ian Warhurst. “The opening of Melett North America Inc. is a very positive step for us, as it reflects a significant expansion of our business. The new American facility will enable us to serve our US customers better, target new customers, enhance our competitive advantage and create new jobs.”

In addition to the sales and service staff already covering this area, further jobs will be created at the North American facility. This is anticipated to increase by the end of the year, Warhurst added.

About Melett Melett supplies replacement turbocharger repair kits, complete balanced CHRA/Core Assemblies and individual turbo components to the turbo repair industry. The company’s customer base ranges from small turbo workshops through to volume turbo remanufacturing facilities. Twice winners of the prestigious UK Queen’s Award for Enterprise 2006 and 2009, Melett currently supplies CHRA and turbocharger repair parts to turbo reconditioners in over 100 countries worldwide.

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NEWS FROM THE INDUSTRY

John Deere deeper into remanufacturing Renowned US manufacturer of agricultural equipment, John Deere has embarked on a multi-million dollars investment in an additional 275,000 square-foot facility near its existing remanufacturing plant in the state of Missouri. At a cost of $14 million, the new

facility will eventually add 55 jobs to John Deere’s existing workforce of 200 in Springfield.

“This is our core receiving facility for parts that have come back because they have failed in the marketplace and we bring those back in the remanufacturing and re-processing and make them like new,” says Don Flatau, General Manager of John Deere Reman and Marketing. “So we receive all those failed parts from around the world essentially into this facility.”

One of the world’s largest suppliers of agricultural machinery, John Deere operates a global sales and service network. The current reman facility in Missouri opened in 1998.

Mopar launches reman brake caliper range Mopar, the automobile parts and service arm of Chrysler has announced the addition of remanufactured loaded brake calipers to its line of more than 4,000 remanufactured parts. As with all the company’s remanufactured products, reman loaded brake caliper components are meticulously inspected, tested and upgraded or replaced to meet the strictest OE engineering standards, the company says.

“With the addition of Reman Loaded Brake Calipers to Mopar’s roster of remanufactured parts, Mopar is offering its customers a high-quality, cost-effective option when it’s time for brake repairs,” said Kathy Wideman, Senior Manager, Mopar Repair/Reman Portfolio.

ReMaTecNews

Showcase your Company and Product now!

If you have news about your company or a new product, please send it to our editorial staff via editorial@rematecnews.com.

The only international magazine and website dedicated to automotive and heavy duty remanufacturing worldwide. An independent channel for news, views and developments within the remanufacturing industry, with more than 13,230 readers worldwide.

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NEWS FROM THE INDUSTRY

Alto sets up turbo charger division Alto Products Corp has established a new turbo charger division named ‘Alto Turbo Products’.

This new division of the world’s oldest and largest independently owned and operated clutch manufacturer, will supply a complete line of parts for rebuilding turbochargers, the company says. It has been launched to meet the needs of continually increasing market demands within the field. “Supplying turbo parts is a natural progression for us in supplying high quality precision products to the most technologically advanced segments of the markets we serve,� stated David Landa, President of Alto. “Turbo parts will complement our existing line and leverage our engineering, marketing and global distribution networks.�

New reman facility in China In July China Yuchai International, one of China’s rapidly expanding remanufacturers, opened a new permanent factory at Suzhou Industrial Park in Eastern China. The new plant replaces Yuchai Remanufacturing’s operations at a nearby temporary facility.

Yuchai Remanufacturing is a joint venture company between Yuchai’s operating subsidiary, Guangxi Yuchai Machinery Company and Caterpillar China with the aim at providing remanufacturing services mainly for diesel engines and components. The new plant comprises 14,000 square meters and is expected to reach full operational capacity in 2014 with approximately 400 employees.

Benny H. Goh, President of China Yuchai, commented: “Our remanufacturing services will minimize raw mater-

Quality

ial usage and waste during the remanufacturing process thereby enhancing our ‘green’ environment agenda. We expect Yuchai Remanufacturing to become the leader in China for remanufactured engine parts.�

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NEWS FROM THE INDUSTRY

New sales manager for the ReMaTec exhibitions Ewoud Barink, 28, has been shows and attracting appointed Sales Manager new participants from for Amsterdam RAI’s across the world.”

ReMaTec exhibitions with In his spare time effect from July 2nd.

Barink is a keen tennis Although Barink, who has a player and sailor. degree in Business Adminis“We’re pleased to tration, is new to the remanwelcome Ewoud Barink ufacturing industry, he has to the ReMaTec team,” considerable experience in said Niels Klarenbeek, sales. He also has proven the Domain Manager for results in long-term comthe ReMaTec show. “As mercial projects in banking we continue to expand and local government. and improve the show, The international enviwe need more qualified ronment of the remanufacpeople and that’s what turing industry appeals to Ewoud Barink (right), new sales manager at Amsterdam RAI with Domain Manager Niels Klarenbeek. we’re getting with him: “The size and global Ewoud. I’m confident presence of the reman industry have come as the scope of such an important factor in the that his arrival will further strengthen our ties something of a surprise to me,” he says. “As automotive aftermarket. I’m now looking with exhibitors and with the reman industry an ordinary car driver, you are hardly aware of forward to further enhancing the ReMaTec in general.”

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From a small starter/alter n business to a leading core d The story of Germany’s RG GmbH is a case story of how deviating from the original business plan can lead to greater things. ReMaTecNews visits Germany’s leading independent core dealer.

Back in 1994, RG GmbH in Gemünden in central Germany started out with a vision of becoming a small but efficient remanufacturer of starters and alternators. Both founders, Otto Bartel and Rudolf Geist, saw an opportunity in a somewhat competitive market and decided to set up business together in the small town of Reichenbach between Frankfurt and Würzburg on the northern fringe of Bavaria in Germany.

They were right about the opportunity.

They were wrong about the starter and alternator business. Which Bartel and Geist are pretty happy about today as they have developed RG into Germany’s largest independent core dealers with deliveries across the world.

All from a humble start in a garage with a small office above. Today not only is the address different – in the nearby town of Gemünden. The facilities, too, have, undeniably, undergone a significant change: a warehouse of 8,500 square meters of cores and a staff of 18 at the Kessler Strasse Industrial Estate on the outskirts of Gemünden.

“Over the years we have had to move into bigger premises a few times,” explains Otto Bartel during ReMaTecNews’ recent visit to RG. “We have now reached a size that is appropriate to the business. If we need further space, there is room for that also.”

Product range

The family behind RG: from left Otto Bartel, Ilona Bartel, Manuela Emrich, Michael Geist, Rudolf Geist and Joachim Seitz.

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RG’s growing need for space, of course, reflects the expansion of its product range.

Once, after just a year, the decision to move from starters/alternator remanufacturing into core dealing was taken, the product range began to expand at a rapid pace. Not unnaturally, the initial focus was on supplying cores to remanufacturers. This however was quickly extended substantially where today, RG supplies AC-compressors, turbochargers, diesel injectors, injection pumps, high pressure pumps and injection valves as well as engines and transmissions in addition to starter and alternators. Since 2001 the company has also supplied new parts for these applications.

“New parts account for an important part of the turnover,” Bartel says. “This is necessary for us because of occasional shortages

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er nator e dealer or, in some case total lack of cores. To remanufacturers and their suppliers this is a constant issue which is not always easy to deal with.”

With an education in IT and accounting behind him Otto Bartel heads RG’s commercial activities, sales and business development with partner and co-owner Rudolf Geist taking responsibility for purchasing, the warehouse and quality control.

Family firm

From the office above RG’s warehouse 5 administrators handle worldwide purchasing, sales and accounts.

That, however, is not the full extent of the Bartel and Geist names in the running of the company. In fact, the next generation of the two families is already occupying key roles in RG’s administration and, barring any unfore-

‘Now I sell RG’s products all over the world and I enjoy communicating with and meeting so many different people’ seen developments, is set to take over full responsibility at some date in the future. Continuity, therefore, seems assured.

On the Bartel side are the two daughters Ilona Bartel and Manuela Emrich in charge of day-to-day book keeping and sales and purchase and sales respectively. On the Geist side there is son Michael Geist and sonin-law Joachim Seitz who are also key figures in purchase and sales. As members of the company’s Executive Board Ilona Bartel and Michael Geist, like their fathers, sign on behalf of the company.

