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Lean Remanufacture of an Automobile Clutch
Tony Amezquita* and Bert Bras**
Saturn Corporation Systems Realization Laboratory
Spring Hill, Tennessee Woodruff School of Mechanical Engineering
Georgia Institute of Technology
Atlanta, Georgia 30332-0405
Abstract
In the history of manufacturing there have been three production systems, namely, craft production, mass production, and lean production. In many automotive remanufacturing operations, craft production and mass production systems are used as the basis for remanufacturing processes. The lean production system has proven to be more effective in the manufacture of automotive parts and it has allowed manufacturers who use it to produce in much greater varieties, with higher quality levels, and with lower costs. Hence, if used in remanufacturing, it would greatly enhance it. In this paper, a current remanufacturing process of an automobile clutch is analyzed, and a lean remanufacturing process is developed and compared to the as is process. Our findings indicate that the lean remanufacturing process provides a more robust process with lower costs when compared with the current clutch remanufacturing process that utilize craft and mass production practices.
1 Our Frame of Reference – Remanufacture in the Automotive Industry
Remanufacturing is the most economically sustainable form of reuse and recycling of manufactured goods, and it can be defined as the industrial process where worn out products referred to as cores, are brought back to original specifications and condition. In some cases, especially in the remanufacture of OEM automotive parts, remanufactured products exceed original specifications. The reason is that the latest engineering design and specifications, coupled with failure mode countermeasures derived from failure analysis, are used instead of the original specifications. The benefits of remanufacturing are many, but the most salient are:
1) Remanufacturing salvag
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