PREMANUS

Product Remanufacturing Service System

PREMANUS 2
Personal Information
ROSSELLA LUGLIETTI
Environmental Engineer
POLITECNICO DI MILANO
MAIN TOPIC:
Evaluation of environmental implications of products or services in a lifecycle
perspective, combining different Life Cycle Assessment (LCA) techniques.
PREMANUS:
Developing a Business Decision Support System to evaluate rank
different end-of-Life strategy from an environmental and economic
perspective.
Rossella Luglietti
25
th
26
th
September Rochester New York
Cost and Environmental Impact Evaluation
for End-of-Life Strategies in
Remanufacturing
PREMANUS 4
PREMANUS Context
The research leading to these results has received funding from
the European Communitys Seventh Framework Programme
(FP7/2007-2013) under grant agreement n285541.
Rossella Luglietti, World Remanufacturing Summit, 25
th
-26
th
September 2014
PREMANUS 5
PREMANUS OVERVIEW
PREMANUS is a Software Platform which facilitates the
products End-of-Life management
Remanufacturing Strategy
Environmental and Economic evaluation of End-of-Life
strategies, knowing Product Lifecycle data.
Rossella Luglietti, World Remanufacturing Summit, 25
th
-26
th
September 2014
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PREMANUS Architecture
Rossella Luglietti, World Remanufacturing Summit, 25
th
-26
th
September 2014
PREMANUS Gateway is
responsible for making
services and information
available to the rest of the
PREMANUS.
PREMANUS Client
makes the information,
services and resources of the
Network available to the
client logic, the BDSS
PREMANUS Cloud
provides a number of key
services to the PREMANUS
Clients and Gateways
connected to the
PREMANUS network
PREMANUS 7
PREMANUS Pilots
Waste of Electrical and Electronic Equipment
management strategy
Wind turbine gearbox remanufacturing
strategy
Engine remanufacturing strategy
Rossella Luglietti, World Remanufacturing Summit, 25
th
-26
th
September 2014
PREMANUS 8
PREMANUS Business purpose
B
D
S
S
Evaluates the best End-of-Life option for complex products,
considering both environmental impacts and economic costs,
using lifecycle data.
Focus on the influence of different recycling plant strategies for
WEEE.
ENVIRONMNETAL EVALUATION:
employs a streamlined Life Cycle Assessment (LCA) methodology. The
system boundaries have been extended considering the benefits of the
avoidance of equivalent raw material extraction (for general use) and product
manufacturing.
Rossella Luglietti, World Remanufacturing Summit, 25
th
-26
th
September 2014
ECONOMIC EVALUATION:
includes all the direct costs: Process costs
Product cost purchasing
Revenue for selling remanufactured/reused product
or fractions after material recovery
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PREMANUS Pilots description
Waste of Electrical and Electronic Equipment
management strategy
Wind turbine gearbox remanufacturing
strategy
Engine remanufacturing strategy
Rossella Luglietti, World Remanufacturing Summit, 25
th
-26
th
September 2014
PREMANUS 11
Engine remanufacturing evaluation process
ASKING FOR A QUOTE
A dealer wants to sell
the core to FIAT, and
sends a request for a
quote.
Makes the inspection
and inserts available
lifecycle data.
EVALUATION AND QUOTE
RESULTS
Calculates the overall
cost and environmental
impact, including the
missing information
fetch into the cloud
service.
The dealer receive the
quote
VALIDATION AND REMAN
PROCESSING
A production manager
makes a detailed
inspection and updates
relevant data.
Does remanufacturing
reducing stock, time
and manpower
Rossella Luglietti, World Remanufacturing Summit, 25
th
-26
th
September 2014
PREMANUS 12
Engine BDSS application
ENGINE REMANUFACTURING Strategy
DIFFERENT ASSESSED
ALTERNATIVES CONSIDERING:
Remanufacturing;
Reuse
Recycling;
Raw materials
extraction
Manufacturing Use phase End of Life
Material Recovery
Remanufacturing
Reusing
Disposal
D
i
s
a
s
s
e
m
b
l
y
Washing Sandblasting
Checking
Crankshaft
Con rods
Cylinder head
Cylinder block
Pistons
Flywheel
Camshaft
Turbo
M
a
c
h
i
n
i
n
g
Cores
A
s
s
e
m
b
l
y
T
e
s
t
i
n
g
S
h
i
p
p
i
n
g
New
components
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ENVIRONMENTAL ANALYSIS
Streamlined Life Cycle Assessment
all input and output that take part on
the remanufacturing process
the process avoided raw material
production and manufacturing engine
phase