In an industry sector known for being short of women executives former tax adviser Ilona and former banker Manuela have no regrets helping to turn RG into a family business. “Working with our fathers has gone very well, they both agree. Our father (Otto) listens and takes advice and we’re free to test new ideas. We’re proud of what he has achieved and love working in the reman industry.”

Adds Manuela Bartel: “When I was working in the bank, I sold banking and insur-

Otto Bartel’s daughters Manuela and Ilona – very much part of the next generation at RG GmbH.

RG’s workforce comprises a total of 18.

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ReMaTecNews REMANUFACTURING INTERNATIONAL The only international news magazine and website dedicated to Automotive and Heavy Duty remanufacturing worldwide

Do you want to keep yourself updated with news within the remanufacturing industry?

Sign up for the electronic newsletter via www.rematecnews.com

at Meet us hanika in Automect Frankfur0031 629074397 Contact

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ReMaTecNews is aimed at • Remanufacturers/rebuilders • Core suppliers • Suppliers of OE components • Suppliers of components for remanufacturers • Suppliers of rebuilding equipment and machinery • Suppliers of test equipment • Suppliers of cleaning equipment • Distributors – importers of rebuilt parts • wholesalers of rebuilt parts • Government and non-government organisations • Chambers of Commerce • Insurance companies • Fleet operators • Automotive trade associations • Car manufacturers – OEMs

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ance products mainly to a local market. Now I sell RG’s products all over the world and I enjoy communicating with and meeting so many different people.”

Workforce All together the workforce totals 18 persons.

In addition to Bartel and Geist and their daughters, son and son-in-law, the staff comprises five warehouse employees, five administrative people and two cleaners. Between

‘We value the personal contact with our customers’ them they handle, collect, inspect and dispatch in excess of 500,000 units per year from Gemünden. From this some 20 per cent goes to German customers with the remaining 80 per cent dispatched to customers worldwide.

Taking some pride in the selection and inspection of the cores, the RG family is keenly aware of maintaining close relations with its OE partners. Buying stock lots from OEs accounts for an important part of the business and mutual trust is essential.

Founders, Partners and Managing Directors Otto Bartel and Rudolf Geisel started RG twenty years ago.

Today the company’s is Germany’s largest, independent core dealer.

“We value the personal contact with our customers wherever they are and they appreciate their relations with us,” Otto Bartel says. “We buy a lot of surplus stock from OEs and we have established mutually trusting relationships with them.“

“In my view, the key to core dealing is no different from most other businesses if both parties are fair in their dealings with each other. For this to happen both parties have to be honest and ensure that both make a profit.”

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CLEPA’s Josef Frank

Why remanufacturing is really important A driving force in the conversion to remanufacturing, Josef Frank talks about CLEPA’s commitment to remanufacturing.

In the late nineties, a European executive working for Bosch in the automotive industry brought a video recorder into a shop in Singapore for repair. The reaction from the shopkeeper was that it would be better to buy a new one. With more capacity. With larger memory. With better specifications. At a higher price.

The memory of that first encounter with the ‘throw-away’ society has remained with the owner of the recorder ever since. Why throw something away if it can be used again?

Over a life-long career in the automotive industry Josef Frank has often pondered

tling, a somewhat dirty business that fell outside CLEPA’s remit,” Josef Frank remembers.

“But then we started to take a closer look at brake calipers.”

The more Josef Frank and others considered the many safety aspects of brake calipers, the more they realised that, from a safety point of view, there was a need for clearer definitions of remanufacturing. The same applied to a number of other remanrelated components. Subsequently, a working group was established to come up with a range of proposals for taking CLEPA further into reman. The group has since developed into a powerful voice on behalf of remanu-

‘Our task is to lobby on behalf of the remanufactured products.

To do that we have to speak with one common voice’ on the question. First, while working at an automotive wholesaler in Europe, later at Bosch, the German giant, in Europe and Asia and for the past six years as Aftermarket Director at Europe’s Association of Automotive Suppliers, CLEPA, a powerful voice in the corridors in Brussels. Moreover, over the past three to four years, Josef Frank has been a key mover behind CLEPA’s recent focus on automotive and heavy duty remanufacturing.

Once a distant cousin on the periphery of the automotive industry, remanufacturing is now clearly recognised by CLEPA for what it is: an answer to many of the environmental and resource challenges facing the automotive industry across the world. Only a few years ago, in fact, there was some doubt within CLEPA about the relevance of reman to the association. Today those voices have subsided.

“Yes, it’s true that there were sceptics from OE-oriented members who argued that remanufacturing was not a matter for CLEPA – that reman was somehow akin to disman-

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facturing and a European partner for America’s MEMA and its reman division MERA. As a first result, CLEPA in 2009 issued a definition for reman including a description of the process.

“A remanufactured product fulfils a similar function to the original part. It is

manufactured using standardised industrial process in line with specific technical specifications. The industrialised process incorporates defined core management standards. A remanufactured spare part is warranted as a new spare part.”

“The definition lies at the heart of it all.

What does remanufacturing mean? Now we have agreed that the definition has a process behind it,” Josef Franks says. “It has been hard work to find a common definition. But I believe that it’s a job well done. This has be so since Michael Cardone Jr., the Chairman of MERA in the US, has accepted it.”

Although other organisations, associations and companies may apply different definitions of remanufacturing, the support

by MERA in the US makes this as close as possible to a worldwide standard. It’s certainly a very significant step forward towards the ambition of establishing reman on a par with all other activities in the automotive industry.

As to when one common standard will apply worldwide Frank smiles and shrugs his shoulders: “A good question. Maybe only if you put all the players together in one room and not let them out until they raise a white flag... but if you look at all the definitions, they are not too far from each other.”

However, CLEPA is offering all other players to join in a common definition and is working together with APRA, FIRM, MERA and the car manufacturers via the VDA and

CLEPA’s Core Management initiative CLEPA’s recent ‘Core Management’ initiative is part of a broader CLEPA initiative to create more awareness and understanding of the safety, employment and environmental aspects/ advantages of remanufactured products for end users (car drivers), carmakers, distributors and garages as well as the relevant decision making authorities. Remanufacturing of products is seen as a future core business suitable for mechanical and electronic products.

The objective of the ‘Core Management’ initiative is to propose an easier way to handle cores through the complete chain of distribution, simplifying core return management and reducing customer logistic and administrative tasks.

The ‘Core Management’ initiative was a collaboration of several companies which are key actors in the European automotive remanufacturing sector. These companies CLEPA wish to use this initiative to develop best practice solutions for their customers and for the trade in furtherance of their remanufacturing businesses.

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ACEA. “We are sure to come out with a revised definition supported by APRA, FIRM, MERA and RIC during Automechanika, where CLEPA will have a reman booth,” Frank said.

The number of its members involved in remanufacturing is stimulating further interest within CLEPA – as is the growing focus on the environmental aspects, CO2 savings, the benefits of opting for ‘reman’ instead of ‘new’ and the importance of the industry in economic and employment terms. “It all makes a compelling case for remanufacturing,” Frank says.

CLEPA comprises 93 of the world’s prominent suppliers of car parts, systems and modules and 25 national trade associations and European sector associations representing more than 3,000 companies with a total of 5 million people. Based in Brussels, CLEPA is recognised as the natural discussion partner by European institutions, United Nations and trade associations (ACEA, JAMA, MEMA).

With regard to employment figures reman in the United States remains the bigger employer by far with an estimated 300,000 people working in the industry and perhaps up to 2 million financially dependent on it. “In Europe employment in automotive remanufaturing reman it’s much less, of course,” he observes. ”Perhaps some 30,000 people are directly employed in remanufacturing here. Nevertheless, the turnover for remanufacturing in Europe is estimated to have reached 8-10 billion euros with engines and gearboxes accounting for around 10 per cent of the market. As the OEs also now regard reman as a core activity, this is likely to go up.”

In terms of remanufacturing CLEPA has obviously achieved a great deal in a few years.

Where do you see the association heading now?

“Within CLEPA there has been a complete change in attitude. Early on there was probably too little knowledge or understanding of

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reman. That’s gone now. In CLEPA everyone is now talking about remanufacturing, including our President in press releases or at conferences. You see large companies buying up reman companies so there is a clear trend here. Now, I think, we need to cooperate on a larger scale within the industry – and among different players such as APRA, FIRM and MERA and the OEs. Fortunately, we’re already seeing some progress here but it’s crucial that we continue to do so because we have to make it clear that reman has nothing to do with reuse. Reman is ‘manufactured again’ – giving components a second life.

