ReMaTecNews | edition 5 2014

REMANUFACTURING INTERNATIONAL

SEPTEMBER/OCTOBER 2014 | NO 5 | VOLUME 14

A new era in Vegas: BigR/ReMaTecUSA

Hamid Mughal: Huge future for reman

3D Printing: The next big thing?

Borg’s Søren Toft: The prospects are bright www.rematecnews.com

Exhibitions Las Vegas BigR/ReMaTecUSA I November 1-3 I Booth M121 AAPEX I November 4-6 I Booth 4267

In the first week of November Pos Service Holland will be exhibiting at Big-R ReMaTec and AAPEX in Las Vegas.

Besides starter motors, alternators and cores, PSH will introduce and demonstrate the testers of the brand Motoplat.

We will also unveil the newest addition to the brand: the Motoplat CV-411 alternator test bench. The famous Motoplat test bench with the newest testing technology.

For more information, please visit our websites: WWW.PSH.NL I WWW.MOTOPLAT.NL

POS SERVICE HOLLAND T: +31 (0)35 656 3180 I E: PSH@PSH.NL I WWW.PSH.NL

BigR/ReMaTecUSA Rio All-Suite Hotel & Casino Nov 1 I 01.00 p.m. - 05.00 p.m.

Nov 2 I 11.00 a.m. - 05.00 p.m.

Nov 3 I 09.00 a.m. - 01.00 p.m. www.bigrrematecusa.com

AAPEX Sands Expo Nov 4 I 09.00 p.m. - 05.00 p.m.

Nov 5 I 09.00 p.m. - 05.00 p.m.

Nov 6 I 09.00 p.m. - 05.00 p.m. www.aapexshow.com/

CONTENTS

ReMaTecNews | 3

10 | Rolls Royce – reman is a key part of the future

12 | BigR/ReMaTecUSA: Top reman show in 2014

18 | 3D printing – opportunities for remanufacturers

Hamid Mughal is Managing Director, Production, at Rolls Royce, the engineering and technology giant.

He is also a strong proponent of remanufacturing.

He sees reman as an important part of the legendary company’s future – and the world’s.

Hamid Mughal has given a special interview to ReMaTecNews

The BigR/ReMaTecUSA show in early November is set to become the remanufacturing event of the year. With more international visitors, larger floor space and more activities, the revitalised, annual reman exhibition in Las Vegas is exceeding all expectations.

The rapidly increasing use of 3D – or additive manufacturing – enables manufacturers to produce high performance parts cheaper and faster than any traditional methods. These recent technologies have obvious implications for remanufacturers. We outline some of them.

“New materials and manufacturing processes will reshape auto manufacturers and Page 26 suppliers” Bill Ford, Chairman, Ford Motor

www.rematecnews.com

Editorial

4

Meritor disposes of reman subsidiary

7

Borg Automotive: Reman’s strengths

22

Consumer survey - 'Dirty' and 'disgusting'

24

Bill Ford on the motor industry’s future

26

Ex-UK minister: More remanufacturing

29

New products

33

Transmission World

37

APRA News

38

FIRM News

41

International exhibitions and events

42

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

EDITOR’S LETTER

ReMaTecNews | 4

ReMaTecNews Sep/Oct 2014 | Number 5 | Volume 14 ReMaTecNews, the only international news m ­ agazine and website dedicated to automotive and heavy duty remanufacturing worldwide, is an independent channel for news, views and d ­ evelopments within the r­ emanufacturing industry.

Published by Amsterdam RAI B.V. P.O. Box 77777 1070 MS Amsterdam The Netherlands In association with

Hang together or hang separately?

By tradition, autumn is the busiest season of the year for remanufacturers and, not least, their organisations and associations. 2014 is no exception. A quick look at the calendar makes it clear that the period from September to December is packed with events of value to automotive and heavy duty remanufacturing.Too many to mention in full, they include Automechanika in Frankfurt, Germany, the 3rd World Remanufacturing Summit and MERA’s Reman Conference, both in Rochester, New York, towards the end of September. Other high-value events are the revitalised BigR/ReMaTecUSA show in Las Vegas in the first few days of November immediately before the giant SEMA and AAPEX events a mile down the road. As for the latter, MERA’s reman section reports continuing interest from its membership with more exhibitors and larger floor space. In December, China becomes the next centre of attention with a number of conferences.

Different events. Different organisers. Different audiences. All dedicated to the cause of remanufacturing of automotive and heavy duty applications in one way or another. In fact, there are so many that often they seem to compete with each other. Is this good for remanufacturing? – or even for the organisers themselves? In view of the plethora of reman events and initiatives, it’s tempting to raise the question. As a former Chairman of APRA Europe, Fernand Weiland points out in an article on page 38 in this edition, there are many other types of reman beyond automotive and HD. Perhaps the time has come to consider a more common approach to them all.

Equally, on page 29 British MP Caroline Spelman, a former Minister of the Environment in the UK government, calls for a more concerted effort on reman on behalf of her own country and in Europe in general. As a somewhat off-beat footnote, a research report from Penn State University in Pennsylvania (Page 24) claims that remanufacturing is seen as “dirty and disgusting” by some consumers – an impediment to reman’s acceptance across the board. It all indicates a growing need for reman associations to work closer together to spread the message of reman as an important solution to some of society’s ills, resource scarcity, CO2 emissions, job losses, when businesses relocate production to low-cost countries. And, once again, to prove the truism that remanufactured parts are “as good as new – or better.”

As an old English saying has it: Hang together – or hang separately.

Editor-in-Chief William Schwarck Phone +33 49 34 02 108 editorial@ReMaTecnews.com Marketing Communications & PR Eva Barten Phone +31 (0)20 549 13 75 e.barten@rai.nl Advertising Sales Ewoud Barink Phone +31 (0)20 549 14 31 Fax +31 (0)20 549 18 89 advertising@ReMaTecnews.com Publisher Niels Klarenbeek (responsible under Dutch Press Law) n.klarenbeek@rai.nl Production & Artwork Maaike van Dijk Phone +31 (0)20 549 16 53 m.v.dijk@rai.nl Design Jenb, Graphic design, Hilversum, The Netherlands www.jenb-online.nl Printing SDA Print + Media Copyright Amsterdam RAI, Amsterdam, The Netherlands Reproduction Permitted, providing ReMaTecNews is credited Subscription magazine and e-newsletter www.ReMaTecnews.com Change of address E-mail info@ReMaTecnews.com Website / ReMaTecNews magazine online www.ReMaTecnews.com Circulation Approx.13,500 readers per edition. The magazine is ­delivered on a controlled circulation basis to ­recipients in Western Europe, Eastern Europe, Africa, North America, South America and Asia.

Reman associations, please, take note.

Follow ReMaTecNews on social media

William Schwarck, Editor-in-Chief

NEWS FROM THE INDUSTRY

ReMaTecNews | 5

BBB to sell to private equity firm BBB, one of America’s largest remanufacturers of starters and alternators, brake calipers and steering pumps, is about to have new ownership. With effect from the fourth quarter 2014 the long-standing family firm in Mobile, Alabama, will be acquired by Pamplona Capital Partners, a large private equity firm.

Founded in 1987 BBB services both warehouse distributors and retailers with an extensive portfolio of 20,000 SKUs. Over the past few years, BBB has experienced significant growth, driven by expansion into new products and strategic acquisitions. The company operates, state-ofthe-art remanufacturing facilities in Reynosa, Mexico, and Sparta, Tenn. BBB’s chief executive, Joe Felicelli told Babcox Aftermarket News: “We are delighted to be partnering with Pamplona.

We have worked hard over a number of years to position ourselves as an industry leader with a broad product offering and a reputation for being the solution provider for our customers.

Under Pamplona’s ownership, we will continue to provide our customers with high-quality products and an excellent distribution service, but most importantly, we will continue our commitment of supporting the growth of our customers.”

Significant opportunities Martin Schwab, the partner at Pamplona leading the transaction, commented, “BBB is an excellent business and we are delighted to be partnering with an exceptional management team that has grown the company significantly over the past few years. Pamplona will work with management to accelerate the company’s growth ambitions by providing long-term financial and strategic support. We believe there are significant opportunities to grow both organically and through acquisition and are excited to be part of the business going forward.” The transaction is expected to be completed during the fourth quarter of 2014. BBB’s customers include a broad range of well-known names such as NAPA, Ford, Carquest, Chrysler and O’Reilly Auto Parts. n

BBB’s plant in Reynosa, Mexico

 Regeneration compressors sale of spare parts

AIRCO A/C             @

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Litens190mmx133mm 7/8/14 7:45 AM Page 1

Decoupler Science

by Litens

Are you using the CORRECT alternator pulley?

Over 60 million vehicles worldwide are now factory-equipped with a Litens Overrunning Alternator Decoupler (OAD) pulley rather than a conventional solid or one-way clutch pulley. An OAD’s primary function is to reduce the noise, vibration and harshness common with today’s lean engine designs, while improving fuel efficiency and lowering the risk of premature accessory drive component failures.

An OAD is similar in appearance to other pulley designs, but its patented internal decoupling system plays a vital role in synchronizing the belt drive system. When replacing an OAD-equipped alternator pulley, the only acceptable choice is another OAD unit.

In future issues, we will explore various topics relating to OADs such as: function, benefits, failure diagnosis, replacement rates, etc.

www.decouplerpulley.com

NEWS FROM THE INDUSTRY

ReMaTecNews | 7

Meritor to dispose of Mascot brand Meritor, one of America’s leading remanufacturers, has decided to reduce its exposure to remanufacturing. While keeping its existing axle and brake shoe reman business, Meritor has decided to dispose of its well-known Mascot brand.

Acquired by Meritor in 2007, Mascot remanufactures and differentials, transmissions and steering gears primarily for original equipment manufacturers. The disposal will significantly reduce Meritor’s reman operations.

The company does not wish to comment on the decision although rumours about the move have circulated within the industry for some time.

However, the decision by Meritor’s Board has been confirmed in a so-called regulatory filing.

