Page 227 - Design for Environment A Guide to Sustainable Product Development

204 Cha pte r T e n

FIGURE 10.4 Material fl ow in Caterpillar remanufacturing operations.

In 2006, Caterpillar conducted a limited study to compare the
environmental footprint of the processes required to manufacture
vs. those required to remanufacture an engine cylinder head. The
study did not include the upstream impacts of extracting, transport-
ing and processing raw materials to produce new parts. Even so, the
results indicate that remanufacturing reduces GHG emissions by
over 50%, water use by over 90%, energy use by over 80%, material
use by over 99%, and landfill space by over 99%. These preliminary
findings were encouraging, and Caterpillar is continuing to refine
and expand on this study.
Aside from the direct environmental footprint reduction, Cater-
pillar’s remanufacturing take-back business model allows the com-
pany to minimize the proliferation of restricted substances such as
lead and chromium. It provides a convenient channel for customers
to return used components such as lead-solder-containing electronic
control modules or chrome-plated hydraulic cylinders, thus enabling
them to responsibly dispose of these substances while extending the
life of the product.
The Reman program has spawned a number of additional initia-
tives that are consistent with Caterpillar’s commitment to sustainable
development. For example:

• Caterpillar offers emissions retrofit kits, which allow engines
to be upgraded from Tier 0 to Tier 1 emissions at the time of
overhaul by replacing components, such as fuel pumps, noz-
zles, and turbo chargers. This results in reductions in nitrous
oxide, particulate matter, carbon monoxide and hydrocarbon
emissions.
• In addition to the standard core take-back process, Reman
purchases cores directly from the marketplace. This not only
creates additional core material for remanufacturing, elimi-
nating the need to supplement with new parts, but also pro-
vides an avenue for dealers and customers to responsibly
dispose of excess end-of-life products.