“What we’re doing is creating a new product with the same guarantees and in a new box so that, in effect, the user does not realise that it’s remanufactured. Our task is to lobby on behalf of the remanufactured product. But to do that we have to speak with one common voice.”

“We should also remember that reman is nothing new. It’s been done for a long time, although not so long ago it probably suffered a bit of a decline because it became cheaper to use new products. Today, reman is seeing a bit of a renaissance. We must not, however, lose track of the fact that reman is not only about mechanical products anymore. It’s also about electric, hybrid, electronics and other highly technological products. Before, reman

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Josef Frank: a driving force in CLEPA’s commitment to remanufacturing.

was perceived as a cheaper solution for cars.

Today it is a solution for the future. This makes a lot of difference.”

Based in Germany and Belgium Josef Frank has been the Director and Senior Adviser Aftermarket at CLEPA, the European Association of Automotive Suppliers, since January 2007. In this role, he represents the interests of the European parts suppliers with regard to regulations, sets up working groups e.g. for brand protection and remanufacturing as well as distribution. He negotiated the Block Exemption Regulation and the access to RMI and VIN for Euro 5/VI vehicles on behalf of the suppliers.. From 1973 to 2006 he worked for Robert Bosch’s automotive aftermarket division with responsibilities in sales, marketing and general management based in Germany, France and Singapore. His last assignment with the company was General Manager of IAM for Western Europe from 2000 to 2006.

Before joining Bosch he worked with an automotive wholesaler. Josef Frank has over 40 years of experience in the Automotive Aftermarket Industry and has knowledge of the European and South East Asian markets. Since July 2011 Josef Frank has also worked as an Independent Automotive Consultant.

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World Remanufacturing Summit in Bayreuth

The future is here – an opportunity to look into it The future of automotive remanufacturing – and other types of remanufacturing – is highlighted at September’s World Reman Summit in Bayreuth, Germany, on September 3 and 4. A number of global players are set to attend. So will a large number of more specialised reman specialists.

Siemens. Meritor. SRC. Bosch. Daimler. Cummins. Deutsche Bahn, Germany’s national railway system. TRW. BU Drive.

The National Key Laboratory for Remanufacturing in Beijing. Injectronics of Australia.

Bayreuth University of Germany. General Motors Powertrain. Rochester Institute of Technology. Flight Systems European Group.

These are just some of the global names giving presentations at September’s World Remanufacturing Summit organised by the University of Bayreuth in partnership with ReMaTecNews. It is destined to become a key event in the growing internationalisation of automotive and heavy duty remanufacturing as well as other types of remanufacturing.

In an impressive display of scientific, commercial and technological knowledge presenters will lecture on - and discuss - some of the most important challenges facing remanufacturers today – and how to solve them.

Included are issues such as Managing Complexity in Remanufacturing Companies, From Starters and Alternators to Future Products, Train Remanufacturing, High Precision Remanufacturing, CanBus Technologies, Remanufacturing of Electronic Units and much more. For the complete programme visit www.remansummit.com.

Tim Roth, SRI

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Right from the start on Monday morning, September 3rd, the international scope of the event will be demonstrated through the apperance of high level experts. In the first plenary speech, Professor Herbert Kohler of Daimler AG will give an insight into the Mercedes’ brands commitment to remanufacturing. This will be followed by a presentation by Dr. Nabil Nasr on ‘Remanufacturing – the view from the US’. Dr. Nasr is the United States’ foremost reman academic and a consultant to governments and organisations across the world. Immediately following Dr. Nasr’s presentation, Professor Sheng Zhu of Beijing’s National Key Laboratory will present China’s rapidly changing view of remanufacturing, an issue of interest to remanufacturers worldwide.

The introductory plenary session will continue with a presentation on ‘The View from Europe’ by Professor Rolf Steinhilper, the Head of Bayreuth University’s Chair of Manufacturing and Remanufacturing. A panel discussion comprising the speakers will round off the morning’s events before the individual sessions begin in the afternoon.

World class programme “We believe that we have assembled a

Christina Schulte-Braucks, Osborne-Clarke

world class programme, which will not only provide the remanufacturing industry with an insight into the future of reman but also assist them in facing current day-to-day challenges,” Professor Steinhilper says. “Looking at the wide spectrum of speakers and their subjects I’m confident that the summit will appeal to remanufacturers across the board – whichever part of the world they come from. Remanufacturing today is a global industry and many of the players share common challenges and solutions.”

Day 2 of the summit will see presentations by Marc Baines of Flight Systems Europe on ‘Consortium Formation with Local and EU Government Bodies when starting Remanufacturing in the former Eastern Europe’, ‘Promoting Remanufacturing as an Exciting Subject in Academic Research and Scientific Publishing’ by Dr. Winifred Ijoma of University of Strathclyde in Scotland and ‘Design for Remanufacturing’ by Shawn K. Zwicker of Cummins, USA. Later the same day, Christina Schulte-Braucks of the international law firm Osborne-Clarke will give a presentation on ‘Remanufacturing vs. Trademark, Patents and Liabilities’.

The summit will be rounded off by Peter Bartel, Chairman of APRA Europe.

Elisabeth Staudinger, Siemens

y n t ” e s o r y d

e U , g c y r f a m n d

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Remanufacturer of the Year at the World Reman Summit Every other year the winner of ReMaTecNews’ Remanufacturer of the Year Award is honoured during the biennial ReMaTec exhibitions in Amsterdam. In the intervening years between the ReMaTec exhibitions, the venue for the award ceremony is elsewhere. So far Frankfurt am Main in Germany, Warsaw in Poland and Budapest in Hungary have all hosted the event, the most prestigious in remanufacturing.

Philippe James, Remy Automotive Europe

Jens Lindholm, Holger Christiansen

François Augnet, TRW

This year the award ceremony will take place during a gala dinner on Monday September 3 during the World Remanufacturing Summit in Bayreuth, Germany. With Dr. Nabil Nasr, Assistant Provost for Academic Affairs and Director, Golisano Institute for Sustainability, Rochester Institute of Technology in New York State, presenting the award to the winner, the ceremony will once again have participation from an international figure.

Firmly established in the reman industry’s annual calendar, the Remanufacturer of the Year Award honours individuals or organisations that have served automotive or HD remanufacturing with distinction. Previous winners constitute a stellar line-up of prominent figures in remanufacturing over the past eight years.

Alexander Schäfer, MS Motor Service Int.

Carsten Bücker, BU Drive Group

Johan van Gerven, MRT Engines

Martin Detzen, MD Rebuilt

r

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CLEANING UPDATE

Clean parts – a competitive edge in remanufacturing Cleaning has always been an essential part of the remanufacturing process. With constantly increasing demands for the cleanliness of remanufactured parts it is now a competitive parameter. How do remanufacturers acquire the necessary levels of cleanliness for their products – economically and ecologically?

By Doris Schulz Due to increasing prices for energy and raw materials as well as rising environmental awareness remanufacturing has increasingly become an important factor in the value creation chain of the automotive, commercial and heavy duty vehicle industry. Regardless of whether complete aggregates like engines and transmissions or single components such as gear boxes, cylinder heads and starters are involved, remanufactured products must offer comparable quality and similar warranties as new parts.

This includes technical cleanliness, which has increased enormously over the past few years. The automotive industry, in particular, has started defining particle size distributions for certain parts in functional modules such as the power train and steering, e.g. no more than 1,000 particles between 200 and 400 µm, 500 particles between 400 and 600 µm etc.

These requirements have not only to be met. They have also to be documented. Even though the very stringent specifications for

new parts may not be adopted on remanufactured components, it is foreseeable that specifications for cleanliness will be developed and determined. Moreover, cleaning technologies used in remanufacturing processes are set to become more efficient as well as more ecological. Introducing innovative technologies for cleaning which allow the required levels of cleanliness to be met - reliably, fast, economically and ecologically - can therefore be a cutting edge for remanufacturers.

Matching the cleaning process to the task Unfortunately there’s no one right cleaning process; each task needs an individually defined solution. Essential factors include part geometry, material, type and degree of contamination, cleaning agent, mechanics, process treatment duration, throughput and cleanliness requirements. In order to take advantage of the opportunities, a require-

ments-based cleaning process frequently offers insight into the performance capabilities of the various cleaning technologies and how they can be used optimally.