The filing states that Meritor Inc., after completion of a strategic review of certain remanufacturing product lines concluded that the company should exit the Mascot business.

Meritor’s reman facility in Plainsfield, Indiana.

Sale or closure According to the filing Meritor has entered into discussions regarding the sale of all of Mascot’s inventory and other assets. In the event Meritor is unable to execute a sale transaction, it will wind down the Mascot business. The company expects

to incur losses on the sale or liquidation of the Mascot business of approximately $24 million with a further $5 million for employee costs and other charges. A deadline for the sale or closure has been set for the fourth quarter of 2014. n

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ReMaTecNews | 9

Official opening of ARTC in Singapore Following two years of construction Singapore’s Advanced Remanufacturing & Technology Centre ARTC, has announced the opening of its new HQ, one of Asia’s leading technology centres. ARTC is part of the Singaporean government’s Agency for Science, Technology and Research (A*STAR).

The official opening will take place on January 28, 2015 with Singapore’s S Iswaran, Minister, Prime

Minister’s Office, Second Minister for Trade and Industry and Second Minister for Home Affairs as guest of honour. ARTC’s home in the new CleanTech 2 Building provides the Centre with 7200 sq.m. with ultra-modern offices, workshops, laboratories and state-of-the-art tools and technologies and “everything that’s needed for its manufacturing and remanufacturing objectives.”

“This will be one of the most significant moments for ARTC,” says David Low, ARTC’s Director. n

ARTC’s David Low

“For sale” sign above Transtar Transtar Industries, the American distributor of replacement and remanufactured parts, is up for sale reports the international news agency Reuters. The agency says that Transtar’s owners, the private equity firm Friedman Fleischer & Lowe, expects to receive 1 billion dollars for the company.

Based in Walton Hills, Ohio, Transtar distributes

driveline replacement parts, kits and components used in transmission repairs. It has about 2,300 employees and more than 130 locations throughout North America. Transtar Industries is a prominent supplier transmission and drivetrainrelated solutions and an active player in the market for remanufactured transmission parts. Its reman range includes remanufactured transmissions,

remanufactured torque converters, transmission rebuild kits and a number of other reman units.

Founded in 1975 in Cleveland, Ohio, Transtar operates a network of more than one hundred locations in the US and Canada and supplies in more than 80 countries across the world. n

ReMaTecNews | 10

The exciting future of reman

Hamid Mughal

By William Schwarck From a commanding position at the top of one of the world’s legendary engineering companies, the view extends well into the second half of the century, encompassing some major technological advances in which remanufacturing plays a very considerable role.

The company is Rolls-Royce, one of the most famous names in engineering. And the vantage point is occupied by Dr. Hamid Mughal, the Director of Global Manufacturing and the man responsible for all manufacturing activities and strategies at this huge engineering-to-aircraft group. For decades, RR has been involved in various types of remanufacturing and Hamid Mughal has every intention of continuing this strong track record - not just within the Rolls Royce Group but in manufacturing across the world.

“Remanufacturing has so many advantages,” he says during a conversation with ReMaTecNews.

“I find remanufacturing fascinating and I believe that reman will become even more important

as the world moves towards greener production and a greater focus on the preservation of raw materials.” According to Dr Mughal, one of the three key drivers in the future development of manufacturing is the narrowing gap between mass production and flexible, adaptable manufacturing.

The second driver lies with the trend towards segregated supply chains as customers exert an ever-greater influence on design. And the third key factor, in Hamid Mughal’s view, is sustainable manufacturing.

It would appear that remanufacturing is almost evolving from the Stone Age into the high-tech era in one generation.

“There are lots of reasons why this is taking place. Deep technologies are coming together and maturing roughly at the same time. Data acquisition and data processing will become important because a lot will depend on how fast we can process in real time. Sensor technologies, powder-based technologies, adaptive technologies; integrating technologies are all roughly maturing simultaneously.

“Resources, the price of energy and the conversion of raw material into finished products will become a lot more expensive.” “There are logistics costs, disposal costs, costs associated with environmental considerations, with regulations and with the emotional attachment to the environment,” he says. “Economic reality will force a change in manufacturing to the point where end-of-life for products will almost become start-of-life for the second phase.

“(A) wonderful future - both for original equipment and for remanufacturing.”

As companies develop methods and technologies, they will take end-of-life products and transform them into as good as new products at 50% or 60% less cost than the original equipment.”

Add to that the environmental pressures, the scarcity of resources, the cost of energy, the globalisation of manufacturing and the intensity

ReMaTecNews | 11

of manufacturing when we are consuming a lot more resources here than, quite frankly, the earth can sustain in the long term. So if you bring all these factors together it shouldn’t surprise anyone why remanufacturing is suddenly accelerating both in terms of need, in terms of opportunity and, I would say, in terms of intellectual challenge.”

Would you say that the industry is entering a golden age?

“An eighteen-month study on the future of remanufacturing that I worked on with eight colleagues and the Department of Business and Innovation in the UK concluded that the future is very exciting. The next 50-60 years will be the golden age of manufacturing because over the past three to four decades the evolution of manufacturing has been gradual, almost like in computing where in the 60s and 70s we had the mainframes and then suddenly in the 90s, it all accelerated.

“People will take pride in, buying and acquiring products that have already been used” “I think the same is roughly going to happen to manufacturing over the next 30 to 40 years because a number of technologies have been simmering away just below the surface and now environmental requirements and the cost of

disposal, plus cost of processing, cost of resources and everything else will accelerate the deployment of those technologies and create exciting opportunities both for original manufacturing and also for remanufacturing. It all provides wonderful opportunities. I think that over the next forty, fifty or even sixty years, the whole low carbon economy will be worth trillions of dollars, and remanufacturing will be a major component of that.

“It’s an exciting phase for Europe and the advanced countries because what they have is innovation and if they deploy that innovation successfully and export it to countries like Singapore and others as well, they can take advantage of this wonderful future - both for original equipment and for remanufacturing.”

Do you think that the public in general or your customers have the correct perception of remanufactured products, including that the industry has been established for many years? For example, people often say that they don’t want a repair job, or second-hand equipment: they want new. Is a problem for the industry?

Again I won’t comment on my own company because we supply to very good sophisticated businesses that understand this. But I don’t think it’s largely understood by society yet.

Remanufacturing is not a common concept but it will become so increasingly. I suspect that society will demand, and people will take pride in, buying and acquiring products that have already been used because there will be a commitment to safeguarding the environment associated with it.

And I think the trend has already started.” n

In terms of your own company, Rolls Royce, how important is remanufacturing?

I will not say too much about my specific company because much of what I have to say is quite generic. However, a company like Rolls Royce has been dedicated to repair and revalidation in our business for a long time. Don’t forget that our products, particularly in the aerospace sector, have operated for 30 years.

“But half of our revenue in the aviation sector derives from services, and a big component of that service is repair and overhaul so we have very good joint ventures with our partners in Singapore and America and elsewhere as part of which we bring products back to the base, strip them down and assemble them after having repaired, cleaned or replaced components that are worn out. We have a very high competence in this area and we will improve further going forward.”

Dr Hamid Mughal Hamid Mughal has over 28 years of experience in the automotive and aerospace industries. During this period he has held senior positions in a variety of disciplines ranging from product engineering to supply chain management. He joined Rolls-Royce in 2001 from BMW Group where he was Director of New Product Programmes. As Director of Global Manufacturing, Hamid Mughal is responsible for Rolls Royce’s manufacturing activities and strategies, including the development and deployment of lean practices and behaviours, methods, standards and technologies. He is also responsible for development of the company’s manufacturing professionals.

Hamid Mughal has an Honours degree in Mechanical Engineering, BA in Mathematics and Technology, MSc. in Production Engineering & Management and a Doctorate in Manufacturing Systems. He closely follows developments within the field of Manufacturing and Supply Chain Management and contributes regularly to professional bodies in his capacity as Pro Chancellor of the University of Nottingham and External Professor at Cranfield and Sheffield Universities. He is a Chartered Engineer, winner of the IET’s International Manufacturing Gold Medal, Fellow of Royal Academy of Engineering.

Outside his professional expertise Hamid Mughal takes a wide interest in music, swimming, cricket, travelling and Manchester United.

Manufacturing - great achievement ahead

BigR/ReMaTecUSA 2014

ReMaTecNews | 12

BigR/ReMaTecUSA: A fresh start

For a decade or more, APRA’s Big R show in Las Vegas has been the meeting place for remanufacturers and reman suppliers worldwide in America. The BigR suffix remains as does the Automotive Parts Remanufacturers Association’s involvement in the show. That aside, everything else about the 2014 event from November 1-3 is new.

This goes for the venue, the Rio Hotel and Convention Center, with its 40,000 sq. ft. newly laid exhibition floor. It goes for the record number of foreign exhibitors that have signed up for booths. It’s the case with regard to new exhibitors - 35. It applies to the extensive programme of technical and marketing sessions in the new ReMaTecTheatre. In particular, it goes for the new co-organiser Amsterdam RAI, one of Europe’s leading conference and exhibition organisers, owner of the large RAI conference centre in Amsterdam, the Netherlands – and organiser of the biennial ReMaTec reman shows in the city.

Having acquired the ReMaTec concept from its Scandinavian founders in 2003, Amsterdam has built the European show into what it is today – the world’s leading exhibition for automotive and heavy duty remanufacturing.

“And now, together with APRA, our partner in Europe for the past ten years, the ambition is to do the same in the US,” says Show Manager Niels Klarenbeek, Amsterdam RAI. “We believe that remanufacturing is a growth industry worldwide and we’re excited about the opportunities in the US. By bringing in Amsterdam RAI’s experience

from organising shows around the world, I’m confident that we’ll bring a spirit of innovation to what used to be the Big R and now is BigR/ReMaTecUSA.” The preparations have been extensive, Klarenbeek says. Numerous hurdles have had to be overcome, legal, cultural, administrative as well as practical - inevitable when two organisations from both sides of the Atlantic decide to pool their resources.“It has not always been totally easy, but the interest shown by the remanufacturing community from all parts of the world has been encouraging and stimulating during the whole process. I’m glad to say that, in view of the positive response we’ve received since we announced the decision to launch a revitalised reman show in Las Vegas, we’re genuinely looking forward to November.”

