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 qua lity 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 indus trialized 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 chall enge. The aging vehicle parc requires avail ability 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. Remanu fact uring is often the only way to pro vide replacement parts for older ve hicles, keeping them on the road. Sourcing obsolete parts and remanufacturing products is one of the major solutions to fulfil TRW s service ob li gation to supply products up to 15 years after the end of pro duction. 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 re man u fact uring 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 com pared 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 qua lity, 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 engineer ing is supported by TRW s global engineering capabilities in: Core cleaning Core dismantling Core stock Core return Core purchase TRW Tech Düsseldorf, Germany TRW Koblenz, Germany Components Rework Commissioning TRW Tech Shirley, UK TRW Jablonec, Czech Republic TRW Dacice, Czech Republic Unusable components Sorting Bodies Painting or zinc plating Rework Workshop stock Assembly End of line test Product into stock Packaging & labelling TRW RPD Rogersville, USA TRW Tech Shanghai, China TRW Engineering Johor Bahru, Malaysia 3rd party supplier New parts Commissioning TRW Pamplona, Spain TRW Gardone, Italy Defined processes ensure original equipment quality Tested to the extreme Through close cooperation with the TRW OE plants and independent insti tutes, TRW can guarantee firstclass quality. The remanufactured components meet all required OE-product specifi cations of the vehicle manufacturers. The remanufacturing process takes place under observation of the strict quality management standards of ISO/TS 16949, DIN ISO 9001 and the environmental 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. 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 durabi lity life-cycle testing. We also conduct in-vehicle testing in cluding Track testing and Alpine testing. Due to the fact that a TRW remanufact ured part undergoes the same pro cesses 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 2. Do not throw the box away 3. Take the old part and put it in the box...from garage 4. Logistics RMG services 1. Core handling The process starts with the core sorting following by the identi fication of old parts based on their part num bers. Then the first quality process takes place, the core is checked against our core acceptance criteria and damaged or incomplete old parts are removed to ensure the quality of the products which will be used for remanufacturing. 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. 3. Assembly and testing The as new individual parts are assembled to TRW specifications. Checks are made throughout the process and final testing guarantees that TRW s high qua lity standards are met 100%. 4. Packaging The remanufactured products are securely packaged for transport, warehousing and sales. 5. Logistics TRW stores the products until ordered and provides worldwide distribution. 1. Product replacement 5. Core acceptance 1. Core handling 6. Refund 2. Remanufacturing Core process 5. Logistics...to distribution! 3. Assembly and testing 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. 3. Take the old part and put it in the box. 5. Core acceptance Each core is checked in line with TRW s core acceptance criteria. 6. Refund If the core matches TRW s core ac ceptance criteria it will be remanufactured and the paid sur charge will be refunded. 4. Packaging
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 appli cations; in 1975 TRW designed the colette caliper, the most pop ular caliper in the world. Committed to being the first to market with new parts, our OE credentials allow us to bring new cal ipers straight to the aftermarket from the OE factory. Using OE processes, materials and innovations, TRW cal i pers offer the strongest quality and the greatest performance. With remanufacturing on the in crease, 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 com plete 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 after market 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 compre hen sive 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 auto motive manu fact urers, you can always be sure of getting the latest tech no logies 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 fit ted to several major platforms. In 2011 TRW announced its electric park brake system for front axles, making the tech nology more afford able 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 integ rates a brushless mo tor, toothed belt and ball nut ass embly 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 elec tronic 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 mecha tronic. 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 Wear to casting caused by brake disc Incomplete and damaged cable ends Incomplete and damaged cable Damaged connector Connector Snapped or damaged entry port Entry port Damaged and dented housing Housing Damaged handbrake cable guide Handbrake cable Broken pad pin holes Pad pin holes Pulley damage Missing lever arm Damaged connector Damaged motor Motor Damage to carrier guide Carrier guide Pipe damage Mounting feet damage Mounting feet Damaged pump body Pump body Remanufacturing. As new Lever arm Connector EPS Steering Column Bracket arm damage Bracket arm 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 Pinion damage Bent rack bar 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.
Michael von Linden General Manager Remanufacturing Group TRW michael.von-linden@trw.com TRW Automotive Aftermarket Stratford Road Shirley Solihull B90 4AX United Kingdom Tel.: +44 (0) 121 506 5700 www.trwaftermarket.com/remanufacturing XFB322EN