Such know-how will be offered by the parts2clean exhibition, which will take place in Stuttgart (Germany) from October 23rd - October 25th, 2012 inclusive. The fair will showcase the world’s most comprehensive programme for industrial parts and surface cleaning and feature a broad portfolio of systems and processes. On display will also be a range of process media for degreasing, cleaning, deburring and pre-treatment of parts, parts baskets and workpiece carriers, handling and process automation, cleanroom technology and much besides. In addition to the exhibitor presentations the complementary, bi-lingual (English/German) parts2clean expert forum will provide plenty of other information on recent development within the industry, including information relevant to remanufacturers.

New benchmark for workshop systems A new high-power aqueous parts washer, which is set to be introduced industry-wide by Safety Kleen next month (September), appears to set a benchmark for workshop systems and could make remanufacturers throughout the EU sit up and take notice.

The speed of the Jetkleen unit - which is said to be around ten times faster than conventional systems as well as being safe, economical and environmentally responsible to use ensures dismantled components can be cleaned, examined and reassembled much faster.

Based at Brentford in West London, Safety Kleen UK is a leading parts washing systems supplier and waste product management com-

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pany, with Pan-European interests. The new machine is typical of new standards of equipment designed to help producers of hazardous waste throughout the EU work more efficiently, while meeting increasingly tighter legislative requirements at the same time.

A ‘Waste Framework Directive‘, which began rolling out throughout EU member states from December 2010, established a legal framework for waste treatment. Its aim is to protect the environment and human health by achieving a recycling society.

The directive introduced the concept of a ‘Waste Hierarchy’, which now compels all producers of waste to take the cleanest available disposal routes.

The Jetkleen is part of Safety Kleen’s response to help producers such as workshops in remanufacturing operations comply, by reducing the total volumes of waste they produce. This means less disposal altogether. It operates like a power washer inside a box, while the aqueous fluid used means it is both safe and fume-free to use. Solvent-based systems can also comply with the latest EU regulations. For example, the company also supplies parts washers that automatically recycle solvent, so that the solution used is always clean.

Since its acquisition of Partswash UK in October 2011, Safety Kleen can also design, build and supply parts washers built for specific industrial uses, a service that gives users even less of an excuse not to be able to comply with the EU’s tough legislative stance on hazardous waste.

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CLEANING UPDATE

Rosink RFL The Rosink front loader RFL, a flexible system for powerful aqueous cleaning, has been developed for cleaning and degreasing of small and medium-scale lots. Due to its modular concept it can be adapted to various needs in remanufacturing processes and is able to achieve high levels of cleanliness. Within the washing chamber different programs can be carried out.

Bio-Rust – pH-neutral deruster Bio-Rust is an innovative product for the fast and reliable removal of rust from metals in the pH-neutral range. The bio-deruster produces exceptional results in the fields of slight rust films and fingerprint corrosion, and also in the removal of thick rust layers. Tarnish is effectively removed from brass and copper, and the metal will be brightened. The deruster is water-based and dispenses with aggressive acids in high concentrations. It contains selected ingredients that are easily biodegradable in accordance with OECD standards. Parts can be derusted even at ambient temperature and with process times of approx. 30 minutes. Rust removal times can be accelerated by increasing the temperature and by using ultrasound.

Integrated process control BvL offers their industrial cleaning systems with an integrated light version of Libelle ‘Fluid Control’. This process control system monitors bath contamination continuously which helps plant managers to extend intervals for expensive, time-consuming residual dirt analysis.

Even with different impacts of parts the change of baths can be carried out to the optimal point of time. Also filter bursts get detected immediately.

Laborex floodwasher The Laborex flood spraying system is especially designed for the cleaning, rinsing and drying of parts with complex geometry and machined components where a high cleaning degree is required. It is equipped with two fixed spray pipes, an oscillating spray pipe with high impact pressure nozzles and rotation device for the basket. During the cleaning process the parts are fully immersed. The nozzles, which are under water, cause a strong flow in the washing chamber. The combination of spaying and floodwashing ensures intensive cleaning.

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CLEANING UPDATE

Workshop on clean-up costs Best known as a fuel injection diagnostics systhe older systems in use often rely on more tems specialist supplier to the automotive corrosive chemicals than some of the more vehicle repair industry, ASNU Corporation Europe has issued a warning about a shadow lurking in many remanufacturing workshops - the rising cost of waste chemical disposal.

Owner and managing director Phil Ellisdon is well placed to comment, as the Hertfordshire-based automotive equipment company is also a supplier of ultrasonic bath cleaning systems to vehicle repairers and parts remanufacturers.

“The problem is educating the industry. It’s not easy trying to convince users and workshops to upgrade their older systems,” he says.

ASNU says remanufacturers are among those finding it harder and more expensive to dispose of the essential cleaning fluids that are a key Phil Ellisdon part of the reman process. Some of

modern systems. Indeed, some of the older systems themselves might not have been designed specifically for automotive use.

“The ASNU range of cleaning systems uses water-based, biodegradable chemicals that have been specifically designed for the automotive industry,” he adds.

Phil Ellisdon believes rising disposal costs can lead to a temptation to re-use chemicals more often than is recommended, which can also compromise the efficiency of both the cleaning and remanufacturing processes. He believes it makes sense to replace older systems sooner rather than later as the chemical disposal costs will only increase: “It’s a ticking time-bomb, as far as many users are concerned,” he says.

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Reman opportunities at Automechanika 2012

By Steve McQueen

With almost 5,000 exhibitors from across the globe and 154,000 visitors spread just as widely, the last Automechanika exhibition in 2010 reaffirmed its position as the world’s premier aftermarket event. This trend is set to continue when the massive 2012 show opens it doors in Frankfurt, Germany, between September 11 and September 16.

While still accounting for a modest part of the total, automotive remanufacturers, too, will display a broad range of products and services in Frankfurt. Altogether at least 50 companies, from giant car makers to small independent remanufacturers and their suppliers, will showcase reman-related activities.

Visiting remanufacturing specialists, therefore, will get the opportunity to see not just what rival companies are up to, but to

Remaned combined operation

learn about new business opportunities provided by exhibitors that will help them to extend their own parts catalogues.

For example, Spanish Diesel remanufacturing systems specialist Remaned is displaying a range of reman engines for the first time. Serbian reman engine producer MR Group is among those exhibitors keen to forge new business relationships abroad, while Spanish company Secore is offering visitors the chance to gain access to new services that could spawn fresh profit opportunities.

Trade visitors will also find support from exhibitors that serve the remanufacturing industry. Whether it’s an oil and lubricant supplier, a cylinder head gaskets, kits and oil seals supplier, or a timing belts, tensioners and drive systems specialist, Automechanika 2012 has something for every visitor.

The following provides a selection of some of the remanufacturers and suppliers exhibiting at Automechanika.

Company name RG GmbH Hydra-Test Andre Niermann automotive electrical products Cummins Kuhn Remy Automotive Europe Turbo Technics Emmetec Pos Service Holland Automatic Choice Europe Autoenterprises Kardes Sussex Autoparts Wood Auto RASED Spaco Diesel Melett DB Automobile GmbH Auto-Starter

Booth 3.0 H10 1.1 G12 3.1 F60 5.1 B94 6.1 E19 3.0 B21 5.1 E69 3.0 D01 3.1 C69 5.1 E40 3.1 F67 3.1 A51 1.1 H11 3.0 G78 5.1 E35 5.1 D62a 3.0 A60 3.0 G41

Subject to changes

Spain’s largest diesel systems remanufacturer, Remaned, gets a first opportunity to demonstrate the extent of its newly acquired engine remanufacturing prowess, at Automechanika.

The move follows the incorporation of Avima Motor - the parent company of Remaned - under Remaned management. It is a move that comes just four years after Avima established Remaned as an independent diesel systems remanufacturing specialist.

Earlier this year, Remaned’s growth was rewarded with a rating among the top 300 automotive parts players in Spain.

Benefits of remanufacturing

This combined operation gives Remaned access to new expertise and new product ranges, such as remanufactured engines and cylinder heads, the company says.

As a result, Remaned arrives at the show with not only a new diesel systems catalogue that includes VDO CR injectors and Denso CR injectors for the first time, but a new remanufactured engines catalogue as well.

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The Danish remanufacturer Borg Automotive brings its own branded reman ranges to Automechanika - DRI and Elstock - as well as other well known reman names such as Lucas.

The company acquired its Danish competitior DRI in 2007 and since then has embarked on a programme of expanding the markets for its multiple brands range throughout Central and Eastern Europe.

