Remanufacturing. As new

Remanufacturing. As new
The TRW Original
Exchange Parts Program
braking. steering. suspension.
TRW – Remanufacturer of the year 2010
“The potential for automotive remanu­
facturing is tremendous – an excellent
compromise for the environment and
consumer costs.“
Michael von Linden
General Manager Remanufacturing Group
TRW Automotive
As one of the leading automotive
remanufacturers, TRW is working hard
on providing you not only with costefficient and environmental friendly
repair & service options, but also with
high-quality products.
This was recognised when TRW was
named ’Automotive Remanufacturer
of the Year’ 2010, by the international
remanufacturing magazine „ReMaTec
News“, supported by the international
remanufacturing industry body APRA.
TRW was cited to have:
• An outstanding record within the
field of automotive remanufacturing
• Automotive remanufacturing facilities
that are admirable examples of
qua­lity and innovation
Remanufacturing. As new
“A remanufactured product fulfils
a similar function to the original part.
It is manufactured using a standard­
ized industrial process in line with
specific technical specifications. The
indus­trialized process incorporates
defined core management standards.
A remanufactured spare part is
warranted as a new spare part.“
This is the official CLEPA definition of
a remanufactured product; however
TRW‘s standards of remanufacturing
are even higher – we believe that a
remanufactured part delivers equiva­
lent performance to a new part.
“TRW’s automotive remanufacturing
facilities are without doubt amongst
the industry‘s most professional
remanufacturing operations and offer
a combination of high technical know­­
ledge, high quality and innovation as
well as commercial competence.“
William Schwarck
Editor ReMaTec News
Why buy
As new – but with a cost saving of up to 25%
Three main reasons to buy remanufactured products:
1 S
ustainable supply chain
Supply chain is an increasing
chall­­­enge. The aging vehicle parc
requires avail­­­­ability of parts a long
time after end of vehicle type
production, and the increasing
usage of electronics in automotive
components represents a special
challenge: Due to the product
life cycle of electronic units the
supply is impossible to sustain
on a long term basis. Remanu­­fact­uring is often the only way to
pro­vide replacement parts for older
ve­­hicles, keeping them on the road.
Sourcing obsolete parts and
remanufacturing products is one
of the major solutions to fulfil
TRW´s service ob­­li­gation to supply
products up to 15 years after the
end of pro­duction.
2 Commercial benefit
for older cars
Compared to the high OE volumes,
the service demand is rather low,
which means low batch production
with higher manufacturing costs.
Together with a long product life
and rising raw material prices,
remanufacturing has the best cost
versus benefit ratio.
3 Environmental advantage
As a manufacturer, we firmly believe
that it is our responsibility to make a
difference wherever and whenever
we can. Automotive remanufacturing
is one way in which TRW is helping
to safeguard the environment:
• Significant CO2 emission reduction:
Based on 2011 automotive re­man­u­
fact­uring production figure, we
saved 5.000 tons of CO2 which
is equivalent to 22.270.000 kilo­
meters driven or 86.000 Truck loads.
•8
0% less energy used when
com­pared to new production
•C
onserving raw materials, such
as steel, aluminum and copper
• Waste reduction: Extending
the product life saves our worlds
natural resources.
Remanufacturing old parts to become
exchange parts that are ‘as new’ not
only saves precious resources, but
especially for older vehicles it may be
the only repair method that makes
sense financially. Perfect function and
safety at lower prices – it is a repair
solution to suit the times, especially as
vehicles are spending even longer on
the road.
Almost all electrical, electronic and
mechanical components are remanu­
factured to ‘as new’ condition in the
‘TRW Original Exchange Parts Pro­
gram‘. Under strict compliance with the
stringent vehicle manufacturers’
old components are disassembled,
cleaned, tested and rebuilt using
new parts. Here we benefit from our
experience as an original equipment
supplier and our close cooperation with
the vehicle manufacturers. During the
remanufacturing process, all wear and
tear parts are replaced and fed back
into the recycling loop. In terms of
qua­lity, service life and appearance,
the finished products are as good as
new parts. At two locations in Europe,
TRW is ensuring that used parts are
turned into exchange parts for vehicle
manufacturers, Independent Aftermar­
ket and Industry garages.
