Environmentally Conscious Design amp; Manufacturing.ppt

Environmentally Conscious Design Manufacturing Why Remanufacture? Why Remanufacture ? E.g. - Cartridge remanufacturing saves 38,000 tons of metal plastics annually 18 million gallons of oil needed annually to make cartridges Encourages local small business 1000 years needed for plastics to decompose Remanufacturing Processes Example - 1 Step 1 Engines are stripped bare. The block is baked for eight hours in a thermal oven at 700 degrees. Naturally cooled, then steel shot for ten minutes. The block is then magnafluxed and carefully inspected for flaws. Example - 2 Step 2 The block is align honed to insure the crankshaft main journals are on the same centerline; this reduces bearing wear and improves oil pressure and performance. Cylinders are then bored to specification and honed. Example - 3 The block deck surfaces are checked in reference to the crankshaft centerline. The block then goes through a high pressure wash to clean all galley holes followed by the application of several coats of rust protectant after deburring and tapping. New plugs and a set of cam bearings are installed. Example - 4 Step 3 The crankshaft is precision ground, and oil holes are chamfered, micro polished, and rebalanced. Shafts that wont grind to size arc discarded. Connecting rods are resized and balanced, pistons are precision fitted to connecting rods, and assemblies are weighed and checked for balance. Example - 5 Step 4 The block receives three coats of high temperature engine paint. All bolts are heat treated, stress relieved, deburred, and hand inspected. All external parts are inspected, painted, and brought to the clean room for final check out and final assembly. Example - 6 Step 5 Cylinder head castings are remanufactured to exact specifications. All heads receive hard seats for unleaded or regular fuel. Valve seats are triple angle cut, and valve guides are replaced or resized. Valves are refaced or replaced as required. Example - 7 The head surface i