In addition to steering racks and steering pumps, AC compressors, starters and brake calipers are now key product ranges and the the company has paid great attention to its finishing processes, core management, packaging, quality control and training: “When distributors realise the benefits

of remanufacturing and the support and training we give to implement the collection of old units, the attractiveness of the concept is clear.

We have many cases to show in Eastern Europe, and I urge any distributor from the region to contact us for a further discussion about this,” says European Sales Director, Jarl Gorridsen.

Borg has recently published guidelines for the safe installation of AC compressors, and this information is now included in every box.

The company adds that the introduction of a new aluminium cleaning process should help distinguish its products from those of other competitors, as well as delivering at least 10% more corrosion resistance.

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Reman profit opportunities Sercore, a Spanish company that began as a family business remanufacturing drive shafts and steering racks for passenger cars back in 1980, now employs over 70 people and has extensively expanded its product range to include steering gearboxes, electronic power steering, steering pumps, cv joints and

suspension spheres, to name just a few.

The company, which currently exports to more than fifteen countries, has a presence on TecDoc and is keen to seek business opportunities with new partners. It is also offering visitors the chance to develop new profit opportunities.

A new service called R2R (rebuilder to rebuilder) gives companies the chance to develop new items or product lines that ‘may be of interest to other rebuilders, even items outside the European market’. Moreover, the company says it provides the necessary electronic technology support.

Thinking that’s out of the box As well as supplying a high profile parts range for diesel injection systems and operating as an agent for turbocharger specialists such as Garret and Honeywell, Redat supplies the parts kits and tools used by remanufacturing workshops.

Rebuild and reman partners sought Serbian engine parts remanufacturing specialist MR Group returns for a second appearance at Automechanika with ambitions to expand its customer base throughout Western Europe.

Its markets include passenger cars, trucks, railstock, industrial plant and marine applications. it seeks contact with dealers of used or rebuilt spare parts, or engine rebuilders who don’t have the capacity to fully rebuild engines.

The company claims to provide spare parts (pistons, liners, bearings, valves, valve guides, gaskets, seals ) for most engines. It rebuilds all kind of engine parts, such as crankshafts up to 3600 mm, engine blocks and engine heads from various types of vehicles.

As part of a new service, engines will be received and returned following a complete rebuild to the required specifications.

For example, it designs, builds and supplies balancing machines used by turbocharger remanufacturers as well as producing the tools used to repair and calibrate diesel injection pumps suitable for major brand names such as Bosch, Denso, and Hartridge.

Based at Turin, in Italy but with branches all over the world, the Redat service also includes the design and supply of complete ‘out of the box’ turbocharger workshops.

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TRANSMISSION WORLD

Applause for US state action on fleet remanufacturing

Industry report published

The state of Michigan’s recent decision to prioritise the use of remanufactured parts, including a very substantial volume of transmissions, throughout the state’s motor vehicle fleet has been met with applause in the UK. The UK’s newly formed Federation of Engine Remanufacturers has praised the move and called upon local authorities in the UK to follow the lead: “When industry associations like FER can testify to a wide range of reliable remanufactured products - built to Brian Ludford recognised standards - it not only means good workshop practice, but makes sound economic sense. It shows voters that local government is spending tax payers

The Strategic Analysis of the North American Remanufactured Transmission and Components Aftermarket is a new report from global research and consulting group Frost & Sullivan.

The objective of the study is to provide a comprehensive evaluation of the overall transmission repair market in North America. It provides a detailed analysis of the remanufactured transmissions market. Categories covered include remanufactured product, used or salvage transmissions, rebuilt transmissions and high demand transmission components.

The components category evaluates demand for torque converters, overhaul kits and electrical parts including solenoids, sensors, wiring harnesses, pressure switches, and connectors. The base year of the study is 2010 and the forecast period of the study is from 2011 to 2017. The report is available from http://bit.ly/MWQOqM.

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money more wisely,” said secretary Brian Ludford. The move by Michigan Governor Rick Snyder is also welcomed by Meritor, a major US remanufacturer, which applauded the state’s official endeavours to reduce state fleet maintenance costs by making remanufactured parts its preferred source of supply.

Meritor called Governor Snyder’s decision ‘an important example of Michigan’s efforts to secure the greatest value for its taxpayers’.

“Remanufactured parts are an effective way for fleets to ensure the performance of their vehicles while keeping maintenance costs contained,” said Joe Mejaly, President, Aftermarket and Trailer, at Meritor.

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TRANSMISSION WORLD

New smart phone app identifies transmissions

Remy in hybrid alliance with VIA

A new smart phone app that identifies automatic transmissions in virtually any vehicle in the world is now available free of charge from Corteco, the supplier of TransTec® transmission and power steering kits, the company has announced.

Developed to eliminate confusion over look-alike transmissions, the mobile app identifies transmissions by vehicle make, model, year, and engine. The Transmission-byVehicle app includes global coverage of import and domestic applications through the 2012 model year.

This, for example, means that users can determine that a 2012 Citroën Elysée with L4 1.6L engine has a 4-speed front wheel drive transmission (model AL4). The mobile app is continually updated so users always have access to the

Remy International’s Electric Motor Division and the American VIA Motors have announced a joint agreement to supply powertrains for the VIA Extended-Range Electric Vehicle (eREV).

VIA offers a full lineup of extendedrange electric trucks, vans and SUVs called VTRUX, each equipped with the company’s eREV powertrain. The eREV powertrain enables the VTRUX to drive up to 40 miles in a full electric near zero-emission-mode achieving an equivalent 100 mpg, according to the company.

“We are proud to enter this supply agreement with VIA. We believe integrating the Remy HVH motor into the VIA eREV powertrain will yield a system with unmatched levels of performance,” said Remy’s Vice President, General Manager Global Hybrid, Kevin Quinn.

most current and comprehensive vehicle listings on their smart phones and tablets.

“The Transmission-by-Vehicle smart phone app was a logical extension of our popular pocket Transmission Guide, now in its 10th edition,” noted Patty Richards, Senior Marketing Manager for Freudenberg-NOK Sealing Technologies. “We are very proud to offer this first and only global transmission guide as a mobile app,” added Richards. The Transmission-by-Vehicle app can be used on Android phones, iPhones, and any smart phones and tablets.

New TransTec® Transmission-by-Vehicle smart phone app identifies automatic transmissions in virtually any vehicle in the world.

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TRANSMISSION WORLD

Additives add reman value Transmission remanufacturers should use additives to enhance the quality of their services, says lubricants supplier Lucas Oil Products (UK).

The company supplies the UK, Europe and Scandinavia with the full range of oil products. “Once a reman job has been completed to the appropriate industry standards, additives can enhance the longevity of the

product. For example, a transmission fix or fluid with conditioners will help prevent valves sticking, stop bands slipping and protect seals from the outset. The remanufacturer can be confident that the transmission is being looked after from the word go,” says UK Managing Director Les Downey.

Lucas Oil claims to have one of the largest automotive additive ranges on the market,

HD clutch reman UK HD remanufacturer Truckfix has responded to the decline in UK engineering opportunities by developing a reputation as a bespoke provider of transmission solutions.

Its range of reman and other clutch products includes parts for everything from conventional vintage truck restoration clutches through to electro-magnetic dog tooth clutch products for applications across the

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automotive spectrum. A large part of its market is to provide clutch solutions for operators

lists Transmission Fix and also ATF with Conditioners as its main products for automatic gearboxes.

Les Downey Its Heavy Duty Oil Stabilizer can also be added to manual transmissions to help prolong operational life.

of trucks, crane and buses: “We keep fleets such as Ainscough Crane Hire running with a mix of new and remanufactured product, depending on the age and requirement of the application,” says Director Di Forbes. “We pride ourselves in using the same standards for both new and remanufactured and offer the same guarantee across the board.”

Much of Truckfix’s work is ‘one off’ - and that often includes HD motorsport work, such as supplying reman clutch replacement parts for some of the UK’s professional truck racers.

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ELECTRONICS & MECHATRONICS

Remanufacturing in Europe – a roadmap for the industry New book on remanufacturing in general and electronics/mechatronics in particular serves as a guide through some of the challenges facing automotive remanufacturing.

By William Schwarck

For OE remanufacturers, the automotive industry’s rapidly increasing reliance on mechatronics and electronics, is not likely to be a huge challenge unless they remanufacture components for their competitors. They will have at their disposal most, if not all of the required knowledge and tools. For independent remanufacturers, however, who do not have access to the original technology and original data, substantial investments in reverse engineering and test equipment will be required.