Considering remanufacturing and reusing market:
SCENARIO 1 a remanufactured or reused engine replaces a new one:
Considering a substitution ratio to compare reused engine with a new one.
About remanufactured engine it has been considered an equal product
SCENARIO 2 a remanufactured or reused engine does not replace a new one:
Reused and remanufactured engine generates new demand.
Possible future scenario which will consider different substitution ratio to compare old
engines with new ones.
Engine BDSS application
Rossella Luglietti, World Remanufacturing Summit, 25
th
-26
th
September 2014
PREMANUS 14
Engine remanufacturing results
Environmental impacts
Remanufacturing Reusing Recycling
Reman activity plant
time (h) 8,39 0,79 1,15
Energy consumption kWh 127,20 19,74 17,89
Air compressed m
3
30,71 0,00
Oil liters 0,05 0,00 0,00
Water liters 0,85 0,85 0,85
CO
2
Emissions kg CO
2
eq 81,37 11,49 10,41
Production new engine
Energy consumption for manufacturing (kWh) 1613,56 1613,56
CO
2
Emissions kg CO
2
eq 938,90 938,90
kg CO
2
eq avoided for manufacturing 938,90 375,56
Recycling process
Energy consumption for recycling (kWh) 337,15
kg CO
2
eq avoided for recycling 640,72
Total CO
2
Emissions kg CO
2
eq -858 -364 -293
Different results
without including
impacts avoided
Rossella Luglietti, World Remanufacturing Summit, 25
th
-26
th
September 2014
PREMANUS 15
Engine remanufacturing results - Costs
Remanufacturing Reusing Recycling
Reman activity plant
energy consumption 39,78 6,17 5,60
operator costs 176,27 16,49 24,05
Total operation costs 216,06 22,66 29,64
Revenue selling engine
-2562,00 -612,00
Revenue selling materials
-108,46
Total -858 -364 -293
Rossella Luglietti, World Remanufacturing Summit, 25
th
-26
th
September 2014
PREMANUS 16
Engine DSS benefits
1. Time saving
2. Costs reduction
3. Environmental perception
4. Increasing remanufacturing demand
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Waste management BDSS Application
WEEE Strategy
DIFFERENT ASSESSED ALTERNATIVES
CONSIDERING:
the waste treatment;
the fractions as output of recycling plants;
the collection of waste from consumer to
different treatment plants.
DSS gives a quote about the economic cost and environmental implications to
dismantle a non-functional equipment for different treatment plants
Rossella Luglietti, World Remanufacturing Summit, 25
th
-26
th
September 2014
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Waste management BDSS Application
Trasportation
from Consumer
to treatment plant
Treatment
process
Recycling of
Secondary Raw
Materials
Disposal
Production of raw
materials
ECONOMIC ANALYSIS
costs of the overall treatment process
the disposal costs and revenues of
hazardous components and different
fractions
transportation costs
ENVIRONMENTAL ANALYSIS
Energy consumption of the overall
treatment process and relative
environmental impacts
Environmental benefits/costs of
commodities recycling
transportation environmental impacts from
consumer to dismantling plant
Rossella Luglietti, World Remanufacturing Summit, 25
th
-26
th
September 2014
PREMANUS 20
Waste management results Environmental
impacts
Rossella Luglietti, World Remanufacturing Summit, 25
th
-26
th
September 2014
PREMANUS 21
Waste management results - Costs
Rossella Luglietti, World Remanufacturing Summit, 25
th
-26
th
September 2014
PREMANUS 22
Waste management plant analysis
Rossella Luglietti, World Remanufacturing Summit, 25
th
-26
th
September 2014
PREMANUS 23
Waste management DSS benefits
1. Best plant options
2. More competitive on waste market
3. Environmental perception
rossella.luglietti@polimi.it
Info about PREMANUS: www.premanus.eu
Contacts:
Rossella Luglietti
Politecnico di Milano