Current Situation in Cleaning Process of Remanufacturing in Malaysia: A Case Study

Remanufacturing process among industries is relatively new in Malaysia. In USA, Europe, Japan, China and India, remanufacturing is already viewed as a huge business opportunity that significantly stimulates growth in Gross Domestic Product (GDP) and employment. The aim of this paper is to expose all possible causes of failures using the Ishikawa diagram and identify the most significant failures using Failure Mode and Effect Analysis (FMEA) with two Risk Priority Number (RPNs). The cleaning process is both time-consuming as well as the most costly of the entire remanufacturing processes. The case study is performed in an automotive contract remanufacturing environment in Malaysia, specifically the remanufacturing of cylinder heads. This work outcome explores the current situation pertaining to the cleaning process in a real world situation, and attempts to promote among researchers green ideas that will bring Malaysias remanufacturing on par with that of other developed countries.

[1]  Deborah L Thurston,et al.  Remanufacturing: Impacts of sacrificial cylinder liners , 2003 .

[2]  A. Darker,et al.  TOTAL QUALITY CONTROL , 1987 .

[3]  María Teresa Lamata,et al.  Selection of a cleaning system for engine maintenance based on the analytic hierarchy process , 2009, Comput. Ind. Eng..

[4]  Slavek Kshonze,et al.  Remanufacturing Process of Gasoline and Diesel Engines to OEM Requirements , 1998 .

[5]  Alf Inge Wang,et al.  Improving the effectiveness of root cause analysis in post mortem analysis: A controlled experiment , 2009, Inf. Softw. Technol..

[6]  B. Bras,et al.  CHARACTERIZING THE REMANUFACTURABILITY OF ENGINEERING SYSTEMS , 1995 .

[7]  Michael R. Beauregard,et al.  The Basics of FMEA , 1996 .

[8]  Bert Bras,et al.  Issues in the Automotive Parts Remanufacturing Industry - A Discussion of Results from Surveys Performed among Remanufacturers , 1998 .

[9]  L. H. Shu,et al.  Application of a design-for-remanufacture framework to the selection of product life-cycle fastening and joining methods , 1999 .

[10]  T. P. Bagchi,et al.  Problem solving in sintering of tungsten heavy alloy product — a case study , 2001 .

[11]  Bernard Kamsu-Foguem,et al.  Continuous improvement through knowledge-guided analysis in experience feedback , 2011, Eng. Appl. Artif. Intell..

[12]  Winifred Ijomah,et al.  Remanufacturing: a key strategy for sustainable development , 2004 .

[13]  Pooja Sharma,et al.  Integrated framework to optimize RAM and cost decisions in a process plant , 2012 .

[14]  Levent Kurt,et al.  Failure mode and effect analysis for dairy product manufacturing: Practical safety improvement action plan with cases from Turkey , 2013 .

[15]  Wei Wu,et al.  Development of a risk-based maintenance strategy using FMEA for a continuous catalytic reforming plant , 2012 .

[16]  Chao Chung Ho,et al.  The use of failure mode and effects analysis to construct an effective disposal and prevention mechanism for infectious hospital waste. , 2011, Waste management.

[17]  Cheng-Chung Lin,et al.  A study of storage tank accidents , 2006 .

[18]  Yogesh Chandra Sharma,et al.  A critical review on corrosion of compression ignition (CI) engine parts by biodiesel and biodiesel blends and its inhibition , 2012 .

[19]  Yanbin Du,et al.  An integrated method for evaluating the remanufacturability of used machine tool , 2012 .

[20]  Jianfeng Yang,et al.  Criticality evaluation of petrochemical equipment based on fuzzy comprehensive evaluation and a BP neural network , 2009 .

[21]  Michael Bommer,et al.  Design charts for remanufacturing assessment , 1999 .

[22]  Hong-Zhong Huang,et al.  Design FMEA for a diesel engine using two risk priority numbers , 2012, 2012 Proceedings Annual Reliability and Maintainability Symposium.

[23]  Francisco Jurado,et al.  Study of a downdraft gasifier and gas engine fueled with olive oil industry wastes , 2013 .

[24]  Marianne Wallis,et al.  The impact of organisational and individual factors on team communication in surgery: a qualitative study. , 2010, International journal of nursing studies.

[25]  E. Sundin,et al.  Making functional sales environmentally and economically beneficial through product remanufacturing , 2005 .

[26]  Noor Ezlin Ahmad Basri,et al.  Focusing on Recycling Practice to Promote Sustainable Behavior , 2012 .

[27]  Rodolfo Valdés,et al.  Application of a risk analysis method to different technologies for producing a monoclonal antibody employed in hepatitis B vaccine manufacturing. , 2012, Biologicals : journal of the International Association of Biological Standardization.

[28]  Mimi Haryani Hassim,et al.  Fugitive emissions in chemical processes.The assessment and prevention based on inherent and add-on approaches , 2012 .

[29]  C. C. Wang,et al.  Application of RPN analysis to parameter optimization of passive components , 2010, Microelectronics Reliability.

[30]  Paul Barach,et al.  Quality improvement methods to study and improve the process and outcomes of pediatric cardiac care , 2011 .