Remanufacturing engine
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Remanufacturing differs from simple “repair†and “refurbishmentâ€, but aims at improving the performance of used equipment.
Should you consider changing the platform and remanufacturing the engine? This may be the choice for all car owners in the future.
Several factories in Shenzhen Industrial Park, Gaoyang District, Xiangyang City, have heard from time to time the sound of various equipment operating. Entering the factory through the sound, looking forward to seeing here is different from the ordinary workshop, all over the place are looks like the stained and discarded auto parts. A dozen workers in blue uniforms are working in various devices. This is the production workshop of Cummins (Xiangfan) Machining Co., Ltd. The task of the workers is to remanufacture damaged engine parts.
“Remanufacturing in Dongfeng Cummins is no longer a concept. As a pilot enterprise for the remanufacturing of auto parts determined by the National Development and Reform Commission, it has sold 3,000 engines in 2011 and the total turnover exceeds 100 million yuan. It is estimated that the engine will be remanufactured by 2015. Production and sales volume will reach 10,000 units,†said Hu Tao, a Dongfeng Cummins remanufacturing project manager, who told reporters on China's Economy and Information Technology.
Start
"Remanufacturing" means "recycling." Remanufacturing differs from simple “repair†and is also different from “renovationâ€. Instead, it is guided by the life cycle theory of the equipment and aims to achieve the improvement of the performance of used equipment. It is based on the principle of high quality, high efficiency, energy saving and environmental protection, and advanced technology. Technology and industrialized production are the means by which a series of technical measures or engineering activities are carried out to repair or reconstruct used equipment. Compared with new products, remanufacturing can save costs by 50%, save energy by 60% and save materials by 70%. The adverse impact on the environment is significantly lower than that of new products.
Automobile remanufacturing is one of the important technical ways for the automotive industry to develop a circular economy. Through remanufacturing, the traditional automobile manufacturing industry chain is closed. In western and other developed countries, auto parts have been remanufactured for decades. After World War II, the production capacity of auto parts was insufficient, and automakers introduced cheap, quality-assured parts that were remanufactured from scrap parts. Today, almost all mainstream car brands have remanufacturers and replacement parts businesses.
"For automotive engines, the remanufactured engine is to disassemble the recovered engine, replace or repair the substandard parts, assemble it according to the new engine manufacturing standards, and finally restore the engine to the original product. Technical performance and product quality,†said Hu Tao.
China introduced the concept of "remanufacturing" in the late 1990s to carry out industrial innovation in environmental protection and sustainable development. In 2005, the relevant documents of the State Council clearly stated that the state “supports the remanufacture of used mechanical and electronic products†and “organizes the research and development of related green remanufacturing technologies and their innovative capabilitiesâ€. In November of the same year, six ministries and commissions including the National Development and Reform Commission jointly issued the Circular on Organizing and Conducting Circular Economy Pilot Work, among which remanufacturing was listed as one of the four key areas. In the "People's Republic of China Circular Economy Promotion Law," which took effect in 2009, the remanufacturing industry was also elaborated. In 2010, China re-invented the remanufacturing industry, including automobiles, as a national "Twelfth Five-Year Plan" strategic emerging industry.
At present, China's car ownership has exceeded 100 million, and the annual scrapped scale exceeds 5 million. Car remanufacturing makes full use of discarded resources, realizes win-win results of economic benefits and environmental benefits through value reconstruction, meets the requirements of resource-saving and environment-friendly economy, and becomes an important direction for the future development of the automobile industry.
In March 2008, the National Development and Reform Commission awarded 14 domestic auto and parts and components companies the qualification to carry out "remanufacturing" projects. These 14 corporate brands have great influence, strong social responsibility for energy saving and emission reduction, and strong technology in their respective fields. Dongfeng Cummins is one of them. This has also become the start of Dongfeng Cummins' remanufacturing business.
In September 2008, Dongfeng Cummins Engine's remanufacturing pilot program was reviewed by the National Development and Reform Commission. In February 2009, Dongfeng Cummins signed a cooperation agreement with Cummins, its parent company, and invested RMB 100 million to advance Dongfeng Cummins' remanufacturing project.
“Cummins has been remanufacturing projects in the US market for more than 50 years and accumulated a large amount of technical resources. It has provided Dongfeng Cummins with support in terms of standards, technology, talent, and craftsmanship, and has made Dongfeng Cummins' remanufacturing projects work together. Walking in the forefront of the industry, said Hu Tao.
In March 2010, Dongfeng Cummins's "remanufacturing" plant was formally launched. In December of that year, the company officially launched its product, and its annual output of the engine was 10,000 units.
In 2012, Dongfeng Cummins officially passed the acceptance of the National Development and Reform Commission and became a pilot unit for remanufacturing. The state provided financial support of 4.2 million yuan.
Difficulties
"Remanufacturing is not a second-hand goods." Hu Tao popularized this idea for people around him whenever he had the opportunity.
Although Dongfeng Cummins has started remanufacturing for two years, although it has repeatedly promised that product quality is equal to new product, user commitment and warranty of three guarantees are completely consistent with new products, users are still hard to accept. The old half price." Little do they know that due to the incompleteness of the domestic automobile engine recovery management system, there is a huge gray recycling network, while the regular manufacturers of the old parts of the acquisition cost is higher, resulting in engine production costs of remanufacturing and the new machine is almost the same.