For APRA Chairman and President, Joe Kripli, expectations are also high. Whilst relinquishing the position of Chairman during APRA’s annual meeting during the show, Kripli, currently the Global Business Development leader of Wabco Reman and one of remanufacturing’s veterans, will remain president of the organisation for the next few years. Since its inception, he has been instrumental in forming the new BigR/ ReMaTecUSA.“The automotive remanufacturing industry stands at a crossroads,” Kripli told ReMaTecNews. “Interest in reman and acceptance of its benefits is rising across the world and the time has never been better for the industry to come together in all its forms. The new BigR/ ReMaTecUSA clearly provides remanufacturers from across the world with the opportunity to come together and for APRA to demonstrate

the value that we, as an association, bring to its members.” The 2014 BigR/ReMaTecUSA show is open from November 1 to November 3 at the RIO All-Suites Hotel & Casino, Las Vegas, Nevada. For details about BigR/ReMaTecUSA, visit www.bigrrematecusa.com. n

BigR/ReMaTecUSA in brief: • • • • • • • • • •

More than 100 exhibitors More than 35 first-time exhibitors Exhibitors from over 15 countries Over 900 hotel rooms booked at the RIO 17 technical sessions at ReMaTec Theatre 1 ReMaTecNews Remanufacturer of the Year Award ceremony 8 international trade delegations expected Opening reception with up to 400 attendees Strong programme for APRA seminars and the ReMaTec Theatre Largest APRA convention in years

Niels Klarenbeek and Joe Kripli

BigR/ReMaTecUSA 2014

US government puts blue stamp on BigR/ReMaTecUSA For the first time, the American government, in the shape of its business arm, US Commercial Services, is acknowledging the value of remanufacturing exhibitions.

The honour goes to the ReMaTec concept where BigR/ReMaTecUSA and next year’s ReMaTec show in Amsterdam, the Netherlands, will both be part of the Service’s official IBP program. IBP, the name stands for International Buyers Program, and entitles qualifying trade exhibitions to full support from US Commercial Service embassies and representative offices around the world.

As a result US embassies will be organizing delegations to BigR/ReMaTecUSA from Peru, Brazil, The Netherlands, Spain, Slovenia and Romania. Moreover, at the time of writing, the US embassy in London is looking actively into the potential for facilitating a UK delegation to the show.

The embassies’ package to prospective participants in these missions includes entry to the show and its co-located ATRA Powertrain

show for the transmission industry, matchmaking sessions and an industry breakfast. Entry to the two huge AAPEX/SEMA automotive shows that run immediately following BigR/ReMaTecUSA is also included. Moreover, Commercial Services will organize an export seminar for exhibitors aiming at expanding international sales.

“We’re genuinely pleased with the Department of Commerce’s acknowledgement of the opportunities and benefits of the automotive and heavy duty remanufacturing industries,” says Exhibition Manager Niels Klarenbeek, Amsterdam RAI, which co-organises BigR/ReMaTecUSA with APRA, the Automotive Parts Remanufcturers Association. “ This means that the US reman industry will receive important support from the US government and its network of commercial specialists at US embassies around the world. It also means that BigR/ReMaTecUSA exhibitors can expect greater international attendance then they were used to in the past.” n

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New exhibitors •. Emmetec - Italy •. Orpav - Italy •. KTS TurboBillet X - Malaysia •. B&C Truck Electric Services - USA •. PINO Import + Export - Germany •. River City Truck Parts - USA •. TurboTechnics - UK •. Premanus - Italy •. Holonix - Italy •. Tie Kinetix - Netherlands •. BD Electrical - USA •. SKC Karbon - Turkey •. Puente Internatinal Mexico - Mexico •. KARDES Electric - Turkey •. ERC Reman - USA •. CoremanNet - Germany •. Global-sa - USA •. Autoenterprises - UK •. Arrowhead Electrical - USA •. Pos Service Holland - Netherlands •. Pollution Control Products - USA •. Enginedesk – Netherlands •. Euro Car Parts - Australia •. Henkel Corporation - USA •. Kinergo - Lithuania •. Wabco Reman - USA •. Ciona Technologies - USA • New Stream - USA • Global Recovery Corporation - USA • Hastings Manufacturing Corporation -USA

More non-US exhibitors The international flavour of the new BigR/ ReMaTecUSA is proving to be a magnet for foreign exhibitors. Two months ahead of the show in Las Vegas (November 1-3) some 30 exhibitors have already announced their participation and the final count may well exceed this, the organisers believe. While the majority of foreign exhibitors come from Europe, a total of 15 foreign countries from five continents will be represented along the aisles. This amounts to the largest non-US exhibitor attendance for decades, if ever.

The list includes: POS, The Netherlands, Coremanet, Germany, Zen, Brazil, Melett, UK, AT Hydraulic, Lithuania, Euro Car Parts, Australia, Malaysia KTS Turbo Billet, Kinergo, Lithuania.

Naifu, China, Emmetec/Orpav, Italy, Pino Im/ Export Germany, Auto Enterprises, Premanus, Holonix, Tie Kinetixs, Turbo Technics and Engine Desk.

In addition, the list of “first time” exhibitors also exceeds previous years. “We are extremely pleased with the fact that so many exhibitors from around the world are travelling all the way to Vegas to join this event,” said Sales Manager, Ewoud Barink. It confirms that the industry is, indeed, ready for a major, international show in the US and that the remanufacturing industry is taking an optimistic view of the future.” n

Sales Manager Ewoud Barink: 'Extremely pleased'

BigR/ReMaTecUSA 2014

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Pos Service Holland One business using the opportunity to gain stronger exposure in the US market is the Dutch supplier of test equipment and a starters/ alternator specialist, Pos Service Holland (PSH).

Based in ‘s Graveland near by Amsterdam. And with offices in Spain, Belgium, Germany and South Africa, the company has been a significant player in the starter/alternator market for a long time. In recent years, it has also strengthened its focus on test equipment and now wishes to

explore the US market in greater depth. At BigR/ ReMaTecUSA it will, for instance, display its new MotoPlat hand-held or bench top test device for starters and alternators, which PSH has developed in-house. “The MotoPlat is an important step for us and we’re looking forward to launching it in the US,” says Nardo Stremmelaar. “We think the time is right to increase focus on the North American market and feel BigR/ReMaTecUSA is the right platform. n

Nardo Stremmelaar

Kardes - Turkish Delight

Siri Kardes

Turkish manufacturer of brushes and brushholders for more than 50 years, Kardes Elektrik is another first-timer at the show. Having recently opened a Mexican subsidiary, SKC Karbon SA in Monterrey, the company now aims to broaden its activities directed at OE starter/alternator manufacturers and rebuilders in North America. ‘‘Kardes has served customers in the USA for many years, but our objective is now to show

them that we’re a local player in the North American market with good technical support in their native languages - whether English or Spanish,” says owner Sirri Kardes. Participating in PAACE in Mexico City in July, Kardes registered considerable interest in its product line. BigR/ ReMaTecUSA Show will be another excellent opportunity for us,” Sirri Kardes says. n

Melett - British turbo specialist: Supplier to 100 countries Melett is far from inexperienced in world markets. Since 2012, it has operated a US sales & distribution facility, Melett North America Inc., in Memphis, Tennessee and also has subsidiaries in Poland and China. Its target groups and partners range from small turbo repair workshops through to volume turbo remanufacturing facilities.

Back in the UK, Melett is a three times winners of the prestigious UK Queen’s Award for Enterprise in 2006, 2009 and 2014. “Exhibiting at the BigR/ReMaTecUSA show will give us a great

opportunity to speak to existing customers and potential new prospects, and discuss how Melett turbo components can help them produce a quality turbocharger repair,” says Marketing Manager, Victoria Mellor.

“We’re confident that Melett’s highly qualified, in-house team of engineers, together with our knowledge and expertise on the turbo aftermarket and future trends of the industry in general will appeal greatly to the US market.” n Victoria Mellor

CoremanNet - CoremanNet: Heading towards new territory With services ranging from reverse logistics, core identification, assessment and warehousing to accounting and consulting, CoremanNet has established itself as a major new factor in the European core collection market since its inception in 2012. Today the service has spread well beyond the initial partners, Bosch and ZF. By joining the BigR/ReMaTecUSA, Germany-based CoremanNet has its eyes firmly on the US market.

Niklas Appel

“By reducing the complexity of core management, we enable our customers to focus on their distinctive competencies,” says Niklas Appel, a recent recruit to the CoremanNet team. “At the same time, we can exploit the available synergies

and bring cost and resource benefits to all participants. Moreover, we address the common industry issue of making cores available when and where they’re needed. In this way, we’ve become a partner to traders and manufacturers/ remanufacturers in Europe.” In the autumn of 2013, CoremanNet opened a logistics centre in Atlanta, Georgia, offering providers a full service range to the North American market. A locally based network is in the planning stage.“After the strong interest shown by the European industry, CoremanNet is now looking forward to new territories and new customers, bringing the same benefits to the US market as it has done in Europe. n

BigR/ReMaTecUSA 2014

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Honouring distinguished remanufacturers

From left to right: William Schwarck, Chairman of the Jury, last years winner Alan Smart and Doug Wolma, winner in 2012 Since 2005, ReMaTecNews, the trade magazine for automotive and HD remanufacturers across the world, has honoured a remanufacturer/reman company that has made a special effort on behalf of the industry. On November 1, a new name will be added to the list of eminent recipients, when ReMaTecNews names the 2014 Remanufacturer of the Year during the opening reception of the BigR/ReMaTecUSA. The award ceremony will be on the first show day, Saterday November 1 during the opening reception from 05.00 P.M. till 07.00 P.M. “The growing respect for the award over the past decade reflects, I believe, the rising importance

of remanufacturing in general over the past ten years,” said William Schwarck, Editor-in-Chief and Chairman of the award’s Panel of Judges.

