Caterpillar Accelerates Layout Machinery Remanufacturing

In many domestic large-scale mines, such as the Shenhua Opencast Mine, the “off-highway trucks” that are responsible for the main transport of ore are already uncompromising, and large-scale equipment that can easily be maintained at around 20 million yuan will remain stable. The state, I believe, is what every mine owner wants to see. “However, some off-highway trucks are discarded after more than 30,000 hours of work. Take the CAT 777D off-highway truck as an example. If the remanufacturing process of Caterpillar and its agents, then the service life of the machine can be extended. 1-3 times, can play a greater role in the use of equipment." Caterpillar responsible for the global vice president of remanufacturing and parts business unit Greg Folley said so.

Greg Folley, Global Vice President of Caterpillar's Remanufacturing and Components Business Unit, is interviewed by this site as one of the world's top 500 companies. Caterpillar is the world's largest construction machine, mining equipment, diesel and natural gas engine, industrial gas turbine and A leading company for diesel-electric hybrid locomotives. For 85 years, Caterpillar has been making unremitting efforts to actively and sustainably transform itself in all continents. At the same time, Caterpillar is also a leading provider of total solutions with Caterpillar Financial Services, Caterpillar Remanufacturing Services, Caterpillar Logistics Services and Rail Services.

"First, remanufactured products are not used, used, or damaged products! Remanufacturing is the process of reprocessing matured products in an industrial production environment to restore the quality and performance of an equivalent new product. The performance, reliability, durability, and maintenance guarantees are an advanced form of recycling.” Greg Folley gave such a definition to the reporter of the first engineering machinery network around “remanufacturing”. According to statistics, the Caterpillar remanufacturing business originated in 1972. The number of remanufactured products of Caterpillar amounts to 2.2 million pieces every year. About 9,000 pieces of remanufactured finished products are shipped to the world every day, and 100 pieces of engine/gearbox are manufactured every day. Use about 60 million kilograms of old pieces. Caterpillar remanufactured product parts maintain the same quality and warranty service as the "new" but are priced lower than New Products.

The domestic remanufacturing industry has just begun

Compared with the development achievements of many industrialized countries in foreign countries in terms of remanufacturing, China is much later in this respect. For a long time, in the domestic equipment manufacturing industry economy, some sub-sectors have “extensive economic development methods”, poor technological innovation capability, insufficient product stability, poor salvage value, and low value-added products. In the domestic construction machinery industry, the market competition headed by loaders, excavators, etc. has become increasingly fierce in recent years, and price wars are not uncommon. Although the market share of domestic brands has risen steadily, the stability of products has been doubted by the owners. According to relevant statistics, from the year 2000 onwards, the domestic domestic excavator products have more than 1.2 million units, and the huge market capacity means that many excavators are immediately eliminated as waste steel after being “finished”. If the entire machine is dismantled and remanufactured and recycled for key parts and components, sustainable development will become extremely important to the industry and even society.

In 2005, the State Council made clear its support for the development of remanufacturing in the "Several Opinions on Accelerating the Development of Circular Economy." The first batch of circular economy pilots will focus on remanufacturing. The "Circular Economy Promotion Law" implemented in January 2009 incorporated remanufacturing into the legal system. In May 2010, 11 ministries jointly issued the "Opinions on the Development of Remanufacturing Industry." Figures show that remanufactured products can save energy by 60%, save 70% of materials, save costs by 50%, produce almost no solid waste, and emit atmospheric pollutants. The amount is reduced by more than 80%. In September 2011, the National Development and Reform Commission issued the "Notice on Deepening Remanufacturing Pilot Work", expanding the types and scope of remanufactured products, and intensifying support. The Development and Reform Commission and related departments have studied the corresponding preferential tax policies.

Ben Wang reporter believes that for the domestic construction machinery industry, it is necessary to treat "remanufacturing" as one of the important means of sustainable industrial development as soon as possible. It is gratifying that in May 2011, the Standing Committee of the China Construction Machinery Industry Association passed the application for the maintenance of the Engineering Machinery Maintenance Subcommittee to the Maintenance and Remanufacturing Sub-committee, and was approved by the China Machinery Industry Federation, the State-owned Assets Supervision and Administration Commission and the Ministry of Civil Affairs. At present, “remanufacturing” has officially become an important branch of the trade association’s functions and scope of work. Its purpose is to promote the development and innovation of engineering machinery maintenance and remanufacturing industries, and to improve the management and maintenance of construction machinery maintenance and remanufacturing enterprises. To promote the technical progress of the maintenance and remanufacturing industries of construction machinery and meet market demand services.

In spite of this, people in the industry believe that there are still some problems that need to be resolved in China compared with the mature remanufacturing industries abroad. First of all, due to its early development, the national policy is not sound. Second, the remanufactured industry standard is still a blank in China. Third, domestic users generally have repelling psychology on remanufactured products and need the industry to promote and guide remanufacturing.

Caterpillar urged the Chinese government to strengthen development work <br> remanufacturing industry <br> Caterpillar Remanufacturing layout China

In the global engineering machinery industry, Caterpillar's remanufacturing business is becoming a model for learning and transcending at home and abroad. Caterpillar entered China as early as in the 1970s and has achieved leaps and bounds in China. After previous cooperation projects such as technology transfer, Caterpillar has been accelerating its deployment in China and has four major construction machinery dealerships. At the same time, it has 18 manufacturing plants in China, 9 new factories under construction, 4 R&D centers, and 3 logistics and parts centers.

