Process engineering is as important as the product engineering
Disassembly and cleaning
It all starts in disassembly. A clearly defined process (or lack thereof) can make or break a Reman operation. We have step-by-step processes for:
- Disassembling components
- Defining parts that get discarded immediately
- Cleaning standards specific to the type of part
- Visual inspection
- Specifying which photos to capture to document core condition
- Organization of the cleaned parts for the assembly and kitting processes
- Parts ordering
- Routing of the different parts to their specific next stage in the process
Reclamation, certification and inspection
Our fully equipped internal machine shop is capable of just about any reclaim process that is needed to return a used part to like new condition. Our skilled and trained technicians perform what is required by the process for each unique part. Some of these items are listed below:
- Standardized measurements before and after reclamation processes
- Dimensional / Geometric
- Surface Finish
- Non Destructive Testing (ASTM NDT Level 2 techs only)
- Metal Thermal Spray
- Machining (milling, boring, grinding, turning)
The kitting technicians assemble the parts into kits prior to assembly so that the assembly technician can work without unplanned work stops. We’ve learned that interruptions impact quality, so eliminating them is a keystone of our quality program. The kits provide a standardized layout for every part in our Bills of Material and consist of all the parts needed by the technician doing the assembly. The kitting operation also eliminates the possibility of leaving a part out during the assembly operation and provides an extra quality check.
Our technicians follow the carefully engineered assembly processes to make sure your product has a successful service life. Detailed electronic work instructions are displayed in their work cells and encourage the discipline needed to build a product the same way every time. Our training dojo provides regular basic assembly instruction so our technicians know the best practices and apply them in their everyday work. The kits provide an extra degree of quality since there should never be parts left over or parts shortages in the assembly cells. In addition, the kits keep the technicians on task and focused to complete their work without having to leave their work areas to look for a part. This also improves our efficiency.
Test technicians complete our standard test plans for each product. While running our components, we use various techniques to verify there are no leaks on the product when it runs in your machine. Our techs also make sure any performance adjustments that must be made during the testing process are completed so the remanufactured component meets all specifications when it is delivered. All necessary operating parameters, temperatures, pressures, and other required measurements are recorded during the test process for later use to use as a baseline for troubleshooting in operation. Oil samples are pulled from the product during the test process and delivered to our on-site oil analysis lab to confirm wear metals and particle counts are within the range of our specifications.
Before any product is painted, our quality department completes a final visual inspection and review of paperwork prior to allowing the paint masking operation. The thorough visual inspection is completed to make sure nothing was missed during the remanufacturing operation, and to verify the proper processes were followed. A quality inspector also performs random audits throughout the reman process.
Painting, packaging and shipping
After final inspection is completed, the paint department masks and paints the products. Smaller components are boxed per customer requirements, while larger products are shrink wrapped in their custom built shipping stands.