As maintenance and capital investment budgets continue to shrink, many manufacturers are beginning to recognize the value of remanufacturing existing assets that malfunction or fail. Just fixing the problem that caused your equipment malfunction/failure isn’t always enough to guarantee its proper operation.
Have you ever been in a storeroom where you saw open boxes with parts in them such as AC drives, DC drives, PLCs, power supplies, and so forth, with handwriting on the box flagging them as “NG” (no good)? The part may have been swapped out during troubleshooting at 2:00 a.m. Or it could have come off a machine because it may, or may not have been, the source of a problem on the plant floor. Reductions in maintenance staff and spare parts inventory often lead to longer downtime and lost revenue when your automation assets malfunction or fail. The rising cost of downtime continues to place increased pressure on plant production lines and budgets. Is remanufacturing a viable option you should consider for failed or malfunctioning equipment? Yes.
What is remanufacturing?
Remanufacturing is the industrial process of returning a product to its original performance. The process involves dismantling a product, restoring and replacing components, installing the latest firmware, testing the individual parts, and restoring the whole product to its original design specifications. The performance after remanufacture is expected to be at least the same as the original performance specification—“like new” or better—and the remanufactured product typically comes with a 12 to 24-month warranty. Regardless of the industry or environment, remanufacture of failed or malfunctioning equipment is a smart choice.
Companies consider remanufacturing as a practical choice for:
- Resolving machine performance issues that decrease machine reliability and extend the duration of unplanned downtime
- Reducing and/or stabilizing machine repair costs
- Accommodating process issues such as machine reliability, production flexibility, and operation at design specifications
Rockwell Automation® has a 7-step Remanufacturing Process that restores Allen-Bradley® equipment to its original operating condition, extending equipment life and allowing it to function in “like new” or better condition. This 7-step process includes:
Rockwell Automation’s proprietary remanufacturing process extends equipment life and gets the unit back to you in “like new” condition. Below is a good overview video from Rockwell Automation® that illustrates their remanufacturing process:
Because remanufacturing recycles existing equipment, it offers a viable and cost-effective opportunity for sustainable development. For some customers who want to reduce overall operating costs plus reduce waste, a new part or equipment might not be the best fit for their business. However, they still need to rely on a high-quality option. With remanufactured equipment, they receive like-new equipment without the new price, plus the confidence of a warranty and the sustainable benefits.
Horizon Solutions partners with Rockwell Automation® to provide complete, cost-effective remanufacturing services and factory enhancements that extend equipment life, while enhancing performance and compatibility. Our remanufacturing services include a comprehensive process to restore Allen-Bradley® and Reliance Electric equipment to its original operating condition. We repair over seven thousand brands of industrial electronics.
Have you put a plan in place to have your malfunctioning equipment remanufactured? What insights can you share on this topic?