The Core Return Process
The remanufacturing process consists of two clusters that are controlled by the IT system as the central interface.
The first sub-process comprises the core reflow and is structured as follows:
At the time a replacement engine is ordered by the retail trade, all information relevant to the spread of the old engine is reported to the system in order to control the return flow. The information package includes the production date, mileage, damage pattern and engine type of the customer's engine. In the process, a decision is automatically made as to whether the return unit should be integrated into the reprocessing process or whether it should be released for scrapping, thus avoiding unnecessary storage and dismantling costs. In the case of reconditioning, the old part is taken to a collection point via a logistics partner and stored there until remanufacturing.
The Reman Production
In the second part of the Reman process, there are two possible scenarios for controlling production. The decision which scenario is implemented is made by Production Planning. The standard procedure is production in stock. The MRP controller makes a forecast of the engines to be produced and can also report an ad hoc order for additional engines at any time during planning. The system automatically checks the feasibility of the order and other forecast production orders for reman parts availability. If the parts inventory is insufficient, the system indicates feasible manufacturing alternatives. For this, the advantages of digital structures are used to determine optimal production lots. This tailor-made proposal is created by considering the current core availability, the specific failure statistics and the demand situation of the respective engine variants.
As soon as production planning has confirmed the construction of a type, the orders are distributed to the various stations. The new and Reman part call-offs are then entered and the downstream logistics process is triggered.