Remanufacturing in the context of today s focus on circular economy and urban mining REMANUFACTURING FOR THE AUTOMOTIVE AFTERMARKET G7 Workshop Industrial Symbiosis I 29.10.2015 I Robert Bosch Ltd GmbH 2015. 2015. All rights Alle Rechte reserved, vorbehalten, also regarding auch any bzgl. disposal, jeder Verfügung, exploitation, 1
Can increasing raw material costs limit the cycle economy in the Automotive Industry? REMANUFACTURING FOR THE AUTOMOTIVE AFTERMARKET G7 Workshop Industrial Symbiosis I 29.10.2015 I Robert Bosch Ltd GmbH 2015. 2015. All rights Alle Rechte reserved, vorbehalten, also regarding auch any bzgl. disposal, jeder Verfügung, exploitation, 2
Costs of Raw Materials 3
Down sizing in the automobile industry 4
Automotive parts are getting smaller & more powerful 1995 1,7 KW 11,6kg 1.1KW 7 kg 2015 3,1 KW 7,9kg 1,4 KW 3,4 kg 5
Critical Materials out of the view of the EC 6
Utilization of rare and expensive raw materials 7
Parts proliferation and availability With the age of the car, the need for service parts increases Small-scale new production for the aftermarket is expensive Remanufacturing down to very few pieces with short delivery time is possible 8
Remanufacturing 9
The footprint of the remanufacturing Industry. REMANUFACTURING FOR THE AUTOMOTIVE AFTERMARKET G7 Workshop Industrial Symbiosis I 29.10.2015 I Robert Bosch Ltd GmbH 2015. 2015. All rights Alle Rechte reserved, vorbehalten, also regarding auch any bzgl. disposal, jeder Verfügung, exploitation, 10
Definiton: Remanufactured Part 11
Remanufacturing Product Portfolio Preconditions for Remanufacturing Costs saving potential due to reusable high raw material or components value Need for high hardware investments in workshops prohibits economical field repair Limited access to components (Age wise, Electronic component generation, EoP, captive products) Access to all-makes product ranges 12
Remanufacturing Products 13
Remanufacturing Products Common Rail Pumps Headlamp Motors Sunroof Motors Tailgate Motors Transfer Case Motors Window Lift Motors & Gear Kits Window Lift Motors w/regulators Wiper Motors & Pulse Boards ABS Modules Body Control Computers Cruise Control Modules Engine Control Computers Generic Electronic Modules PROM Chips Ignition Crank Angle Sensors Ignition Distributors Injector Driver Modules Mass Airflow Sensors Power Supply Modules Relay Control Modules Suspension Control Modules Throttle Body Assemblies Transmission Control Modules Vane Airflow Meters Brakes Starter Alternators Injection Pumps Control Valves Electronic Power Steering Power Cylinders Power Steering Pumps Power Steering Filters Rack & Pinion Units Steering Gears Turbocharge r Drive Axle Prop Shaft Common Rail Injectors Smog Air Pumps Vacuum Pumps Water Pumps 14
Remanufacturing Markets Preconditions for Remanufacturing Logistically mature country enable the core collection process High labor costs in workshops prohibit economical field repair Average age of vehicle population high enough Reman plant close to target market: Economics of core collection, close loop from core collection to sales Legal Issues: Authorization of reman products and processes in different countries, legislation to support remanufacturing and circular economy 15
Markets: Repair & New/Remanufacturing Reman markets: high labour costs, workshops exchange complete units (e.g. alternator) Repair markets: low labour costs, workshops identify & replace solely the broken components (e.g. regulator) Repair & New Markets* Future Reman Markets Established Reman Markets 16
Remanufacturing: Market size and potential Key figures*: 35 Mio remanufactured parts p.a. 32.000 direct related jobs in EU28 Reducing potential of CO2 eq emission by 400kt in EU28 Saving natural resources compared to new units - up to 85% of raw material - About 55% of energy Reasonable price compared with a new unit * With out tires 17
Quality of remanufactured products, opportunities and limitations. REMANUFACTURING FOR THE AUTOMOTIVE AFTERMARKET G7 Workshop Industrial Symbiosis I 29.10.2015 I Robert Bosch Ltd GmbH 2015. 2015. All rights Alle Rechte reserved, vorbehalten, also regarding auch any bzgl. disposal, jeder Verfügung, exploitation, 18
Remanufacturing process 1 2 Sorting of cores Complete disassembly 3 Cleaning and testing of parts 3 1 3 4 Restoring of parts or replacement by new components 5 6 Assembly End-of-line test Packaging 7 2 5 19
Components used in Remanufacturing Re-used is in line with specification 100% replaced 20
Ecological benefits of Remanufacturing 1) Estimation of the impact with the method: Cumulative Energy Demand Version 1.05 Source: University Bayreuth Energy 1) New Production Logistic 21
Remanufacturing for the Automotive Aftermarket. THANK YOU FOR YOUR ATTENTION. G7 Workshop Industrial Symbiosis I 29.10.2015 I Robert Bosch Ltd GmbH 2015. 2015. All rights Alle Rechte reserved, vorbehalten, also regarding auch any bzgl. disposal, jeder Verfügung, exploitation, 22