Those that realise this and acquire the appropriate knowledge and equipment will defeat those competitors who fail to embrace change.

This is one of the main messages contained in a wide-ranging new book about remanufacturing published this autumn.

Books on remanufacturing is not exactly dozen a dime and for that reason alone ‘European Automotive Remanufacturing – Technical Trends and Market Development’ is a welcome addition to existing literature on the subject.

Co-authored and edited by Fernand Weiland, the current Vice-Chairman of APRA

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Europe and one of the induseconomies of scale or try’s senior figures, the book sets economies of overheads. One out to demystify a range of solution is, possibly for tradiissues relating to the future of tional remanufacturers to form remanufacturing. In this the alliances with remanufacturers author and his authors, a group who, in terms of technology, of academic and business leader, operate at the leading edge of succeeds to a significant extent. remanufacturing. Whether the While some chapters will priremanufacturing industry will marily attract technical experts, gain through such mergers and other sections and their concluacquisitions, is an open quessions will have a broad appeal to tion, but, as the book states: anyone working or taking an Fernand Weiland ‘the process has started and will interest in remanufacturing. accelerate in the future’. We Which, on the backdrop of the industry’s have seen and will continue to see both environmental, economic and employment positive mergers and probably not so positive benefits should be more than is probably the mergers. case.

With it’s strong emphasis on electronics/mechatronics the book takes a proactive Consolidation approach to this increasingly important part Consolidation in the reman industry is of the automotive and HD reman industries. already happening and will offer opportuniIn the view of the authors electronics and ties for large remanufacturers who wish to mechatronics will soon be key issues for extend their product portfolio by acquiring remanufacturers, not least in respect of canspecialized remanufacturers. Another quesbus systems. tion is whether medium-sized remanufacturDr. Stefan Freiberger of University of ers will be able to consolidate and make Bayreuth puts it like this: “The complexity, time and cost effort to remanufacture an automotive CAN-bus based mechatronic system should not be underrated. Understanding the communication between automotive mechatronics and electronics implies an understanding of the sensors, actuators, bus communication and protocols as well as the electronic control units in the used system.”

As illustrated by chapters by two managers from Dutch ECU remanufacturer ACtronics, the development of electronics and mechatronics is a fine balance between advanced technology and practical appliance of reman methods in which Can-bus will play a crucial role the value of which can hardly be overstated.

As Dutch ECU-remanufacturer ACtronics Stef de Winter says: “The CAN bus has proven to be a very reliable and fast way to implement network in an automotive environment. Of course the system was designed especially for this pur-

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ELECTRONICS & MECHATRONICS

pose more than 20 years ago by Robert Bosch but communication busses that were introduced over the time like the J1850 bus (Ford) and VAN bus (Peugeot) have all have been phased out and replaced by the CAN bus. CAN is more or less used in nearly all European, UK and Asian produced vehicles, making it a very important element when remanufacturing or repairing automotive electronics.”

Some figures illustrate the rising importance of remanufacturing of electronic component unites in the future.

1 Billion cars With more than one billion cars on the world’s roads and an average of at least 4 high level ECUs in a manual transmission, 5 medium level control units (instrument clusters, climate control, information display, audio system, and airbag system) and a further 40 the total accounts for a very large number of electronic units. In fact, there are today 25 billion control units in service across the world. In just ten years from now the figure is likely to have doubled. Only the sky seems to be the limit.

Moreover, the authors estimate that within long 300.000 ecu’s to be replaced in Europe each year. In other words, plenty of opportunity for enterprising electronics/mechatronics specialist one would say. The other side of the coin, however, is the need for large volumes.

Achieving success “Globally this is a very large market. However, rebuilding an ECU in the right quality involves R&D costs which have to be distributed across the production. If you need to spread these costs over just 200 units, there is no business model anymore. So to achieve something in this business, larger quantities and a good distribution are essential,” ACtronic’s Leon Kleine Staarman points out.

In addition to its wealth of information on electronics and mechatronics, the book also highlight various market segment’s prospects. This, too, provides inspiration and useful information for remanufacturers looking towards the future.

What then is the verdict? As in any other industry the outlook for some segments are brighter than for others. Electronics/mechatronics, obviously provide significant opportunities, whereas other segments will remain static or decline. Power steering, gasoline and diesel injection systems, also offer prospects as is the case with turbocharger where considerable potential remains untapped. CV drive shafts are becoming a mature market, while remanufactured brake calipers continues to lead the

industry in terms of numbers. In summing up Fernand Weiland, who has spent a lifetime in remanufacturing says: “The reman industry has an excellent future. I would like to confirm what the London based Investors Carbon International recently reported recently: ‘The potential for remanufacturing is large, but so are the risks if you are not sure what you are doing!’ For my part and for those remanufacturers which I know, they know what they are doing.”

European Automotive Remanufacturing – Technical Trends & Market Development.

Authors: Professor Rolf Steinhilper, Dr. Stefan Freiberger and Alexander Nagel, Bayreuth University, Germany; Dr. Daniel Köhler and Fernand Weiland, Germany; Leon Kleine Staarman and Stef de Winter, ACtronics, The Netherlands; Edwin R. M. Tom, TRW, Germany. Published by FJW Consulting.

Electronics remanufacturing – a growing business With the number of electronic modules on a car as high as 30 for a standard vehicle and up to 60 for high-priced vehicle the parts proliferation is very substantial. This not only applies to product lines but also to car models. For some components volumes are too low to be considered for remanufacturing, at least at this juncture. Remanufacturing of fast movers are becoming an attractive business model.

Nevertheless, remanufacturing of automotive electronics is a challenging business.

Although, in theory, only remanufacturers with access to OE data can remanufacture these components many independent specialists have been able to resolve this by reverse engineering. Investments for them are of course high and the same is true for the special test equipment they have to design.

Because economies of scale are important remanufacturers have, by and large, decided to remanufacture the fast moving components first.

For the survey, Fernand Weiland has selected what in his view are the most attractive electronics components, i.e. electronic control units for: • Engine management for petrol/gasoline fuel injection • Engine management for diesel fuel injection • Chassis control for brakes and steering • Automatic transmissions Secondly, the electronic infotainment units for: • GPS navigation • Audio (DVD, radio, etc.)

• Instrument clusters To assess the European annual replacement volumes for all these electronic units, Fernand Weiland has based his estimate on known failure rates for engine computers.

“I believe that for electronic control units the total annual European aftermarket yearly replacement demand is approx. 2.5 million units, of which ca. 300.000 units are remanufactured every year,” he says.

“Remanufacturing represents only twelve per cent which is low but I believe that it is growing steadily despite the fact that complexity is a major barrier for remanufacturers.”

For electronic infotainment units the best estimate is an annual European demand of ca. 2.4 million units. The share of remanufacturing units is ca. 400.000 or 17 per cent of the total demand.

For all product lines total demand is 4.9 million units and the share of remanufacturing is 700.000 units or only 14 per cent. By comparison, the remanufacturing share in the USA is much higher, around 50 per cent! The conclusion for Europe is that remanufacturing has significant room for expansion. “It is, however, difficult to predict because the products are complex and not all companies are keen to develop it,” Weiland says.

Electronics remanufacturing

Blue: New Units Red: Remanufactured products

ReMaTecNews l 31

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marketPLACE ASSOCIATIONS

APRA (office Europe) Neustrasse 8 48653 Coesfeld Germany phone +49 (0)2541 80068-18 info@apra-europe.org www.apra-europe.org

FIRM Rue Vautier, 54 1050 BRUSSELS Belgium phone +32 (0) 498 802740 secretariat@firm-org.eu www.firm-org.eu CLEANING EQUIPMENT

Metalas Cleaning Systems BV James Wattweg 28 3133 KK Vlaardingen The Netherlands phone +31 (0)10 4356036 info@metalas.com www.metalas.com

POWERGENT PEERESS INTERNATIONAL ASSOCIATES 302, Shimizu Bldg., 2-18-20, Shinmachi, Nishi-Ku Osaka, JAPAN #5500013 phone +81 6-6536-6325 info@powergent.net www.powergent.net

Proceco Ltd. 7300 Tellier Street Montreal, QC H1N 3T7 Canada phone: +1 514 254 8494 cleaning@proceco.com www.proceco.com

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CORES

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

R.A.S.E.D. S.p.A. Spaco Diesel Via Padova 183 20127 Milano Italy phone +39 022722161 info@rased.it www.spacodiesel.com www.rased.it