In 2006, Caterpillar signed a letter of intent with the China Development and Reform Commission to provide relevant expertise to support the development of China's remanufacturing industry. Caterpillar Remanufacturing Services is the first foreign-owned company to obtain remanufacturing licenses in China. In order to support Chinese customers and agents and other customers in the Asia Pacific region, Caterpillar has established a regional remanufacturing center in Shanghai. In December 2009, Caterpillar Remanufacturing Shanghai was approved by the Ministry of Industry and Information Technology as a remanufacturing pilot company.

In order to realize the scale development in China, Caterpillar established a remanufacturing joint venture with domestic diesel engine giant China Yuchai at the end of 2009. The company is Yuchai diesel engine and its components, and part of Caterpillar diesel engines and its Parts provide remanufacturing services. After three years of trial construction of plant construction and remanufacturing business, on July 9 this year, that is, not too long ago, Caterpillar and Guangxi Yuchai Machinery Co., Ltd. jointly announced that Yuchai remanufacturing service factory was formally established in Suzhou. This marked the opening of Caterpillar's second remanufacturing facility in China.

"The combination of Caterpillar and Yuchai machines will enable both parties to flexibly meet China's market demand through remanufactured products and at the same time promote the sustainable development of the manufacturing industry. This is also in line with the sustainable development and environment advocated by the Chinese government. "The concept of protection." Li Zhengyu, general manager of Caterpillar Global Mining and the remanufacturing business in the Asia-Pacific region, told the reporter of the First Construction Machinery Network. It is reported that the Yuchai remanufacturing service plant is located in the Suzhou Industrial Park, with a production area of ​​approximately 14,000 square meters in the first phase. When the plant is fully put into production in 2014, the number of employees is expected to reach 400 people. "It is expected that the first-phase production capacity of the Suzhou plant will be approximately 15,000 remanufactured engines. After the second phase of production, the production capacity will increase to approximately double the current level."

Caterpillar E Series Excavators As of now, Caterpillar's global remanufacturing facilities are located in North America, Mexico, Singapore, Shanghai, and Suzhou. Caterpillar has a wide range of over 6,000 product lines for remanufactured products, including engine and engine related parts, transmission systems, hydraulic products and electronics.

“The development of remanufacturing requires the exchange of old parts, and there is no remanufactured product without old parts. For example, after a certain period of use, if the customer returns the old part, it will be 40 yuan; after remanufacturing process After that, the product can be sold at an actual price of 100 yuan.” Li Zhengyu, the general manager, gave such a metaphor. “The new price of this part is actually much higher than 100 yuan, but everyone can get the same performance as new products by buying remanufactured parts, and the purchase cost is reduced a lot.”

Taking a turbocharger as an example, some quality problems may occur after the cover has been used for 3,000 hours (expected life of 5000 hours). At this time, the customer can select three treatment options: First, repair, replace cover, After repairing other components, the remaining service life of the repaired equipment is 2000 hours; followed by refurbishment, covers, bearings, and other damaged parts are replaced, and the remaining service life of the equipment after refurbishment is 4000 hours; however, if Caterpillar is selected Remanufacturing, complete dismantling of the turbocharger, diagnosis of usability, replacement of caps and bearings, and remanufactured all of the components that were recycled and reused to the same specifications as the new product. The new parts are assembled, balanced, and tested with the remanufactured parts. The remaining life of the remanufactured turbocharger is 5000 hours, the same as the new product life.
It is usually simpler to keep the identity of the parts normally. Consistent factory environment Repairing a problem is more advanced than repairing. Upgrading absorbs the latest process changes. Parts are usually collected by the agent, customer or refurbisher (discarding the original identity). Original specifications directly dealt with by engineers and factory processes may not use original branded parts 100% use original brand parts refurbishers need to undertake maintenance obligations remanufactured products provide the same durability as new products repair services refurbishers need tools, terms of equipment, training and other investment needs of old parts remanufacturing, customers return exchange <br> domestic remanufacturing industry need to improve the environment

After comparison, remanufactured parts have obvious advantages over new parts. However, according to the reporter of the First Construction Machinery Network, the actual situation is not as good as imagined. For the development environment of China's construction machinery remanufacturing industry, Li Zhengyu raised his own concerns. “Remanufacturing is very good, but the lifeblood of this industry development is whether there is sufficient supply of second-hand parts. If there is no suitable second-hand parts recycling mechanism, Everything may be empty talk.” He said that the current domestic price increase is mainly due to the high cost of circulation costs. As a result, the cost of second-hand construction machinery parts recovery will be high if the remanufactured parts are remanufactured. If the selling price exceeds the new parts, then it will lose the significance of remanufacturing itself. Secondly, the domestic construction machinery industry currently lacks effective second-hand construction machinery circulation and old parts recycling mechanisms. After many used construction machines reach a certain age, they are arbitrarily regarded as waste iron and iron, and the current industry still lacks “saving social resources as a whole”. Improve the concept of environmental awareness.

The author believes that the development of the remanufacturing industry in the construction machinery industry should be established as soon as possible, the policy support for the remanufacturing industry should be enhanced, the import and export taxation mechanism for the remanufacturing of construction machinery parts should be improved, and the entire industry should be trained to popularize the concept of remanufacturing of construction machinery. It's all we need to do urgently. The remanufacturing of domestic construction machinery has just begun and the establishment of a sound development environment is of utmost importance.