“ReMaTecNews is proud of having established the award and the judges look forward to honouring yet another worthy winner. The panel of judges consists of Volker Schittenhelm of FIRM, the European Engine Remanufacturers Association, Fernand Weiland, former Chairman of the European Division of APRA, the Automotive Parts Remanufacturers Association, Doug Wolma, Head of Remanufacturing at DANA Corporation and a board member of MERA, MEMA’s reman division, and William Schwarck, Editor-in-Chief, ReMaTecNews. n

Previous winners are: 2005 - Jens Lindholm, Holger Christiansen, Denmark; 2006 - Alexander Schäfer, Germany; 2007 - Martin Detzen, MD Rebuilt,

Germany; 2008 - Johan van Gerven, MRT, the Netherlands; 2009 - Carsten Bücker, BU Drive, Germany; 2010 - Francois Augnet, TRW, Europe; 2011 - Philippe James, Remy, Belgium; 2012 - Doug Wolma, Meritor, USA; 2013 - Alan Smart, ATP, United Kingdom.

One Plus One Equals Three Co-located with BigR/ReMaTecUSA, ATRA’s PowertrainEXPO is USA’s key event for the transmission rebuilding industry. With 82 exhibitors in 142 booths covering 3,300 sq. m, this year’s Powertrain will exceed its predecessor in Las Vegas in 2012 by no less than 50 per cent. Sold out months before doors open at the Rio exhibition halls, the PowertrainEXPO show, therefore, reflects the current state of the US transmission rebuilding industry.

“2014 marks the fourth time that ATRA and APRA are co-hosting their annual trade shows. In the beginning, there wasn’t much of a crossover between the audiences of the two shows. ATRA serves the transmission-rebuilding industry,

comprising mostly of independently-owned transmission repair shops. APRA, on the other hand, serves the automotive remanufacturing industry, which consists largely of distributors of remanufactured parts,” says Dennis Madden, CEO of ATRA, the Automatic Transmission Rebuilders Association. “Notwithstanding the difference in targeted markets, the co-hosted events have allowed attendees from both sectors to explore new products, services and even business models and examine how they might use them to expand their own businesses,” Madden explains.

Reaching out to Europe Partly as a result of this, in recent years ATRA has reached out to other markets in Europe through trade shows like the 2013 ReMaTec show in

Amsterdam in an effort to share technologies and ideas between the businesses of the US and European markets. In Dennis Madden’s view, the recent partnership between APRA and ReMaTec expands on such opportunities. “The combined show of ATRA, APRA and ReMaTec brings 15 countries together with a combined show of close to 150 companies, making it a truly international event,” Madden says, adding: “The lines between the traditional businesses ATRA serves and the remanufacturing sector are beginning to blur in that we all have a common purpose: to fix cars through the aftermarket. As we continue attracting businesses from other regions of the world and from different markets, we can envision a show that serves an ever increasing blend of aftermarket solutions. I can’t wait.” n

Visit America's largest

automotive remanufacturing event

Discover the world of Automotive Remanufacturing! reman parts reman equipment reman components 40,000 sq ft show floor strong educational program Mediapartners:

GLOBAL CONNECTION Organized by:

Venue:

Co-located with:

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BigR/ReMaTecUSA 2014

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Trends at the theatre A regular feature at the ReMaTec shows in Amsterdam, the ReMaTec Theatre is a platform for the latest trends and developments. Located at the heart of the exhibition floor in a semi-open set-up, the theatre will feature a variety of speakers from leading companies in the international remanufacturing industry.

Visitors to the show can attend the presentations free of charge, with no need for preregistration.

This year’s speakers include representatives from Melett, Pos Service Holland, Coremanet, Germany, Enginedesk, the Netherlands, SRC, USA and US Commercial Service, USA and Premanus, Germany. More information about available time slots, speakers and subjects is available on www.bigrrematecusa.com. n

ReMaTec Theatre – a platform for new trends and developments in remanufacturing.

Spreading the message The launch of BigR/ReMaTecUSA has attracted considerable interest among American trade media. Over the past several months, magazines and web media have reported on the show and the organisers are confident that the targetted communications campaign over the summer will not just benefit the BigR/ReMaTecUSA show but also remanufacturing in general.

There has been a lot of interest from American automotive aftermarket media. There is clearly a buzz around BigR/ReMaTecUSA and people are curious about this new venture,” said Eva Barten,

Communications Manager, Amsterdam RAI. “It’s satisfying to note that many of our press releases have been used by print media as well as by online publications – and not just in the US.”

Show Guide The No. 1 reman show in North America INCLUDING:

Practical information Program Exhibitor list

Media that have covered BigR/ReMaTecUSA include RAI-owned ReMaTecNews, Truck Parts & Service, Automotive News, Counterman, Engine Builder, Aftermarket International, Remanufacturing Today, Global Connection, Engine Professional, Engine Builder, Parts & People, E-connection, Global Edition of Remanufacturing Today, Remanufacturing News (MERA), MEMA Industry News and Warsztat (Poland). n

Floor plan Platinum Sponsors

Gold Sponsors

Silver Sponsors

Bronze Sponsors

BigR/ReMaTecUSA - practical information Opening hours: Saturday Nov.1: 1 pm to 5 pm Sunday Nov. 2: 9 am to – 1 pm Monday Nov. 3: 11 am to 5 pm Entrance fees: There are two types of entrance badges: • Expo Only Pass: Three days’ access to the show and free entrance to the ReMaTec Theatre.

Price: $45.00 ($30 for association members) • Full Conference Pass: Three days access to the show, the ReMaTec Theatre and to all APRA Seminars, APRA

Breakfast, Highlight Breakfast and the Opening Reception (including the Remanufacturer of the Year 2014 ceremony) on Saturday, November 1, at 5.00 PM. Price: $250 ($225 for association members) During show days visitors with Expo Only Passes may buy additional vouchers for APRA Seminars at the registration desk at $50,00 each. Tickets for the Opening Reception on Saturday November 1 (5 pm to 7.00 pm, can be purchased at the registration desk for $30,00.

www.BigRReMaTecUSA.com

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Show Guide available online The Show Guide with all inside information about BigR/ReMaTecUSA is allready online available.

Check www.bigrrematecusa.com for a complete overview of the exhibitors, show floor, daily program, background information etc. n

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3D Printing – a new opening for remanufacturers

By William Schwarck In just a few years, the concept of “3D Printing” has gained considerable traction.

In less than half a second, Google, for instance, will come up with more than 8,000 references. However, that figure is likely to multiply as businesses and industries worldwide investigate, examine, adopt and exploit 3D Printing or, as it’s also called, Additive Manufacturing.

3D Printing/Additive Manufacturing is taking a damaged or disfigured core and using 3D laser printing with different materials, including metal, to remanufacture the core back to its original shape and functionality. The process involves applying layer after layer of material, e.g. liquid metal to the core with a special printer until the component has reached the desired form. Such printers can be deployed in factories, offices or even private homes. At least in theory anyone with the right equipment and CAD (Computer Aided Design) can operate their own factory.

Consequently, the popularity of 3D Printing has skyrocketed, and it has been projected to become a $16 billion global industry by 2018. These processes do not just increase the number of cores that can be reused dramatically, they also raise the number of times a specific core can be reused.

For instance, whereas today some cores can be remanufactured two or maybe even three or four

times, Additive Manufacturing/3D Printing allows for numerous repeats of the remanufacturing process. Moreover, and no less important, like other types of remanufacturing, it allows for a very significant reduction in consumption of raw materials and energy. This, in turn, enables manufacturers to produce products on demand instead of “just-in-case.”

As there are few limits to the use of 3D Printing technologies, the perspectives are huge and a broad range of manufacturing as well as other industries are bringing them into their production processes. Electronics, Energy, Life Sciences and Aerospace industries are prominent among them as is the motor industry - and now companies engaged in remanufacturing. Among the latter you find big names such as Cummins and Detroit Diesel. It’s a safe bet that more will follow.

Optomec Albuquerque, New Mexico-based, Optomec, in the US is one example of the growing range of specialists that are spearheading the development of 3D Printing for manufacturing.

Optomec, which delivered a presentation at a MERA conference in July, supplies patented Aerosol Jet systems for printed electronics and LENS 3D printers for metal components and reports growing interest - and sales - across the world. The recent LENS Print Engine, which allows metal 3D Printing capabilities to be installed into existing machine tools, enables integration with

new or pre-owned CNC tools. This means that customers can use existing equipment to realise the benefits of 3D Printing in a less disruptive manner.“ The LENS process can either fully build 3D metal parts or selectively and precisely add materials on to an existing metal component of almost any 3-dimensional shape, making it also ideally suited to perform repair/remanufacturing operations,” explains Vice President Ken Vartanian to ReMaTecNews. “The process leverages LENS “blown powder” technology, which is an industrial proven method to add metal directly on to an existing metal part.” One strength of the LENS technology is that the print head delivers powdered metal and a highly focused laser beam to the damaged part area. This enables repair of components in a way not possible with traditional repair methods such as welding. As the low heat input of the LENS process creates a lower Heat Affected Zone (HAZ) of the part under repair, this reduces the chance of distortion.

Automotive/HD “3D Printing is used today by the automotive/ heavy duty equipment industries to create plastic prototypes of new product/component designs.

These prototypes are useful for engineers to examine the visual appearance of a new product,” explains Ken Vartanian. “As the technology gains more acceptance, manufacturers will go directly

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from CAD to a physical part printed in the desired material. This will reduce time to market and reduce capital expenditures for tooling.”

He adds: “Moreover, 3D Printing enables products that can’t be manufactured using traditional methods. For example, 3D Printing technology can be used to print metal parts with internal cavities, such as cooling channels or shrouded features that are lighter in weight and have improved integrity over joined structures. Also, 3D Printing produces less wasted materials than conventional manufacturing methods such as machining.”