INFORMATION For more information please contact Eva Barten, phone +31 (0)20-5042800 advertising@rematecnews.com www.rematecnews.com

REMANUFACTURED PRODUCTS

ERA Benelux Drieslaan 78 B-8560 Gullegem Belgium phone +32 56 439300 info@erabenelux.be www.erabenelux.be

Wah Seng Industry Sdn. Bhd. 22 Jalan Industri Beringin 14100 Juru Industry Park S.P.T. Penang Malaysia phone +6 04 5079982 marketing@wahseng.com www.wahseng.com

• Cleaning equipment • Consultancy - Research • Cores • Environmental products • Lubricants - Chemicals • Organisations - Associations • Parts for remanufacturers • Production equipment • Remanufactured products • Test equipment Rates 2012 1 placement 1 160 5 placements 1 695

Alto Europe BV Marconistraat 2a 7442 DD Nijverdal The Netherlands phone +31 (0)6 10432191 rudy.cents@altousa.com www.altousa.com

TEST EQUIPMENT

S.D.A. Im-Export BV Duizeldonksestraat 7 5705 CA Helmond The Netherlands phone +31 (0)492 524463 Info@sdaim-export.nl www.sdaim-export.nl

Auto-Matic C/ Laguna 20 (Pol.Ind.Urtinsa II) 28923 Alcorcón Madrid Spain phone +34 91 644 44 22 auto-matic@auto-matic.es www.auto-matic.es

Van Der Star Bvba

Dynostar Hogerwerf 15 4707 RV Roosendaal The Netherlands phone +31-165521336 info@dynostar.com www.dynostar.com

TRANSMISSION PARTS

Van Der Star Bvba Ind. Leuerbroek 1094 B-3640 Kinrooi Belgium phone +32 (0)89 703657 vanderstarbvba@msn.com www.vanderstarbvba.com

A.E.S. Auto Electric Service BV Cannenburgerweg 59c 1244 RH Ankeveen The Netherlands phone +31 (0)35 6563444 info@aes.nl www.aes.nl

Gobbi Spare Parts Srl Via Capannaguzzo, 3681-47521 Macerone di Cesena (FC) Italy phone +39 0547 3111346 info@gobbisp.com www.gobbisp.com

BU DRIVE GmbH Friedrich-Ebert-Str. 129 49811 Lingen/Ems Germany phone +49 (0)591 71050 info@bu-drive.com www.bu-drive.com

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

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NEWS FROM OTHER ORGANISATONS

ReMaTec to exhibit at AAPEX 2012 Thanks to strong interest from remanufacturer and supplier members of the Motor & Equipment Remanufacturers Association (MERA), the MERA portion of the Automotive Aftermarket Products Exposition (AAPEX) 2012 Remanufacturing Section is sold out. Among the exhibitors at the 8,000 square-foot remanufacturing section on the main show floor will be ReMaTec2013/ReMaTecNews.

MERA and the Automotive Aftermarket Industry Association (AAIA) Engine Rebuilders

New president at AERA The US Engine Builders Association (AERA) has named Paul Hauglie president of the association with effect from August 12. He succeeds John Goodman who led AERA through a period of expansion since 2002 and retired earlier in the year. Hauglie comes to Illinoisbased AERA after 16 years with Melling Engine Parts where he rose from customer service rep to sales manager for North Eastern USA and Canada. “I have a big heart for engine builders and really believe in the job they do,” Hauglie says. “My goal is for them to be as successful as possible and to have AERA be a big part of that success. I believe my experience from the manufacturing side will serve a springboard to bring AERA to a prominent, positive fixture in the automotive aftermarket.” A father of three, Hauglie has a Bachelor of Science degree in public relations from Western Michigan University.

Bovag in major drive Bovag Revisiebedrijven, the reman section of the Dutch trade association for automotive suppliers and garages, is organizing a major promotion for remanufacturing in the autumn. On October 6, the 90 members of the engine reman section will host ‘Open Days’ in their plants across Holland. The nationwide event is expected to attract a significant number of visitors to workshops, plants and other reman-related facilities.

Concurrently, Bovag Revisiebedrijven, is issuing a number of videos designed to inform professionals in the automotive industry and in the offshore, agriculture and marine segment as well as consumers in the benefits of remanufacturing. They are also aimed at some other organisations like Innovam, the knowledge and training centre for the Dutch mobility industry.

SMMT goes to Automechanika

John Chalifoux, President and COO of MERA.

Council (ERC) will co-host the section which will be open from October 30 to Nov.1.

The following MERA members will exhibit in the area: Boles Parts Supply, Electronics Remanufacturing Company, ETE Reman, Flight Systems Electronics Group, GB Remanufacturing, Knopf Automotive, LKQ, MCI Cores, Phoenix Automotive Cores, Rebuilders Automotive Supply, Remy International, Undercar Express, USA Industries and Wabco Reman Solutions.

In addition, MERA will host an exhibit highlighting the environmental, economic and product performance benefits of remanufacturing.

“MERA and its members look forward to promoting the benefits of remanufacturing before the more than 125,000 aftermarket professionals that participate in AAPEX and Automotive Aftermarket Industry Week,” says John Chalifoux, president and COO of MERA.

UKs influential SMMT, (The Society of Motor Manufacturers and Traders), in London is taking a UK Delegation to exhibit at the Automechanika Shanghai show this year. The event, which takes place from December 11 to December 14, is growing year on year with an increasing presence from international companies and an increasing number of international pavilions, including a remanufacturing pavilion.

US senator to open reman conference U.S. Senator Debbie Stabenow from Michigan will speak about promoting green manufacturing during a remanufacturing and sustainability conference in Troy, Michigan, on October 2. The conference will be co-hosted by the Motor & Equipment Remanufacturers Association (MERA and the Golisano Institute for Sustainability at the Rochester Institute of Technology. As Chair of the Senate Agriculture Committee and a member of the Senate Energy, Finance, and Budget Committees, Debbie Stabenow plays a key role in shaping official US manufacturing, health care, and agriculture policies. The conference, ‘Remanufacturing and the Sustainable Organization’, links remanufacturing with organisations’ overall sustainability strategies. It will highlight how remanufacturing helps companies meet their sustainability goals at a time when green products can be critical or have valuable incentives, the organisers say.

Hannie Tak, Manager, Bovag Revisiebedrijven.

“The objective is to promote the industry to the automotive trade and consumers and place remanufacturing on the map,” says Hannie Tak, Manager, Bovag Revisiebedrijven.

“We believe that too many consumers are unaware of the value of remanufactured products and that a great deal can be achieved if they become more familiar with the benefits in terms of the environment and economic.”

In a parallel initiative Bovag Revisiebedrijven, is organizing a visit to Opel’s Insignia factory in Rüsselsheim, Germany, on October 13 for its remanufacturing membership. The group will learn about Opels’s car manufacturing activities and be taken for a guided tour of the plant. “This provides the participants with an excellent opportunity for networking and gaining new knowledge,” Hannie Tak says.

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For further news about APRA Europe, please visit www.apra-europe.org

APRA Europe

NEWS Convergence at the Bayreuth summit Over the years I have, of course, realised that remanufacturers from different countries have different habits and different values.

However, when discussing remanufacturing they all share basically the same views and objectives and have the same conceptions of remanufacturing.

One other observation is that, thanks to the new communication technologies and the English language that we all share, remanufacturers have converged significantly and now rarely appear distrustful of each other. This is particularly encouraging and I can only recommend to my international colleagues and fellow APRA board members that we strengthen our international rela-

tions. As proved at our events in Krakow and Shanghai over the past year, the A in APRA does NOT stand for ‘America’. APRA is a truly global organisation.

Nevertheless, regional parochialism is unfortunately still present - at least in some areas. To me this is cause for some concern at a time when there are brilliant opportunities for coming together in a common global strategy - in support of a greener - and cleaner - earth and a better environment. To act multi-laterally and on a multi-national basis should not be a difficult task for any of us. All we have to do is to walk the talk.

Within this context I welcome the World Remanufacturing Summit in Bayreuth, Ger-

By Fernand Weiland, Vice-Chairman of APRA Europe

many, in September. Congratulations, therefore to Dr. Nabil Nasr of Rochester Institute of Technology in the US; Professor Rolf Steinhilper of University of Bayreuth, Germany, Professor Zhu Sheng of China’s National Key Laboratory and William Schwarck, the Editorin-Chief of ReMaTecNews, for organising the global reman summit on September 3 and 4.

