Increasing the Efficiency of Engine Remanufacture by Optimising Pre-processing Inspection

A Comprehensive Study of 2196 Engines at Caterpillar Remanufacturing in the UK

Sara Ridley

Research output: ThesisDoctoral Thesis

Abstract

Remanufacturing describes the process of bringing used product to an "as-new" functional condition using reclaimed and new components. It is an industrial process operating across the automotive, industrial, commercial and domestic sectors which, despite its low profile, contributes around £2.35 billion annually to the UK economy. Remanufacturing is an enabler for manufacturing, reducing the use of virgin materials and energy thus allowing more cost-effective manufacturing. Key issues for remanufacturers revolve around the lack of industry-specific tools and techniques and this particularly affects effective decision-making for production issues such as the inspection of returned cores and their constituent components. The main aim of the research was to establish the factors that affect pre-processing inspection and this was achieved using causal true-experimental research into the overall remanufacturing process for over two thousand engines at a Caterpillar Remanufacturing pl ant in the U.K. The research found that the three critical factors in determining the effectiveness of the pre-processing inspection are the complexity of the component geometry including internal ports, the number of sub-components and the number of material employed in the construction of the component. These factors were then used to establish a practical method of assessing the true costs of remanufacturing. The findings were validated at several European Caterpillar Remanufacturing facilities. The beneficiaries of this research are both academia and industry: it adds to the body of remanufacturing knowledge enabling future research to be targeted at operations that materially affect the process and also assists remanufacturers to make their operations more efficient, thus aiding profitability. The novelty of the research is the new knowledge concerning the factors affecting pre-processing inspection together with the limitation of the benefits as well as the information gathered from over two thousand engines in an industrial setting.
Original languageEnglish
QualificationPhD
Awarding Institution
  • University Of Strathclyde
Supervisors/Advisors
  • Ijomah, Winifred, Supervisor
Award date20 Aug 2013
Place of PublicationGlasgow
Publisher
Publication statusPublished - 20 Aug 2013

Fingerprint

Inspection
Engines
Processing
Costs
Industry
Profitability
Decision making
Geometry

Keywords

  • remanufacturing
  • pre-processing

Cite this

@phdthesis{ba3bf49551cd4a7f99b28ff59cec5bd7,
title = "Increasing the Efficiency of Engine Remanufacture by Optimising Pre-processing Inspection: A Comprehensive Study of 2196 Engines at Caterpillar Remanufacturing in the UK",
abstract = "Remanufacturing describes the process of bringing used product to an {"}as-new{"} functional condition using reclaimed and new components. It is an industrial process operating across the automotive, industrial, commercial and domestic sectors which, despite its low profile, contributes around £2.35 billion annually to the UK economy. Remanufacturing is an enabler for manufacturing, reducing the use of virgin materials and energy thus allowing more cost-effective manufacturing. Key issues for remanufacturers revolve around the lack of industry-specific tools and techniques and this particularly affects effective decision-making for production issues such as the inspection of returned cores and their constituent components. The main aim of the research was to establish the factors that affect pre-processing inspection and this was achieved using causal true-experimental research into the overall remanufacturing process for over two thousand engines at a Caterpillar Remanufacturing pl ant in the U.K. The research found that the three critical factors in determining the effectiveness of the pre-processing inspection are the complexity of the component geometry including internal ports, the number of sub-components and the number of material employed in the construction of the component. These factors were then used to establish a practical method of assessing the true costs of remanufacturing. The findings were validated at several European Caterpillar Remanufacturing facilities. The beneficiaries of this research are both academia and industry: it adds to the body of remanufacturing knowledge enabling future research to be targeted at operations that materially affect the process and also assists remanufacturers to make their operations more efficient, thus aiding profitability. The novelty of the research is the new knowledge concerning the factors affecting pre-processing inspection together with the limitation of the benefits as well as the information gathered from over two thousand engines in an industrial setting.",
keywords = "remanufacturing, pre-processing",
author = "Sara Ridley",
year = "2013",
month = "8",
day = "20",
language = "English",
publisher = "University of Strathclyde",
school = "University Of Strathclyde",

}

TY - THES

T1 - Increasing the Efficiency of Engine Remanufacture by Optimising Pre-processing Inspection

T2 - A Comprehensive Study of 2196 Engines at Caterpillar Remanufacturing in the UK

AU - Ridley, Sara

PY - 2013/8/20

Y1 - 2013/8/20

N2 - Remanufacturing describes the process of bringing used product to an "as-new" functional condition using reclaimed and new components. It is an industrial process operating across the automotive, industrial, commercial and domestic sectors which, despite its low profile, contributes around £2.35 billion annually to the UK economy. Remanufacturing is an enabler for manufacturing, reducing the use of virgin materials and energy thus allowing more cost-effective manufacturing. Key issues for remanufacturers revolve around the lack of industry-specific tools and techniques and this particularly affects effective decision-making for production issues such as the inspection of returned cores and their constituent components. The main aim of the research was to establish the factors that affect pre-processing inspection and this was achieved using causal true-experimental research into the overall remanufacturing process for over two thousand engines at a Caterpillar Remanufacturing pl ant in the U.K. The research found that the three critical factors in determining the effectiveness of the pre-processing inspection are the complexity of the component geometry including internal ports, the number of sub-components and the number of material employed in the construction of the component. These factors were then used to establish a practical method of assessing the true costs of remanufacturing. The findings were validated at several European Caterpillar Remanufacturing facilities. The beneficiaries of this research are both academia and industry: it adds to the body of remanufacturing knowledge enabling future research to be targeted at operations that materially affect the process and also assists remanufacturers to make their operations more efficient, thus aiding profitability. The novelty of the research is the new knowledge concerning the factors affecting pre-processing inspection together with the limitation of the benefits as well as the information gathered from over two thousand engines in an industrial setting.

AB - Remanufacturing describes the process of bringing used product to an "as-new" functional condition using reclaimed and new components. It is an industrial process operating across the automotive, industrial, commercial and domestic sectors which, despite its low profile, contributes around £2.35 billion annually to the UK economy. Remanufacturing is an enabler for manufacturing, reducing the use of virgin materials and energy thus allowing more cost-effective manufacturing. Key issues for remanufacturers revolve around the lack of industry-specific tools and techniques and this particularly affects effective decision-making for production issues such as the inspection of returned cores and their constituent components. The main aim of the research was to establish the factors that affect pre-processing inspection and this was achieved using causal true-experimental research into the overall remanufacturing process for over two thousand engines at a Caterpillar Remanufacturing pl ant in the U.K. The research found that the three critical factors in determining the effectiveness of the pre-processing inspection are the complexity of the component geometry including internal ports, the number of sub-components and the number of material employed in the construction of the component. These factors were then used to establish a practical method of assessing the true costs of remanufacturing. The findings were validated at several European Caterpillar Remanufacturing facilities. The beneficiaries of this research are both academia and industry: it adds to the body of remanufacturing knowledge enabling future research to be targeted at operations that materially affect the process and also assists remanufacturers to make their operations more efficient, thus aiding profitability. The novelty of the research is the new knowledge concerning the factors affecting pre-processing inspection together with the limitation of the benefits as well as the information gathered from over two thousand engines in an industrial setting.

KW - remanufacturing

KW - pre-processing

UR - http://ethos.bl.uk/OrderDetails.do?uin=uk.bl.ethos.588979

M3 - Doctoral Thesis

PB - University of Strathclyde

CY - Glasgow

ER -