Impact on remanufacturing “There are many opportunities for remanufacturers to take advantage of 3D Printing techniques in their business,” Ken Vartanian says. “By example, the internationally recognised Center for Remanufacturing and Resource Recovery located at the Rochester Institute of Technology (RIT) is considered one of the world’s leaders in the remanufacturing of metal parts. C3R recently purchased LENS technology, which they plan to integrate with a conventional CNC vertical milling machine enabling a fully automated hybrid additive/subtractive manufacturing work cell. The hybrid manufacturing work cell will be used for both research and commercial production in the remanufacture and repair of high value metal components used by the transportation, medical and aviation industries.

“There are many opportunities for remanufacturers to take advantage of 3D Printing techniques in their business.”

3D Printing processes The two most commonly known powder-based 3D Printing/Additive Manufacturing processes for building metal parts are “Powder Bed” and “Blown Powder.” Each has its own advantages.

In Powder Bed systems (example EOS 3D Printers), a laser selectively melts a bed of metallic powder layer by layer to build up the physical part. After the first layer is spread and sintered, the bed is filled again with a second layer of powder and selectively sintered. This process is repeated until the part is fully formed. The resultant part

is buried in the powder cake and is not visible until the excess powder is removed. In Blown Powder systems such as in Optomec’s LENS 3D Printers the process continuously blows powder through nozzles directed at the focal point of a high powered laser or other heat source such as electron beam. The resultant pool of molten metal is then moved using a motion control system and the part is built up in free space. The entire process is visible as the part is grown layer by layer.The Powder Bed method is regarded as better at building smaller, more complexshaped parts and produces a better surface finish. The Blown Powder process is better at adding material to existing parts (as in repair, or hybrid manufacturing) and building larger parts. It produces parts with superior mechanical properties. The Blown Powder process can also blend together two or more different powders to form new alloys and composites to meet specific design challenges. The composition of the powders even can be changed gradually during the build process to create functionally graded materials tailored to avoid corrosion, fatigue, fracture, and stress cracking. As to direct benefits – and challenges – for automotive remanufacturers, Dr. Nabil Nasr of RIT says: “Additive Manufacturing technology has been used in the remanufacturing industry for many years. Previously, additive manufacturing was limited to processes such thermal spray and welding applications, and it was used in certain specialized applications like remanufacturing of diesel engine cylinder heads or jet engine turbine blades and tips. However, the associated high costs and high degree of technical expertise

required have limited its wider application in the remanufacturing industry. However, over the next 5-10 years the application of additive manufacturing, including 3D Printing, should increase as the solid modeling software gradually becomes simpler to use and the cost of 3D Printing and other additive production equipment starts to decline due to an expanding market for the kind of replacement parts that only additive manufacturing can provide.

Additive Manufacturing holds good promise for the remanufacturing industry, because 3D Printing will reduce the development time for lowvolume/high-precision/high-value replacement parts. Laser sintering additive manufacturing systems such as the LENS print engine also helps reduce the production time and tooling costs for surface restoration and material upgrading of remanufactured parts and components.

Additive manufacturing is not a risk because remanufacturing is more than components: it’s a process, a system and additive manufacturing is only a part of the system. In the future, additive manufacturing will enable the expansion of the remanufacturing marketplace because it will help enable the production of more sophisticated replacement parts and components than is now possible with conventional remanufacturing technologies. It will also allow parts that currently cannot be remanufactured to be remanufacturing.

However, both the cost and technical complexity of the additive manufacturing equipment and the steep learning curve required to fully utilize the equipment will remain limiting factors for many years.“ n

ATP has the facilities and parts to re-manufacture large ZF welded converters up to 470mm VOLVO

BELL

LIEBHERR • Re-balanced • Crack Tested • New Frictions • New Steels • New ‘O’ Rings

CASE

MOXY

TEREX

• New Bearings • One Way Clutch • All units pressure tested

These services are available to you and can often deliver a saving of 70% off the price of a new torque converter.

ATP Industries Group Ltd. Cannock Wood Industrial Estate, Cannock Wood Street, Cannock, Staffordshire, WS12 0PL, UK waynepatterson@atp-group.com paultaylor@atp-group.com

+44 (0) 1543 870 336

+44 (0) 1543 870 330

www.atp-group.com

NEWs FROM THE INDUSTRY

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FTE launches new calipers FTE, the German supplier of powertrain and braking systems has announced a new electrohydraulic clutch actuator for commercial vehicles. The company claims that actuator is a world first for the aftermarket range and remanufactured calipers.

The green technology remanufactured brake calipers, which are produced in- house conserves resources, helps to protect the environment and

supplements FTE automotive’s expertise in the field of brake hydraulics, the company says. The product range includes over 1,100 references for almost all European vehicles. The FTE automotive Group develops and produces powertrain and braking systems for the automotive industry. The company is represented on all continents which are important to the industry, and ranks among the leading OEMs in the world for passenger cars and commercial vehicles. n

Euro Car Parts’ Gray joins IAAF The UK’s Independent Automotive Aftermarket Federation (IAAF) announce that Euro Car Parts’ CEO Martin Gray has joined the IAAF council.

Martin Gray has a wealth of experience having been Sales & Ops Director for Heritage Hotel Group and MD in the Caudwell Group (including Phones4U) for seven years driving the business

from 2000 to 15,000 employees. He joined ECP in 2008 as People Director before taking over as CEO in November 2013. Euro Car Parts employ more than 8000 personnel in over 165 branches throughout the UK. Wendy Williamson, IAAF chief executive, said: “The IAAF council features some of the most influential people in our industry and we’re delighted to have Martin as a very active contributor.” n Martin Gray with IAAF CEO, Wendy Williamson

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Reman – “A shot at the future”

By Søren Toft Jensen, Owner, Borg Automotive A humorist from my home country, Denmark, named Robert Storm Petersen, once said: “It’s difficult to make predictions - especially about the future!” Wise words, indeed.

Yet, as anyone working in remanufacturing is all too well aware, looking forward, making predictions, is a key to successful management. Unless we face up to the challenges of the future, there may be no future. With that in mind, I’d like to try to paint a picture of how I see the future for the remanufacturing industry.

Borg Automotive remanufactures a variety of automotive parts for cars including brake calipers,

starters, alternators, EGR Valves, AC compressors, various forms of steering parts like hydraulic racks, electrical racks, electrical columns, hydraulic pumps and even electro hydraulic pumps. And there’s more to come. In total, Borg Automotive’s 1000 employees produce about 1.2 millioin parts annually. Beginning with rotating electrics our range has developed significantly over the years.

What then have been the drivers behind it? Let’s start with looking at the alternatives to scrapping parts - or simply buying new ones: • We can find another, similar part and reuse that part to replace the defective one • We could repair the defective part • We could remanufacture the defective part • We could recycle the defective part

Incentives What are the incentives that would motivate us to chose between them? Let’s look at some of the drivers: 1. Cost of energy 2. Cost of raw materials 3. Cost of parts availability 4. Costs of servicing aging cars and impact of kilometers driven 5. Job creation versus labor costs 6. Age of the cars and miles driven 7. Political focus Some comments on each point would be: 1. Energy prices are steadily going north, if not in real terms, then because of tax.

BORG Automotive is a Denmark-based group of automotive aftermarket companies with activities in development and distribution of remanufactured automotive parts. Through an extensive network of distributors, BORG Automotive which specialises in remanufacturing of starters/alternators, A/C compressors and brake calipers, has a strong presence throughout Europe.

From a humble start as an auto electrical mechanic workshop more than 30 years ago, BORG Automotive has developed into one of the largest independent remanufacturing companies in Europe with more than 1,000 employees.

The group is active within Automotive, Aftermarket, Remanufacturing, Starters, Alternators, Steering, Calipers, EGR Valves and comprises the Elstock, Lucas Electrical Europe and DRI brands.

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2. Raw material prices are fluctuating. Although they seem to follow a fairly uniform trend, some follow an even steeper curve. As a consequence, new products are continuously downsized in order to save on weight, energy and raw materials.

Nowadays, less is more.

3. Once the vehicle has reached around 5-8 years of age, car manufacturers dislike replenishing spare parts stocks because parts produced after the car’s launch are either out of production, tend to be expensive and require largescale orders which means big inventories. Remanufacturing can provide parts down to very few pieces without incurring high production costs.

4. Statistics reveal that the demand for exchanging key parts peaks at 10 years. By then the car has lost a considerable amount of value, which is yet another incentive to chose remanufactured and, therefore, cheaper parts.

5. Due to the high proliferation within each product line, the remanufacturing process is very labor intensive. This leads to a high employment rate compared to actual sales. Additionally, where volumes are high, some jobs can be created for individuals without special prequalifications, e.g. people with limited educational backgrounds.

6. We live in times with strong political focus on production that does not require a great deal of energy and reuses as much raw material as possible.

Raw materials In contrast to recycling, remanufacturing is also capable of redeploying raw materials that are coated (or partly ceramic), sometimes in thin layers of very expensive raw materials. Such materials cannot be recovered with pure recycling and, therefore, will be lost. Research made by Bayreuth University proves that in respect of passenger car starter motors, the remanufacturing process saves 88% of the raw material and 55% Co2 compared to new production of the same unit. Yet another driver is that cars tend to enjoy ever longer lives and drive more miles. Today, two thirds of the car population is five years old and the average

Borg’s new core warehouse in Zdunska Wola, Poland

BORG opens Northern Europe’s largest core warehouse Borg Automotive, recently opened what is believed to be Northern Europe’s largest core warehouse. Located in Zdunska Wola in Poland, where the Borg Group has extensive reman interests, the warehouse covers more than 3,000 square meters and holds 400,000 units ready for remanufacturing. “The new core warehouse is a result of a significantly increased demand for the company’s products,” said Group Supply Chain Director, Kenneth Rønne Jensen. “In recent years we’ve experienced rapid growth with sales quadrupling since 2008 to a whopping 1.2 million units in 2013. We are now able to receive much larger quantities and offer a wider selection of units.”