It is not only difficult for users to confuse, but also the design and production problems of the first manufacturing of components. Hu Tao said that at present, there are mainly two types of remanufacturing methods, namely size reduction method and recovery size method, and the two methods have advantages and disadvantages. The main advantage of the size reduction method is that the quality is relatively stable, the cost is relatively low, and it is more suitable for mass production. However, due to the different scrap sizes, the processing consistency is poor, and it is not easy for users to accept, and it will cause inconvenience in maintenance; The products remanufactured by the recovery dimension method are basically the same as those of the new products. The user acceptance is good, and the repair parts of the new products can be directly used, but the quality is difficult to control, the process cost is high, and the production efficiency is low. Any one of the two processes requires the possibility of rework of parts. At present, many parts of our country have not considered the possibility of remanufacturing at the beginning of design, which has caused many troubles for remanufacturing.
In view of the market conditions, in order to facilitate rapid acceptance of remanufacturing by users, the state requires that remanufactured products do not enter the new machine assembly market and only enter the spare parts maintenance market. Dongfeng Cummins has targeted the remanufacturing market for the old engine replacement market in the large transportation industry. The user provides the old engine and pays 60% of the new engine for a remanufactured engine. The old-fashioned remanufacturing model enables users to obtain newer engines with minimal expenditures, and cultivates a stable source of raw materials for remanufacturing.
Although the number of domestic end-of-life scrap engines is as high as 5 million, for Dongfeng Cummins, the recovery of old engines is also a major problem that has plagued remanufacturing. "Because of overuse by domestic users, the degree of engine damage is much greater than that of foreign countries; some of the engines have been repaired, and the original parts have been replaced with parallel imports or even counterfeit goods. These actions make it necessary to use new parts for remanufacturing repairs. Replacement of the parts increases the cost of remanufactured engines.†Hu Tao complained.
Zuo Shiquan, director of the Sadie think tank Equipment Industry Research Institute, believes that automobile remanufacturing is mainly the remanufacturing of auto parts. Although it faces very good opportunities for development, some deep problems within the industry have restricted its healthy development for a long time. According to the State Council's Decree No. 307 of the State Council, the "Administrative Measures on the Retirement of Scrapped Vehicles" stipulates that "five major assemblies" such as engines, transmissions, and front and rear axles must be sold to steel companies as raw materials for production.
On the whole, China's auto remanufacturing industry is still in its infancy, and there are only about 6 companies that can form a scale and have remanufacturing capacity.
At present, the automobile remanufacturing industry is relatively confusing and there are some small workshops that lack qualifications. They rely on private sales of engines, transmissions, and other assemblies to obtain huge benefits.
The overall technical level of automotive remanufacturers also needs to be improved. The remanufacturing of auto parts needs to be dismantled, cleaned, tested and classified according to specific procedures, remanufacturing processing or replacement of failed parts, and product reassembling. After rigorous testing, they are finally delivered to the market. China's auto parts remanufacturing industry generally lags behind in equipment, the input cost is too high, and the burden on the company itself is very high. This has led to a large gap between the domestic remanufacturing industry and foreign counterparts in terms of technology and quality.
Xu Chunlin, deputy director of the Automotive Industry Office of Xiangyang City, believes that current auto remanufacturing as a new concept has not yet been widely recognized. Consumers do not really realize the benefits of using remanufactured products; the country has not yet formed a policy for the development of the auto remanufacturing industry. surroundings.
activation
In recent years, China's auto remanufacturing has made positive progress. Remanufacturers have achieved initial results in terms of technology, policies, standards, and market regulations.
The huge domestic market has also attracted some international auto remanufacturing companies. In addition to Dongfeng Cummins has already aimed at this market, Germany's ALBA company, the British Liszt Group have already entered China's auto remanufacturing industry. "Although China's auto remanufacturing industry has just started and is in its infancy, the future is very promising. With the rapid increase in the number of car ownership in China in recent years, the number of scrapped cars will also increase steadily every year, providing for remanufacturing. Abundant resources.If we look at the proportion of car ownership in the developed countries, such as the United States, and the proportion of remanufacturing industries, there is still huge potential for development in China's auto remanufacturing industry, said Xu Chunlin, deputy director of the Automotive Industry Office of Xiangyang City.
Looking at the world, automotive engine remanufacturing has become a sunrise industry. Compared with other developed countries in Europe and America, the development of China's automobile remanufacturing industry started slowly during the “Eleventh Five-Year Plan†period.
Zuo Shiquan believes that in order to promote the healthy and orderly development of the automobile remanufacturing industry, it is necessary to strictly follow the “Administrative Measures for Pilot Remanufacturing of Auto Parts†promulgated by the State, strengthen the management of pilot enterprises for auto parts remanufacturing, and nurture and foster advanced technologies. A group of leading enterprises with good economic returns continue to strengthen publicity and policy guidance, encourage consumers and public institutions to give priority to the use of remanufactured products through financial subsidies, gradually increase consumer awareness of remanufactured products, and expand the market for remanufactured products. scale. At the same time, it is necessary to strengthen collaborative innovation in the integration of production, education and research in automobile remanufacturing, especially the research and innovation of key common technologies, establish corresponding mechanisms, coordinate the interests of all parties, and shorten the gap with foreign automotive remanufacturing industries as soon as possible.
As a remanufacturer, Hu Tao hopes that domestic remanufacturing can be industrialized as much as Europe and the United States. He suggested adopting a series of comprehensive measures such as fiscal, taxation, and industry to quickly make remanufacturing scale, form an industry, and form a new economic growth point.