TRW‘s remanufacturing facilities
Frydlant, CZ
• Opened in 1999
• Brake Caliper Remanufacturing
and Assembly
• Steering System Remanufacturing
and Assembly
• Pumps Remanufacturing
and Assembly
Wrexham, UK
• Acquired by TRW in 2007
• Over 30 years of
remanufacturing experience
• Brake Caliper Remanufacturing
• Steering System Remanufacturing
and Assembly
• Distribution
Remanufacturing process
Global engineering centres
Our customer product engineer­ing is supported by
TRW´s global engineering capabilities in:
tli
ng
an
re
di
sm
Core
purchase
st
oc
k
ni
ng
Co
TRW Tech
Düsseldorf, Germany
in
g
TRW
Jablonec, Czech Republic
m
m
is
s
nt
TRW
Dacice, Czech Republic
d
En
em
ss
Product
into
stock
TRW Engineering
Johor Bahru, Malaysia
TRW RPD
Rogersville, USA
si
is
m
m
Co
N
3rd
party
supplier
ew
pa
rt
s
on
in
g
A
Re
of
bl
y
or
w
or
k
g
in
nt
Pa
i
es
di
Bo
Workshop
stock
Sorting
lin
e
Pa
te
ck
st
ag
in
g
&
la
be
pl
nc
zi
s
U
nu
co sa
m ble
po
ne
nt
TRW Tech
Shanghai, China
lli
at
ng
in
g
Co
w
or
k
Re
ne
po
m
Co
TRW
Koblenz, Germany
TRW Tech
Shirley, UK
io
n
s
Co
re
cl
ea
re
Co
Core
return
TRW
Pamplona, Spain
Defined processes ensure
original equipment quality
Tested to the extreme
Through close cooperation with the
TRW OE plants and independent
insti­tutes, TRW can guarantee firstclass quality. The remanufactured
components meet all required
OE-product specifi­cations of the
vehicle manufacturers. The remanu­
facturing process takes place under
All our remanufactured products are
tested to the extreme, at TRW‘s test
and validation centres where we have
numerous product release tests,
including; Dynamic performance
testing, Fatigue life-cycle testing, Salt
spray testing, Full durabi­lity life-cycle
testing.
observation of the strict quality
management standards of ISO/TS
16949, DIN ISO 9001 and the environ­
mental management standard DIN
ISO 14001. In many areas we even
clearly exceed the criteria demanded
and make sure that we keep the TRW
service promise.
TRW
Gardone, Italy
We also conduct in-vehicle testing
in­cluding Track testing and Alpine
testing. Due to the fact that a TRW
remanufact­ured part undergoes the
same pro­cesses and procedures as our
new OE products, we are able to offer
two years warranty for the ‘TRW
Original Exchange Parts Program‘.
Remanufacturing Group (RMG) –
one solution
RMG services
1. Core handling
The process starts with the core
sorting following by the identi­fi­
cation of old parts based on their
part num­bers. Then the first quality
process takes place, the core is
checked against our core accep­
tance criteria and damaged or
incomplete old parts are removed
to ensure the quality of the
products which will be used for
remanufacturing.
3. Take the old part
and put it in the box
2. D
o not throw
the box away
4. Packaging
The remanufactured products
are securely packaged for transport,
warehousing and sales.
4. Logistics
2. Remanufacturing
Old components are completely
disassembled and remanufactured
to ensure they are supplied in an
‘as new’ condition. Individual parts
that cannot be remanufactured are
replaced by corresponding original
or equivalent parts.
...from garage
1. Product
replacement
5. Core
acceptance
1. Core
handling
2. Remanufacturing
6. Refund
...to distribution!