“Aside from the considerable economic and environmental benefits of remanufacturing, we are better positioned to detect the most frequent causes of defects in the units which we receive for remanufacturing. This allows us to take the necessary precautions and reproduce products that perform even better than OE units,” Kenneth Rønne Jensen added.

car lifetime is now around 13 years. This means, that the car remains an “object” for sales of parts for many more years. In consequence, I believe that remanufacturing has enough advantages to more than make up for the one negative relating to remanufacturing - the issue of return logistics.

Key factors These advantages include some very important factors: 1. Availability (and price) 2. Costs of servicing the aging car population 3. Cost of energy and raw material

4. Economic and political implications of job creation – including jobs that may require modest skills.

In summary, to me the opportunities for remanufacturers outweigh the potential negatives by a significant margin. Yes, it’s difficult to make predictions – especially about the future. But for those who possess the ability to see an opportunity within a challenge, there is much to be confident about – and, in my experience, that applies to remanufacturers. n

DEFINITION of Remanufacturing * A remanufactured part fulfills a similar function as the original part. It is restored from an existing part using standardized industrial processes in line with specific technical specifications. A remanufactured part is given the same warranty as a new part and it clearly identifies[ the part as a remanufactured part and the remanufacturer. *This is the common definition of APRA (Automotive Parts Remanufacturer Assication in USA, Europe and ASIA), CLEPA (European Association of Automotive Suppliers), FIRM (International Federation of Engine Remanufacturers and Rebuilders, Europe), supported by MERA ( Motor and Equipment Remanufacturers Association, USA) and RIC (Remanufacturing Industries Council, USA).

ReMaTecNews | 24

Reman - 'dirty' and 'disgusting' An American university survey indicates that many consumers perceive categories of remanufactured products as dirty and disgusting. “As a result, firms looking to increase market share of remanufactured consumer products will have to overcome a big barrier to do so,” says a study from the Penn State Smeal College of Business in Pennsylvania. The study was carried out by faculty members Meg Meloy and V. Daniel R. Guide Jr., “Remanufactured products, also known to consumers by terms such as refurbished or rebuilt, are products that have been disassembled, cleaned, and -- after replacement of any worn or defective parts -- reassembled and returned to the market,” the authors write. “They (the remanufactured products) represent a significant opportunity for businesses aiming to increase sustainability.

However, currently they only account for about 5 to 10 percent of the consumer market.”Part of the reason these products haven’t gained greater

market share is the consumer perception that many of these products are dirty or disgusting -- despite the thorough sterilization process that products undergo as part of the remanufacturing process, the study concludes. “Disgust plays a particularly strong role when the remanufactured products are used for food preparation (e.g., a food processor) or personal care (e.g., an electric toothbrush).”

“The perception that remanufactured products are somehow dirty and disgusting due to their prior ownership adds a previously undocumented and powerful predictor of remanufactured product attractiveness,” the authors wrote. “Fully mitigating these negative perceptions may prove difficult.”

Upside “The upside of this market is that remanufactured products are more environmentally friendly.

Consumers are often more willing to adopt remanufactured technology products (e.g., smart phones or tablets). “Because remanufactured

products derive from direct reuse (in contrast to new or recycled products), the environmental impacts of production can be lower than for new products,” the authors write. But contrary to their hypothesis, the authors found that consumers who self-identified as being committed to environmentally friendly practices and products did not necessarily have a significantly more positive perception of remanufactured products.

Consumer percentions “This indicates that some green-minded consumers may not fully appreciate the potentially environmentally friendly or green attributes of a remanufactured product.” The authors indicate that remanufacturers will need to reduce consumer perceptions of disgust directed at these products in order to make them more viable.

Reminding consumers of the environmentally friendly aspects of remanufactured products may increase “green” consumers’ positive perceptions of these products and, thereby, potentially remove some of the barriers to this market.n

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'Cars will be part of larger ecosystem'

Bill Ford, Chairman of Ford Motor Company

By Bill Ford, Chairman, Ford Motor Company During the past decade, the automotive industry emerged from one of the most challenging periods we have ever encountered, and has now entered one of the most exciting and promising times in our history. Yet, even more important is our focus on the future, which will be defined by an important trend: the automobile as part of a larger ecosystem.

This requires a change in our view of the car as an individual object to seeing it as part of our broader transportation network. It also requires a fundamental change in how we think about transportation. Customers today have extremely diverse priorities, and we must embrace these differences as we design and sell automobiles.

The facts that underpin this trend are compelling.

With a growing global population and greater prosperity, the number of vehicles on the road could exceed two billion by midcentury. Combine

this with a continuing population shift toward cities, with a projected 54 percent of the global population in cities by 2050, and it becomes clear that our current transportation model is not sustainable. Our infrastructure cannot support such a large volume of vehicles without creating massive congestion that would have serious consequences for our environment, health, economic progress and quality of life.

Challenge - and Opportunity The good news is that this scenario is not inevitable, and some experts say this challenge represents a $130 billion business opportunity for the automotive market. Some solutions already are under way to develop more space-efficient vehicles with clean engines that run on gas or alternative energy sources. Yet other answers will require a fundamental rethinking of what the business of being an auto manufacturer looks like. No matter how clean and efficient vehicles are, we simply cannot depend on selling more of them as they function today. Cars will need

to be smarter and more integrated into the overall transportation system. Forward-looking companies will redefine themselves and move from being just car and truck manufacturers to become personal-mobility companies. We will be thinking more intelligently about how the vehicles we build interact with one another and with a city’s infrastructure, which includes trains, pedestrian walkways, buses, bikes and everything else that helps us move through urban centers. Rapidly changing preferences among car owners, including an ever-increasing emphasis on connectivity, will redefine the types of vehicles we bring to market, the features we focus on and how vehicles are marketed and used.

New Ownership Models The rise of companies such as Lyft, Uber and Zipcar underlines individual ownership as not always being the most cost-effective way to obtain access to a vehicle, especially for urban customers. Individual ownership also may not be the primary model of vehicle ownership in

The author Bill Ford, Chairman of Ford Motor Company, recently gave Wall Street Journal a view into the future of the motor industry. The great-grandson of the company’s founder, Henry Ford, Bill Ford has chaired the giant automaker since 1999. ReMaTecNews reprints the article with special permission from Ford Motor Company.

ReMaTecNews | 27

the future. Just how this affects the current sales model is yet to be seen.

“ Cars of the future will be mobile communications platforms that talk to each other and the world around them to make driving safer and more efficient. “ They will be integrated into the transportation ecosystem in ways that optimize the entire system, with software that allows owners to increasingly customize features and functions. We already are in the early stages of this transformation, with wireless communication, infotainment systems and limited functions for automated driving and parking. Continuing to meet consumer demand for greater efficiency also will require more than just changes to engines and energy sources.

New materials and manufacturing processes will reshape auto manufacturers and the suppliers we have worked with for decades. Aluminum and high-strength steel will evolve as the materials that serve as the backbone of the industry.

Carbon fiber will move from the realm of race cars and million-dollar exotics into small cars and crossovers. This will require rethinking the lifecycle supply chain.

Redefining Driving We also will need to rethink what defines the act of driving. Autonomous driving, or cars that navigate themselves, will be possible, and in certain situations, common practice. We already are seeing some of this make its way into vehicles to provide safer and easier driving.

As these technologies develop, we expect they significantly will extend the useful driving life of individuals and offer new opportunities for the physically challenged. Some entrepreneurs are even pushing current boundaries further by exploring the feasibility of flying cars. While these

would require significant regulatory development to become a viable option, they do provide a glimpse of what our future of mobility may look like. All of this serves as the backdrop to how we think about Ford Motor Co. today. Henry Ford redefined mobility for average people, and we have the opportunity to do the same now. The next 20 years will see a radical transformation of our industry, and will present many new ways of ensuring that my great-grandfather’s dream of opening the highways for all mankind will remain alive and well in the 21st century and beyond. n

The heart of the Ford empire: Ford’s world headquarters in Dearborn, Michigan

ReMaTecNews | 29

Former UK environment minister pushes for more remanufacturing A former member of the British government and current Member of Parliament is taking new steps to push the reman agenda – both in the UK but in the longer term also at European level. A co-author of the report, “Remanufacturing: Towards a Resource Efficient Economy”, the Conservative Caroline Spelman, together with fellow MP, Barry Sheerman, Labour, is conducting a survey aimed at ‘identifying and helping to establish the optimal policy environment to encourage remanufacturing activity.”

The two British MPs believe remanufacturing could have a key role in ensuring resource security and derives extensive and additional economic, environmental and social benefits. They are calling on members of the remanufacturing industry to submit evidence on the barriers to – and the potential growth of – remanufacturing in the UK. The results of the survey are expected to be announced before the end of the year. “We want to look at the potential of remanufacturing for the British economy and the wider applications, Caroline Spelman told ReMaTecNews. “The feeling is that remanufacturing is coming of age and that, after a period of austerity, companies need to consider new ways. This, in my view, plays straight into the hands of remanufacturing.”

As co-chairs of two of the UK Parliament’s two all-party groups for manufacturing (APMG) and sustainability (APRSG) Spelman and Sheerman believe governments can do more to promote remanufacturing and, thereby, the economy in general. “This new inquiry comes at a critical time. It is clear to us that the importance of remanufacturing in terms of both resource security and economic potential is not yet fully appreciated by parliamentarians or UK industry,” Caroline Spelman says. “The future of manufacturing is inextricably linked to environmental sustainability, reducing the consumption of raw materials, and

Caroline Spelman, former environment minister in the British government exploiting new areas of comparative advantage.

