Water cooling pump number 51.06500 – 6089 is in a pitiful state. It is dirty, scratched and shows traces of rust. Only recently, it was doing service in an MAN truck until, after more than ten years, the crankshaft was damaged. Last stop the scrap yard? Maybe in the past. Today, all parts still in working order are overhauled and prepared for a new life. Technical changes and improvements are taken into account during the reconditioning process, known as remanufacturing. After its rejuvenating treatment, water cooling pump 6089 will once again be functioning efficiently in an exchange engine.
Strict quality standards for MAN exchange parts
After sorting, the used parts are cleansed in a wash bay and freed from grime and oil. Only then is it possible to see in detail which parts can be reconditioned.
The place where the water cooling pump is waiting to be remanufactured is a hall on the 350,000-square-meter premises in Nuremberg belonging to the MAN Truck & Bus Engine Competence Center. Inside the hall, the parts are cleaned thoroughly. First they are dismantled, cleansed in a wash bay, sandblasted, recoated – and in some cases discarded. After cleaning, you can see what is still useable," explains Georg Kugler, Head of the Thermal Testing and Exchange Units Department at MAN in Nuremberg. "The parts are checked for wear and tear and material fatigue." The quality standards are strict, the exchange parts being subject to the same guarantee conditions as new parts.
After reconditioning, exchange parts are stored or sent to where they are needed. Final assembly of all reconditioned parts for use in exchange engines takes place on site - for instance on the assembly line for D20/D26 engines. Based on a two-shift system, 260 employees produce up to twenty-two engines an hour. When an exchange engine reaches the end of the conveyor belt, is has to overcome a final hurdle – a performance test. During the thermal test, the engine runs for a good half hour on the test stand under various levels of stress.
Top-ten project "MAN Genuine Parts ecoline"
To Stefan Ott, "MAN Genuine Parts ecoline" Project Manager, the advantages of this new line of products are obvious - resources are spared, energy saved, emissions reduced and customers given the same quality and guarantee at a lower price.
For Stefan Ott, Project Manager at MAN in Munich responsible for the new product line "MAN Genuine Parts ecoline", the future began three years ago when business with exchange parts was defined as one of the top-ten projects among the Group´s goals. "By reusing and reconditioning old parts, resources can be spared and energy saved," he says. "And because fewer new parts have to be produced, emission is reduced." This is the 'ecological' part of ecoline. Thus, ecoline also facilitates MAN’s Corporate Responsibility strategy and greatly contributes to protecting the environment while supporting sustainable mobility. The main targets for these parts are vehicles that are at least four years old - which make up 70 to 80 percent of vehicle fleets. For customers operating these older vehicles, there are good arguments in favor of using such "scrap iron". The quality of MAN´s exchange parts is the same as its new parts, since reconditioning is undertaken in accordance with genuine part specifications and MAN offers the same guarantee in both cases - at a price which is up to 50 percent lower than that of a new part. Other advantages of the ecoline project include less time spent idle thanks to replacements instead of repairs and a higher vehicle value by using original MAN parts. After all, ecoline also means 'economical'. Several good reasons why customers make a conscious decision to choose “MAN Genuine Parts ecoline”.
Top logistics performance
"MAN Genuine Parts ecoline" is a major project calling for tremendous logistic skills. In 2013, the total revenue generated by ecoline parts amounted to 140 million euros. Following introduction of the exchange part process in Germany in July 2014, it will be offered in seventeen European countries. The rest of the world´s top fifty markets are also to be progressively opened up.
"MAN Genuine Parts ecoline" makes up a small part of MAN´s entire genuine part portfolio, all of which are manufactured in accordance with MAN´s strict quality standards. On average, some 8,000 genuine parts are readily available at MAN service centers - also for older models and special vehicles. 95 percent of all genuine parts are delivered to workshops overnight.
The reconditioning process
Wellness for machines
Used MAN engines land in the Engine Competence Center in Nuremberg. Here, the old parts are revamped. Following this rejuvenating treatment, they find themselves back in full working order inside an exchange engine.
The reconditioning expert
Georg Kugler heads the Thermal Testing and Exchange Units Department at MAN in Nuremberg. In 2013, he and his team reconditioned 780 engines and 11,325 other exchange parts.
Dismantling an engine
As a first step in the remanufacturing process, employees dismantle the engines. All parts still working are subsequently presorted for cleaning.
The good ones end up in the pot...
In some cases, wear and tear can be seen on the parts even before they undergo thorough cleaning. If even at first glance the material shows too many signs of fatigue, the parts are discarded and not included in the reconditioning process.
Rooting out the rust
After cleansing, an MAN employee uses a sandblaster to remove the last traces of rust. Afterwards, the parts shine like new and are ready for coating.
On the examination table
An MAN employee examines all parts of the used engine with a probe. In this way, parts that are difficult to access or larger areas can be checked for wear and material fatigue.
Measuring the parts
Using a test stand, an MAN employee determines the exact dimensions of specific used parts. All reconditioned parts required for exchange engines remain at the Nuremberg plant and are immediately integrated into the final engine assembly process.
MAN´s quality guidelines are especially strict during final assembly. Thanks to the intensive reconditioning process preceding this phase, the quality of the reconditioned parts is equivalent to the quality of a new part.
Ready for dispatch
At the end of the rejuvenation process, the exchange engines wait to be dispatched from MAN´s Nuremberg plant to their next place of operation. They have the same guarantee as new engines, but cost a lot less.