Analysis of Factors Causing Delays in the Diesel Engine Remanufacturing Process at an Indonesian Company

Abstract

HeavyEq is an Indonesian company that remanufactures diesel engines for the mining industry. The company experiences delays in the remanufacturing process that lead to a sales backlog. The main purpose of this paper is to identify the root cause of, and propose a solution to, the problem. A fishbone diagram is developed to identify the root cause, and the results show that delays in the remanufacturing process are mainly caused by uncertainty over cores (used engines) in terms of their arrival time, quantity, and quality. Based on a literature review and interviews with experts, an improvement in core acquisition activity, separating job orders for disassembly and recovery, and reassembly processes is proposed to reduce delays in the remanufacturing process.

Determining Factors of Quality Uncertainty and Its Control Analysis in Remanufacturing System

“…This study has identified the factors of quality uncertainty in core acquisition, remanufacturing operations, and remarketing activities in remanufacturing system. Prior works have identified the factors in remanufacturing barriers [10], and seven m's with recommended action to remanufacturing practices [11], also the delays problem in remanufacturing processes [13]. However, their study have not focused on quality uncertainty in remanufacturing which has an impact on the control quality needs for improving competitiveness of remanufactured products.…”

“…This study investigated potential factors cause quality uncertainty in remanufacturing activities by means a cause and effect diagram. The importance of using fishbone diagram for identifying root causes of problem in remanufacturing has been demonstrated by Nasr et al [10], Sakao and Sundin [11], Kosacka [12], Soeseno and Kusumastuti [13]. One study by Nasr et al [10] have explored in their empirical research that remanufacturing barriers consists of factors: technology, operations, workforce, core/design, market/environment, and management.…”

“…Moreover, in her case study of automotive parts remanufacturing, Kosacka [12] identified five main categories of threats to health and life problem of workers in remanufacturing, namely: employee, machines, remanufacturing process, core, and management. In a recent study, Soeseno and Kusumastuti [13] identified the main causes of the problem of delays in remanufacturing processes mainly due to uncertainty in the time of arrival, quantity and quality of the core. For this purpose, they developed a fish bone diagram which shows that delays problems are caused by the four main factors: the late arrival in quantity of incoming cores; inaccurate information of reusable parts; incompatible with incoming core with the manufacturing requirements; and the difference between the reassembly and disassembly schedules.…”

Making Tool Equipment for Quality Standard of Hydraulic Cylinder Remanufacturing in PT UTR

“…These are frame of mine to develop every improvement in all section and or department for continuing to be sustain in the future. Remanufacturing is one option so that the product can still be used optimally at a relatively lower cost (Fofou et al, 2021;Liu et al, 2019;Nwankpa et al, 2021;Singh & Jain, 2019;Soeseno & Kusumastuti, 2019). Therefore, many customers choose to remanufacturing their heavy equipment components rather than buying new ones.…”