We believe the government must do more - firstly to better understand the huge environmental and economic potential that remanufacturing offers, and secondly to create precisely the policy and regulatory framework needed in order for UK businesses to fully embrace it.” Spelman points to Caterpillar and Rolls Royce as shining examples of what high value remanufacturing can achieve: “What happens now, however, is that reman as a concept is better understood and that opens up the potential for extending the remanufacturing of lesser value products. I think that, in the past, we had a love affair with “new”. This is changing so that consumers want to extend product life and, therefore, are willing to consider repair/

remanufacturing. Businesses see more value in remanufacturing while, at the same time, people see worn out products less as “waste” than an opportunity to extend the life of a product.”

Although Caroline Spelman considers the British industry as a potential leader in respect of reman, she believes that what she and her MP colleagues are aiming at has ramifications for Europe in general. Pointing to current EU efficiency programmes, she intends to push for more concerted moves on reman within the European Union. “Europe should lead the way by advancing technologies that promote remanufacturing. It’s about putting a more resilient UK at the forefront of global remanufacturing innovation,” she says. n

The new UK survey is aimed at exploring lessons from best practice case studies in “key industries” such as the automotive industry, and which apply to other remanufacturing sectors, including waste electrical and electronic equipment (WEEE). In particular the survey will: • • • • •

consider how remanufacturing increases the potential for restoring parts and products; examine the role of remanufacturing in improving national resilience; explore the potential drivers and barriers for remanufacturing in diverse industries; consider the benefits of alternative types of business models (such as ‘servitisation’) in engaging in remanufacturing; and identify areas where further government regulation or incentives may be needed to stimulate remanufacturing.

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AAPEX 2014: More choice for Remanufacturers Organised by MERA, the Motor & Equipment Remanufacturers Association, and the Auto Care Association, the AAPEX 2014 Remanufacturing Section, introduces a number of new features to the reman community.

Running from November 4 to November 6 incl. at the Sands Expo in Las Vegas, this year’s event will comprise a “REMANedu Conference,” private one-on-one meetings and an invitation-only reception for exhibitors and guests at a leading Las Vegas restaurant.

“Remanufacturing is a significant sector of the automotive aftermarket and the new “Remanufacturing Experience at AAPEX” will help remanufacturers and their suppliers grow their business,” said John Chalifoux, president and COO, MERA.

The new one-on-one meetings will give core suppliers and component suppliers the opportunity to schedule private meetings with key buyers from leading remanufacturers before the beginning of AAPEX, MERA says.

MERA’s sold-out section, which is part of America’s huge AAPEX aftermarket exhibition, will feature 44 exhibitors covering 11,500 square feet against last year’s 39 exhibitors in 8,000 square feet.

Remanufacturing exhibit The section, which will be designated throughout by green carpet, will also feature live engine rebuilding demonstrations by Hendrick Motorsports technicians and an interactive remanufacturing exhibit powered by the Electronics Remanufacturing Company at the MERA booth. n

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ReMaTecNews | 33

Schenck RoTec - New balancing machines

When it comes to remanufacturing turbochargers, balancing plays an important role in ensuring smooth operation and a long service life. Germany’s Schenck RoTec has developed a pair of balancing machines for economic, uncomplicated repair of turbochargers.

Whilst the TBcomfort is a solution for prebalancing turbine rotors and compressor

wheels, the TBsonio is used for the high speed balancing of complete core assemblies. Both crane hook designed machines can be set up and repositioned with a minimum of effort, need neither foundations nor anchoring to the floor and are ready for use immediately after alignment.Turbocharger components and rotor assemblies up to 16 kilo can be balanced perfectly on the TBcomfort, Schenck RoTec says. The machines can also accommodate turbochargers

Remanufactured air struts for Mercedes Arnott Suspension Products has announced the introduction of remanufactured Air Struts for the 2007 to 2013 Mercedes-Benz S-Class.

Based in Florida, USA, and operating a European subsidiary in The Netherlands, Arnott Suspension Products claims to be a global industry leader in manufacturing aftermarket air suspension products and accessories. Arnott’s 200,000 square foot manufacturing plant is located in Merritt Island on Florida’s Space Coast. The facility is located on a 14-acre campus, near the Kennedy Space Center and Port Canaveral. Arnott Europe is located in ‘s-Hertogenbosch, The Netherlands. n

This DOHC V6 engine is available on exchange

Machines for automatic and manual parts cleaning With its AM series German-based cleaning machine manufacturer, Georg Render, has developed new machines for combined automatic and manual parts cleaning in remanufacturing. These allow for removing heavy contaminations such as oil carbon and scale as well as cleaning complicated part geometries.

Reman Jasper engines Jasper Engines & Transmissions, one of America’s leading remanufacturers announces the availability of its remanufactured Nissan VQ40DE 4.0L engine.

for commercial vehicles, construction machines or ship propulsion. The TBsonio carries out the last process step in turbocharger repair where the core assembly is accelerated using compressed air and is balanced under almost real conditions.

After that, the turbocharger has such a low residual unbalance that it matches the quality level of a new charger. Operation of the machines is easy and follows ergonomic criteria, the company claims. n

for the following 2006-2011 vehicles: Nissan Frontier, Pathfinder, Xterra. The remanufactured engine offers several advantages, says Jasper. This includes redesigned pistons with graphite coating, plasma Moly rings, Viton valve stem seals and multi-layer steel heads n.

The machine cover is equipped with window (optional a large observation window with screen wiper is available), lighting and gauntlets, the company says. Manual cleaning can be carried out via a low-pressure pump and spray gun (approx.

3-6 bar) for pressure cleaning or the integrated washing brush unit without any contamination of the operator. For drying a compressed air gun is integrated. n

PEOPLE ON THE MOVE

ReMaTecNews | 35

Martin Coxell joins Germany’s IKA IKA Industrie- und Kraftfahrzeugausrüstung GmbH IKA of Königswinter, Germany, has announced the appointment of Martin Coxell, 56, as Key Account Manager for Russia and Central Asia. He will join IKA’s ten member strong sales team as well as taking responsibility for business development at the well-known German distributor of electrical, mechanical and electronic automotive aftermarket parts.

British-born Martin Coxell, 56, brings to his new

position broad experience of automotive electrics.

Previously Coxell worked as commercial director at Wood Auto Supplies Ltd. and sales director at Unipoint Electric Mfg. Co., Ltd in the UK. “Due to his many years of experience working for a leading manufacturer of starters and alternators, Martin knows the industry business very well, indeed,” said Harald Benninger, Managing Director of IKA Germany. “ Moreover, he has an excellent network. He will significantly strengthen our team and we’re looking forward to working with him. “

IKA’s catalogue includes more than 7,000 items and the company serves remanufactures and wholesalers in over 70 countries on five continents. n

Martin Coxell, from the UK to Germany

Owings assumes PERA presidency PERA, the Production Engine Remanufacturers Association, has a new president. With effect from September Frank Owings, owner of Florida-based Titan Engines, takes over as the associations 66th president.

Frank Owings

Since, as a boy he used to sweep the floors of his father’s business, Owings has been working with replacement parts and engines. After college, he founded a chain of auto parts stores which he later sold to CARQUEST before rejoining the family firm founded in 1947. Subsequently he returned

to the family firm for which he has been working ever since. “I am constantly excited about our industry and believe the industry is going to keep growing,” Frank Owings told ReMaTecNews.

“As producers we have have to realize that the industry is constantly changing. We just have to keep educating ourselves, and improving our product. I think we have a bright future in the engine business.” n

New MD at Mahle Aftermarket During the summer, 46-year old Olaf Henning assumed the role of Managing Director at MAHLE Aftermarket GmbH with worldwide responsibility for the company’s Aftermarket division. At the same time, Olaf Henning joined the MAHLE Management Committee.

He boasts over 20 years management experience with leading automotive suppliers and has worked in the automotive aftermarket for over 31 years within the areas of aftersales services and

automobile repair shop equipment at European and Asian level. Most recently, Henning was Managing Director at Bosch Automotive Service Solutions EMEA.Aftermarket is MAHLE’s business unit specialising in spare parts and supplies trade, repair shops and engine repair partners. MAHLE Aftermarket is represented at 23 locations and employs a world-wide workforce of 1,670. In 2013, the business unit achieved a global sales volume of 805 million euro. n Olaf Henning, new MD at MAHLE Aftermarket.

Service Parts Manager rejoins AMC Arvid Andersen has rejoined AMC Denmark as Service & Spare parts Manager.

Arvid Andersen, who left the former AMCSchou, when the company folded in 1011, now handles spare parts, service and repairs at the now revived Chinese-owned AMC Denmark (see also page 29).

When the engine rebuilding, cylindrical-grinding machines specialist closed Arvid Andersen transferred to Denmark-based Bast & Co. working with parts sales and service. He’s now back in his familiar surroundings under the revived AMC brand. n Arvid Andersen back with AMC

MARKET PLACE

ReMaTecNews | 36

For more information please contact Ewoud Barink | phone +31 (0)6 51 44 83 67 | advertising@ReMaTecnews.com | www.ReMaTecnews.com Cleaning equipment | Consultancy - Research | Cores | Environmental products | Lubricants - Chemicals | Organisations | Associations | Parts for remanufacturers | Production | Remanufactured products | Test equipment | Rates 2014 | 1 placement € 160 | 4 placements € 610 | 6 placements € 875

Associations

APRA EUROPEAN OFFICE Neustrasse 8 458653 Coesfeld Germany P +49 2541 8006818 E Info@apra-europe.org W www.apra-europe.org

FIRM Parc Industriel, 10 B 1440 Wauthier Braine Belgium P +32 (0) 2 3660680 E secretariat@firm-org.eu W www.firm-org.eu

Cleaning Equipment

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

Cores

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

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

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

Remanufactured Products

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

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

Test Equipment

BU Drive GmbH Kölner Straße 89 50859 Köln | Germany P +49 (0) 22 34 / 9 46 680 E info@bu-drive.com W www.bu-drive.com

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

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

Emmetec S.r.l.