This high level event will promote and encourage a global sense of sharing and convergence within the remanufacturing industry.

So, I look forward seeing you in Bayreuth!

Valeo opens reman plant to APRA As part of APRA’s annual seminar and exhibition, which took place in Krakow, Poland, on April 23-24, Valeo opened its doors to 60 APRA members on its reman operation in Czechowice. With an output of around 1 million units per annum, the Czechowice plant,

with a workforce of 360 people, is a highly efficient and ultra-modern production site which lies at the heart of the French giant’s remanufacturing activities.

On behalf of the hosts, Francois de Ribet, Valeo Electrical Systems Aftermarket

APRA vistors to Valeo Remanufacturing in Czechowice (Poland).

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Director explained that Valeo employs 68,000 people at 121 sites worldwide and has a turnover of 10.9 billion euros. Enjoyed by everyone, the visit was very informative and APRA is grateful for the opportunity to have visited this unique remanufacturing site.

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APRA at reman forum & exhibition in Beijing The 2nd China Remanufacturing International Forum 2012, organised

by China’s National Key Laboratory will take place on 19, 20 and 21 September at the Beijing Continental Grand Hotel. The event will kick off with a meeting between scientists and engineers from China and Poland after which the forum will open to everyone on September 20 and 21.

The language of the forum and its presentations will be English, with simultaneous interpretation provided. At the same time and at the same venue, the China Reman Exhibition will be co-organised by Duxes Business Consulting Inc. and be directed by the National Development and Reform Commission and the Ministry of Industry and Information Technology, the two most important Chinese remanufacturing ministries. APRA representatives will speak at the forum and APRA will have a booth at the exhibition.

For forum registration or an exhibition booth rental, please visit www.duxes-events.com/reman

New members APRA Europe welcomes the following new members: Patrimons Automotiv Bojan Krga, Belgrade, SERBIA www.patrimonsauto.rs Turbo-Tec Sp. z o.o. Łukasz Leszczawski, Jaworzno, POLAND www.turbo-tec.eu

APRA applauds European strategic alliance On June 26, 2012 a joint announcement was made by the European Division of the Automotive Parts Remanufacturers Association (APRA) and the International Association of Engine Rebuilders & Remanufacturers (FIRM) about a strategic alliance between them.

According to representatives of both associations this strategic alliance will work cooperatively toward a more sustainable automotive aftermarket, promote the automotive parts remanufacturing industry in Europe and represent and lobby on behalf of the industry in Brussels, Belgium.

FIRM and APRA represent over 22,000 remanufacturing employees in the European Union.

APRA President, Bill Gager, stated: “We congratulate both associations for developing this strategic alliance. This cooperative effort will be beneficial to the entire membership and the end consumers.”

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NEWS

By Volker Schittenhelm, Head of Information, FIRM

Remanufacturing – leaving a shadowy past well behind Current discussions, strategies and activities on the part of governments as well as from inside the automotive industry often focus on concepts like sustainability, environmental protection, CO footprint, energy saving, recycling, waste management and much else. ² Concurrently, facts & figures for the EU, as prepared by CLEPA’s working group, will soon be published. Emphasising the impact of remanufacturing these figures will, amongst others, cover turnover, CO2 footprint and workforce numbers in the remanufacturing industry.

Remanufacturing as the ultimate form of recycling is clearly emerging from its somewhat shadowy existence of the past.

level of remanufacturing in the world’s biggest reman market is considerably better established than in Europe. In the US, we have, in fact, a so-called ‘pull’ effect in the market where customers actually demand remanufactured products. This, sadly, is far removed from Europe’s ‘push’ strategy where we have to actively promote our products and services to our customers – the workshops and the part dealers - to convince them of the

Especially over the past five years there has been a significant, if not spectacular, increase in the interest shown by politicians, associations and industry players across Europe. Brussels’ strategy Europe 2020 will further help us to strengthen general awareness of remanufacturing as a brand.

What, then, about other parts of the world? What, for instance, about North America? The knowledge and acceptance

benefits of reman. By contrast, our American colleagues have left this behind them and are therefore able to focus on the political level.

Not only are reman associations such as APRA, AERA, MERA, PERA well established in the market; their contact with the world of politics is efficient and fruitful. And the results show. Let’s take a recent example: The Fiscal Year 2013 Budget of the State of Michigan (USA) has passed a law on the

36 l ReMaTecNews

prioritized use of remanufactured parts in the state motor vehicle fleet through September 30, 2013.

Congratulations to our colleagues on the other side of the ocean!

Europe is well behind in this respect and we have yet to achieve what you have achieved. Nevertheless, the European reman associations FIRM, APRA and Clepa are also working on it.

And China? Everyone in our industry is monitoring developments here, not least because China is the only nation which has incorporated remanufacturing in its official agenda. In the US and in Europe, both OEMs and the IAM have numerous questions concerning China in respect of legal imports and exports, technical and core management issues as well as market independency. To be honest, however, most of us see the main question as this: China – Threat or Opportunity?

We don’t know the answer yet. But those that are seeking the answer could do worse than attend the increasing number of summits and conferences in China – two, three or even four a year.

In September, however, two important events will also certainly help with some answers: First is the ‘World Reman Summit’ in Bayreuth, organised by the University of Bayreuth, with ReMaTecNews as the media partner. A veritable ‘who-is-who’ in the global reman industry will meet in Bayreuth on 2-4 September. FIRM will be present – what about you?

The second event, of course, is Automechanika 2012 from 11th to 16th of September. More than ever, the show will be a platform for remanufacturing! Come and visit and attend FIRM’s General Assembly which will be held during the show.

e r

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General Assembly of FIRM Also don’t miss the general assembly of FIRM on Friday September 14th, during the Automechanika, the first one after the recent extraordinary meeting in Istanbul. Share activities, successful projects and new ideas with your international colleagues. Be informed about the latest activities for members’ benefits and be an active part of the decisions regarding our new membership campaign. Help to establish a standardised engine reman process and be involved with the next fruitful steps in our new strategic alliance with APRA’s European Division and with the reman activities of the aftermarket division of CLEPA, the European Association of Automotive Suppliers.

We recommend that you make your travel and hotel arrangements very soon.

Details will be sent out by our Brussels office and Filippo Marino.

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INTERNATIONAL EVENTS & TRADE FAIRS 01.09.2012-09.09.2012 CDMS - Chengdu Motor Show - International Exhibition for Automobile and Accessories Chengdu (China (PR)) 03.09.2012 Remanufacturer of the Year Award 2012 ReMaTecNews’ annual reman award University of Bayreuth Bavaria (Germany) 03.09.2012-04.09.2012 World Remanufacturing Summit University of Bayreuth Bavaria (Germany) 11.09.2012-16.09.2012 Automechanika - Trade Fair for the Automotive Industry Frankfurt.Main (Germany) 13.09.2012-16.09.2012 AUTOSHOW NITRA - International Exhibition for Passenger and Commercial Vehicles and Accessories Nitra (Slovakia)

38 l ReMaTecNews

18.09.2012-20.09.2012 Automotive Testing Expo China Shanghai (China (PR)) 20.09.2012-27.09.2012 IAA Nutzfahrzeuge - International Motor Show Commercial Vehicles Hanover (Germany) 22.09.2012-24.09.2012 TRUCK WORLD - China (Jinan) International Truck & Accessory Exhibition Jinan (China (PR)) 26.09.2012-30.09.2012 Vietnam Motor Show Ho Chi Minh City (Vietnam) 27.09.2012-30.09.2012 AUTOMARKET - Autosalon - Automotive Exhibition Kishniev (Moldova) 29.09.2012-07.10.2012 Salon des Véhicules de Loisirs - Leisure Vehicles Exhibition Paris (France)

29.09.2012-14.10.2012 Mondial de l’Automobile - International Paris Motor Show Paris (France) 05.10.2012-07.10.2012 AUTOCLASSICO - International Classic and Vintage Automobile and Motorcycle Exhibition Porto (Portugal) 05.10.2012-07.10.2012 AUTOSALON.AUTOSERWIS - International Car Fair Katowice (Poland) 10.10.2012-12.10.2012 TIR Truck International Review - International Show of Trucks and Commercial Vehicles Kiev (Ukraine) 23.10.2012-25.10-2012 parts2clean exhibition International Trade Fair for industrial parts and surface cleaning Stuttgart (Germany)

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ReMaTecNews REMANUFACTURING INTERNATIONAL

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