Core process
3. Assembly
and
testing
5. Logistics
1. Product replacement
The product is taken from
the box and fitted to the car.
4. Logistics
TRW takes back the cores and
uses them for remanufacturing.
2. Do not throw the box away
It is important to keep
the box in which the product
was delivered – for safe return.
5. Core acceptance
Each core is checked in line with
TRW‘s core acceptance criteria.
3. Take the old part…
… and put it in the box.
3. Assembly and testing
The ‘as new’ individual parts
are assembled to TRW specifi­
cations. Checks are made through­
out the process and final testing
guarantees that TRW’s high qua­lity
standards are met 100%.
6. Refund
If the core matches TRW‘s core
ac­ceptance criteria it will be remanu­
factured and the paid sur­charge
will be refunded.
4. Packaging
5. Logistics
TRW stores the products until
ordered and provides worldwide
distribution.
Remanufacturing. As new
Calipers
Current Product Portfolio
Range coverage
• 3.000 part numbers
• 89% of the European vehicle parc
Calipers
High quality calipers for
best brake performance
Steering
Systems
Pumps
TRW Automotive is the worldwide
leading OE manufacturer of calipers
for both front and rear disc brake
appli­cations; in 1975 TRW designed
the colette caliper, the most pop­ular
caliper in the world. Committed to
being the first to market with new
parts, our OE credentials allow us
to bring new cal­­­ipers straight to the
aftermarket from the OE factory.
Using OE processes, materials and
innovations, TRW cal­­­i­pers offer the
strongest quality and the greatest
performance.
With remanufacturing on the in­­crease,
we are pleased to be leading the way
in this effort to provide top quality
products that are both cost-effective
and more environmental friendly.
With the wide range of remanufactured
calipers that are put through our OE
testing process, you can be sure that
TRW provides you with the greatest
performance, comfort and safety.
All calipers are delivered with fitting
instructions and accessories you need
to get the job done, TRW supplies the
com­plete package.
Steering systems and pumps –
best quality for highest safety
As a leading OE designer, integrator
and manufacturer of all major steering
technologies, TRW provides systems
that enhance vehicle control, increase
fuel savings and improve performance
precision.
With decades of expertise and millions
of systems on the road, TRW delivers
true steering solutions. TRW offers the
largest selection of electrically assisted
steering (EAS) technologies in the
world, and was first-to-market with
electrically powered hydraulic steering
systems for Europe. TRW Remanu­
facturing Group is able to transfer this
knowledge from OE into the remanu­
facturing process; with our experience
in precision engineering you can be
sure that all parts of the system work
perfectly together to improve fuel
economy, while reducing emissions.
Whether it is a new or a remanu­
factured steering gear, TRW has been
supplying both major vehicle manu­
facturers and the global after­market
for more than 25 years. One in three
vehicles across Europe are fitted with
TRW steering gears and pumps. All
TRW remanufactured steering gears
and pumps are in compliance with
the same exacting standards as
new parts and come with the same
performance and guarantee.
Always pushing the boundaries
through innovation, TRW offers a
compre­hen­sive range of parts from
traditional manual steering systems
to the latest hybrid electric systems.
And with a direct research and
development relationship with the
world´s auto­motive manu­fact­urers,
you can always be sure of getting
the latest tech­no­logies from TRW.
Range coverage
• 409 part numbers of non-electrical
steering pumps
• 41 part numbers of electrical steering
pumps
• 87% of the European vehicle parc
Pumps
Range coverage
Steering
Systems
• 790 part numbers of hydraulic
steering gears (including electrical
powered hydraulic steering system)
• 163 part numbers of mechanical
steering gears
• 73 part numbers of column drives
and electrical powered steering
systems
• Over 92% of the European
vehicle parc
Electric Park Brake
TRW is leading the market since the
introduction of the EPB in 2001 which
is fit­ted to several major platforms.