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

Transmission parts

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

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

Parts & Engines

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

Kotek America Inc. 17752 Cowan ST Irvine, CA 92614 United States P 1949 863 3126 E sales@kotek.com W www.kotek.com

Starters & Alternators

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

TRANSMISSION world

ReMaTecNews | 37

Transmission Repair Industry looking for reman opportunities

By Dennis Madden, CEO, ATRA/Automatic Transmission Rebuilders Association Remanufacturing has touched practically every system in automotive repair; rarely (if ever) do we find businesses that rebuild components like alternators and power steering pumps. Instead you buy a remanufactured part. Even engines are more readily offered as remanufactured rather than rebuilt.

The newly developed 9-speed automatic transmission from ZF for cars with fronttransverse motors, planned for volume production in 2013. Photo: ZF

One industry that has not taken so quickly to the remanufacturing model is transmission repair; and for several reasons. One of the greatest reasons is the enormous variety of transmissions. Not only are there a few hundred different models out on the highways but there are usually several varieties of each model - which make them incompatible with other varieties within that transmission family.

The cost is another factor. Not every transmission problem requires replacing or rebuilding the transmission so a cost-effective solution will sometimes involve fixing it, which requires a specialist. Notwithstanding this remanufacturing is gaining ground in the transmission repair industry and the sheer number of varieties is making transmission remanufacturers partners rather than competitors.

Need for reman Still, the transmission-rebuilding industry is vibrant and filled with people who are very proud of their craft. But even for this segment there’s a need for remanufacturing. One area that’s grown over the years is the remanufacturing of valve bodies.

Transmission failures today are often caused by a worn out valve body, making it impractical to rebuild without a replacement. Another area that is open for remanufacturing is the mechatronics component. This is an area that is practically

untouched and in high demand. As we see advancement in transmission design we always also find opportunity.We just have to look for it. n

Dennis Maden

Sonnax acquires valve body specialist Sonnax, the renowned transmission specialist in Bellows Falls, Vermont, has acquired leading remanufacturer of automatic transmission valve bodies and solenoids, Valve Body Xpress in Paulsboro, New Jersey, USA. The deal includes VBX’ subsidiary, Valve Body Xtras, which focuses on valve body components.

“This is a growth opportunity for Sonnax and an opportunity for both the companies to work together and serve the industry better,” Sonnax’ Senior Vice President Steve Jaussaud said in a statement.

The acquisition will further strengthen Sonnax, which, since 1978, has been offering a variety of components for the remanufacture of torque converters, automatic transmissions and driveshafts to more than 70 countries worldwide.

The Sonnax TASC Force links together transmission

specialists, remanufacturers and rebuilders across the globe. In 2014 Sonnax was recognized as one

of the best places to work for in the New England state of Vermont. n

Sonnax Senior Vice President Steve Jaussaud

ReMaTecNews | 38

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

More to reman than vehicles

By Fernand Weiland Together, automotive and Heavy Duty remanufacturing represent the largest sector within European remanufacturing. For most products the segments continue to grow because of the rising cost of materials, energy and maintenance on a global scale. Other reasons include the desire to reduce vehicle downtime, lack of component availability, general scarcity of resources and the need to cut down on pollution, etc.

Many of these factors favour remanufacturing, and not just in Europe and North America. The rest of the world is also realising that resources are finite and there are better alternatives to discarding old products. China is the most prominent example - not only will it soon be one of the world’s largest markets for aftermarket/ replacement components but also because the Chinese government has decided to embrace remanufacturing as an entirely new philosophy.

For remanufacturers, therefore, these are interesting and challenging times. I believe that you now have to start to look over the fence, geographically as well as in terms of other product/ sectors than automotive. Although “automotive” is probably the oldest reman segment, dating

back to World War II or even before, it is not the only one.

Aviation components Remanufacturing of aviation components is as old as automotive and has a similar size. The biggest European aerospace remanufacturer is probably Lufthansa Technik Group, the reman operations of which employ as many people as the biggest automotive remanufacturer. Lufthansa’s list of components is extensive but the biggest component segments are engines, landing gears and airframes. For aerospace remanufacturers the definitions are not very different from the APRA definition although Lufthansa calls it “overhaul”, “repair” or “rebuild”. Aerospace remanufacturers must be approved by EASA or FAA and their standards are such that the difference in terminology between “rebuild” or “remanufactured” is only a semantic issue.

Though important, the next remanufacturing sector, machinery and industrial electrics, is more difficult to quantify. In a comprehensive report on the reman industry, the US Department of Commerce recently stated that machinery and industrial electrics accounted for 15% of the US remanufacturing industry. For Europe, there are no similar figures, but I believe that the segment is probably underestimated. Hopefully, by ReMaTec

2015 in Amsterdam, we will have more facts and figures on this. Let me add that the components/ machines for this segment include more than just machine tools, machinery, compressors, electrical distribution, transformers, electrical motors, etc.

I would not be surprised if the segment will be shown to be the size of aviation or automotive.

Medical equipment Remanufacturing medical equipment or imaging and therapy equipment is another sector which because of its inherent risks is often subject to approval by official authorities. The equipment ranges from computer tomography to ultrasonic devices, from X-ray equipment to MRT devices, mammography equipment etc. The OE remanufacturers have formed an association and, in the USA and Europe, use the term “refurbishing” where we in automotive remanufacturing would use “remanufacturing.”

The important thing is not what they call the process but what it contains. OE manufacturers have their own central remanufacturing operations but also use local, authorised remanufacturers.

Apparently, the size of the sector is not yet very large - but it is growing rapidly. As is the case with truck/fleet owners who are under pressure to reduce their maintenance costs, you can ask whether the health care industry has

ReMaTecNews | 39

similar challenges. In yet another example, the range of electronics and IT products/equipment is vast, perhaps so vast that it is difficult to quantify.

The US Department of Commerce believes that it amounts to 11% of all remanufacturing.

Personally, I have my doubts. Especially if we broaden the definition of remanufacturing, the figure may be bigger.

Short life In fact, a narrow definition of remanufacturing/ rebuilding weakens the claim that remanufacturing makes a significant contribution to the environment. It also does not sufficiently support the argument against throwing away old products. Cell/mobile phones, iPads, notebooks etc. have a short life/design cycles and are mostly refurbished and not remanufactured. Copiers and toner cartridges, however, are remanufactured and so is large IT equipment with longer design/ life cycles. It’s interesting to note that nearly all manufacturers of copiers/printers include refurbished/remanufactured equipment in their product range. If all goes to plan, by next year

we will have further facts and figures to present about this. The list does not stop here. In fact, there are numerous other non-automotive areas such as tyres, railway stock, furniture, household equipment, batteries, construction equipment etc.

The definition of remanufacturing, therefore, is not as narrow as we tend to think. In other words: “automotive” is not alone because across the world there are many other players. Accordingly, what APRA Europe Chairman Peter Bartel has done to help bring together FIRM, CLEPA, ACEA and MERA could be extended to include other reman sectors, e.g. BIPAV and TIA for tyres, EASA for electrical devices, NEMA and COCIR for medical equipment, NKLR for China, IITC for imaging equipment, just to mention a few. The challenge is considerable - but perhaps the time has come to put all our eggs in one basket.

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ReMaTecNews | 41

Engine downsizing – risks, challenges or benefits?

Engine downsizing is one of the automotive industry’s answers for meeting upcoming CO2-emission levels. Under current legislation, from 2020 95 g CO2/km is the target for new passenger cars. This equates to 4.1 to 3.6 liter diesel/100 km. 3-cylinder engines with 1.0 to 1.2 liters displacement and However, a minimum of 60 kW is not unusual. Despite low displacement, turbocharged engines have even higher performance. The slogan “displacement is to be replaced by anything”, clearly, no longer applies.

know full well that the answers are “no.” You could claim that these smaller engines will last for two years until the expiry of the warranty/ guarantee without damage. Little doubt about that. However, subsequently they are likely to fail due to inappropriate servicing by the car owner (extended oil drain periods etc.) and bad driving habits such as quick shut-down after high speeds on motorways and loading the engine prior to reaching operating temperature. Such treatment of the engine, of course, is not new and engine remanufacturers have profited from it for years. So it may seem that as more engines are downsized and the smaller their components become, there may be more work for engine remanufacturers.

To use an example, valve stem diameters with 5-6 mm are now at the top end of the scale. Yet, smaller component tolerances and clearances do

Down-sized engines offer the same performance as “older” natural aspirated, 6-cylinder engines.

But do they have the same reliability - and do they last as long? Car manufacturers are not keen to discuss this, but real engine experts

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not excuse negative thermal impacts. And the consequences? Once an engine fails, the damage levels of smaller engines increase substantially – which, again, could benefit remanufacturers. At the same time, however, higher damage levels may require higher investments in tools and machinery and, therefore, costs. This raises the question of whether repair costs may exceed the value of cars with downsized engines. This could mean that car owners will think twice before placing repair orders. We should all be aware of this. n

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ReMaTecNews | 42

04/10 - 19/10/2014

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Gathering of transmission professionals Las Vegas | USA

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01/11 - 03/11/2014

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04/11 - 06/11/2014 16/10 - 21/10/2014

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International Exhibition for Automobile and Accessories Wuhan | China (PR)

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16/10 - 26/10/2014 S.A. Salao do Automovel

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nternational Automobile Trade Show Sao Paulo | Brazil

06/11 - 08/11/2014 Green Car Korea

19/10 - 21/10/2014

Gwangju | Korea (Republic)

CIAPE China International Auto Parts Expo Shanghai | China (PR)

22/10 - 24/10/2014

12/11 - 14/11/2014 Auto & Parts Uzbekistan International Trade Fair for Automobile and Parts Tashkent | Uzbekistan

SAECCE / CAEMEX SAE-China Congress & Exhibition / China Automotive Engineering and Manufacturing EXPO Shanghai | China (PR)

12/11 - 15/11/2014 Automechanika Buenos Aires International Automotive Trade Fair from Design to Maintenance and Recycling Buenos Aires | Argentina

24/10 - 26/10/2014 Tbilisi Auto Show/Caucasus AutoShow International Specialized Fair of Automobiles, Auto Business, Spare Parts, Auto-cosmetics Tbilissi | Georgia

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