Remanufacturing is an industrial process in which a core – a used, discarded, or broken product – is transformed into a product with a like-new specification and condition. However, to this date, remanufacturing activities on the market are few compared to manufacturing. There are several types of remanufacturers; the least common type is the original equipment remanufacturer, an original equipment manufacturer that not only manufactures new products but also remanufactures cores of its own products. Remanufacturing is potentially becoming a more widely used industrial process for original equipment manufacturers, and increased remanufacturing activities can positively contribute to the environment. The contribution comes from a reduction of raw material and energy consumption compared to manufacturing. Therefore, remanufacturing has the potential to decouple environmental impact from economic growth, thus contributing to more sustainable societies. However, assessing the benefits of remanufacturing does not directly correlate to growth within the remanufacturing industry. To encapsulate the environmental, social, and economic benefits of remanufacturing, manufacturers need to be aware of how remanufacturing can be initiated and implemented in practice. Therefore, the objective of this dissertation is to develop support measures for original equipment manufacturers to initiate profitable remanufacturing.
This research takes a stand in case study and transdisciplinary research where the initiation of profitable remanufacturing is studied at two original equipment manufacturers. The research study developed knowledge of how remanufacturing could be incorporated into existing operations at original equipment manufacturers. In parallel, financial assessments based on cost-benefit analysis were built to measure how well the case companies could perform remanufacturing. For the case study research, seven remanufacturing scenarios were developed, ranging from centralised remanufacturing performed by the original equipment manufacturer to decentralised performed at multiple locations using a retail network. Which scenario is preferable depends on, for example, risk-consciousness, cooperation between actors, and volume targets. However, given ideal circumstances, remanufacturing in-house in a centralised scenario was shown to be the most beneficial for the investigated original equipment manufacturer since the fewer middle hands and economies of scale also potentially enable lower costs.
For the transdisciplinary research, the remanufacturing initiation was business model-centric, meaning that the remanufacturing system was a consequence of a decision for a specific business model. Here, a scenario-based analysis was developed to understand under which circumstances the business model with remanufacturing was more lucrative for the provider – the original equipment manufacturer – and less costly for the users – the customers. For this, a systematic assessment approach was developed consisting of three steps: (1) provide a cost overview for each business model, (2) create scenarios by modifying the cost drivers, and (3) combine scenarios to reach synergetic effects.
Based on the case study, two sets of four prerequisites for initiating remanufacturing were derived. These are divided into essential and supporting prerequisites and illustrated through a framework called the Remanufacturing Rocket. The essential prerequisites highlight fundamental requirements to perform remanufacturing. Should one of these four factors be missing, remanufacturing cannot be successfully initiated. The supporting prerequisites are valuable to enhance the effectiveness and efficiency of the process, such as through streamlined operations, organisational change, or information exchange. Hence, to reach the fullest potential of remanufacturing, both the essential and the supporting prerequisites are needed.
Furthermore, the area of financial assessments was explored in a systematic literature review to identify insights for developing such assessments tailored for individual original equipment manufacturers in initiating remanufacturing. For this, six perspectives for framing financial assessments are proposed. These cover the system boundaries for the assessments as well as the individual needs and visions of original equipment manufacturers. Additionally, a framework was developed to select financial assessment models for remanufacturing initiations based on ease of use and capability to handle complex datasets.
Conclusively, it is proposed to apply the prerequisites for initiating remanufacturing together with a financial assessment in an iterative manner to investigate the profitability for original equipment manufacturers to initiate remanufacturing. The essential prerequisites influence the first iteration of the financial assessment, which then contributes to refinements of how the essential prerequisites should be aligned in an economically preferable way. Once satisfactory, another iterative process could be initiated between the supporting prerequisites and the financial assessment. By using the proposed approach, the prospects of profitable remanufacturing could be thoroughly investigated before attempting to initiate a process in practice, thus reducing the number of resources spent in vain. Additionally, the iterative process was integrated into a 5-step Approach For Initiating Remanufacturing (5AFIR) to guide original equipment manufacturers towards initiating profitable remanufacturing.