In 2011 TRW announced its electric
park brake system for front axles,
making the tech­nology more afford­able
for a wider range of vehicles. The
system can be added with only small
modifications to the front axle calipers
and integration of the necessary
electronic components and software
into the ESC (electronic stability control
system). TRW´s EPB range is already
offered in the ‘TRW Original Exchange
Parts Program‘.
Future technologies
Belt Drive (Steering Systems)
Mechatronic
The most efficient EPS System is
offered by TRW OE. Belt drive EPS
(also referred to as rack drive) is a
solution that integ­­rates a brushless mo­
tor, toothed belt and ball nut ass­embly
with pulley and bearing in one unit.
This setup results in lower inertia and
friction for high power applications, as
well as a more direct steering feel and
superior response. The integrated ECU
(electronic control unit) sits alongside
the motor on the rack, providing a
flexible and cost effective package.
TRW as an OE supplier of belt drives is
already starting to look at the remanu­
facturing process for this part.
Technology is moving at increasing
pace. It is no longer good enough to be
a master of either electric parts or
elec­tronic parts or mechanical parts –
to cater for the supply and demand of
today´s parts, you have to be a master
of all of these areas, as many parts are
a hybrid of them all and this hybrid is
called mecha­tronic. TRW, and in fact
remanufacturing, has reached a new
milestone with the remanufacturing of
mechatronics. Our current product
range of mechatronics includes: EPHS
and column drives.
Furthermore TRW is currently focusing on increasing the amount of
remanufactured products including
ECUs. Due to the diversity of the ECU
range for each product, we envisage a
‘Repair and Return Service’.
As the leading partner of the automotive industry,
we provide a unique competence in corner module
technology: braking, steering and suspension.
With TRW products, you and your customer can rely on
the expertise and manufacturing know-how of a leading
OE manufacturer. Learn more about the corner module
with your local TRW representative or on our home page.
Braking. Steering. Suspension
www.trwaftermarket.com/cornermodule
Excessive damage to
bleed screw
This is how it should look
Wear to casting caused
by brake disc
This is how it should look
Incomplete and
damaged cable ends
This is how it should look
Incomplete and
damaged cable
This is how it should look
This is how it should look
Damaged connector
Connector
This is how it should look
Snapped or damaged
entry port
Entry port
This is how it should look
Damaged and
dented housing
Housing
This is how it should look
Damaged handbrake
cable guide
Handbrake cable
This is how it should look
This is how it should look
Broken pad pin holes
Pad pin holes
This is how it should look
Pulley damage
Missing lever arm
This is how it should look
Damaged connector
This is how it should look
This is how it should look
Damaged motor
Motor
This is how it should look
Damage to carrier guide
Carrier guide
This is how it should look
Pipe damage
This is how it should look
Mounting feet damage
Mounting feet
This is how it should look
Damaged pump body
Pump body
Remanufacturing. As new
Lever arm
Connector
EPS Steering Column
This is how it should look
Bracket arm damage
Bracket arm
This is how it should look
Unfortunately if your core has any of the faults highlighted above it will not be eligible for refund.
Quality begins with the core and TRW has stringent core acceptance standards.
Please follow our acceptance criteria in order to return your core.
Cable ends
Cable
EPHS Pump
Bleed screw
Brake disc
Brake Calipers
This is how it should look
Pinion damage
This is how it should look
Bent rack bar
This is how it should look
Damaged entry ports
Incomplete housing
Pipe
Housing body damage
Pinion
Pulley
Rack bar
Housing
Housing body
Entry ports
Steering Pumps
Steering Racks
Core Acceptance Guideline
Mission: Complete.
The CORNER MODULE.
TRW Automotive Aftermarket
Stratford Road
Shirley
Solihull B90 4AX
United Kingdom
Tel.: +44 (0) 121 506 5700
www.trwaftermarket.com/Remanufacturing
XFB322EN
Michael von Linden
General Manager Remanufacturing Group TRW
michael.von-linden@trw.com