National Seminar on Remanufacturing Organized by ASSOCHAM

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National Seminar on RemanufacturingOrganized
byASSOCHAM Ministry of Heavy Industries
Public Enterprises

• Imperial Hotel, Delhi
• 18th September 2009

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Topics

• User Expectations
• Why Reman.
• Timken Solution
• Customer value from Reman programs Timken Cases

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User Expectations

• Minimize Capital costs
• Operate plant and machinery with the lowest cycle
  cost of components
• Maximize uptime and productivity
• Minimize equipment delays and unproductive time
• Planned maintenance Vs breakdown
• Plant reliability
• Improve product quality
• Maintain minimum inventory of components

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Why Reman
Potential Life without Repair
Ultimate Bearing Life
Potential Life with Repair
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Common Questions

• Will a remanufactured bearing last as long as a
  new one?
• In most cases, they will

Likelihood of Premature Bearing Damage
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Concern There is an optimum cost

• Dont repair too soon, dont repair too late!

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Timken Solution
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Range of Services

• You can select from a range of repair services
• Recertify Clean, examine, verify internal
  clearances, preserve and package
• Reclaim Polish using proprietary vibratory
  process, preserve and package
• Recondition Combines Recertify and Reclaim
  services
• Remanufacture Clean, examine, grind raceways,
  new roller sets, replace major components as
  required, reset internal clearances, preserve
  and package

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Customer Value from Remanufacturing Programs
Timken Cases
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Coiler pinch rolls of a Hot Strip Mill

• Market
• Primary Metals
• Application
• Hot Strip Mill
• The Timken Advantage
• Timken worked with customer to identify solution
  to
• extreme wear in coiler pinch rolls.
• Timkens new rolls with Mill Clad steel overlays
• Reduce wear and lengthen service life
• Increase coiler uptime and reduce maintenance
  hours
• Reduce roll inventory
• Results
• Increased coiler uptime and increased strip
  quality
• Reduced Roll inventory
• Reduced maintenance 8 mandays every 2wks to
  every 16 20 wks
• Reduced redressing time for rolls -

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Machine Tool

• Market
• Machine Tools Horizontal Machining Center
• Application
• Cross Roller bearing for table mounting
• The Challenge
• Existing bearing requiring repair and machine
  downtime cost is Euro 30,000
• per day
• New bearing leadtime is minimum 6 months
• The Timken Advantage
• Timken turned arround the bearing repair
  installed new rollers and race
• grinding - at its plant in 7 days
• Results
• Machine was producing quality product in 7days
• Frequent downtimes and adverse product quality
  on operating with damaged
• table bearings eliminated

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Mining Equipment

• Market
• Mining
• Application
• Mining Equipment Repair Operations
• The Timken Advantage
• Timken Advantage Bearing repair, on-site
  maintenance
• training, quality products and good customer
  service help
• to improve Equipment Service providers
  performance in serving the
• mining industry.

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Bearing Repair - Lafarge Cement

• Application KHD Roller Press
• Bearing Make Part No. FAG 517680A
• Value of two bearing - 102,360
• Average life of the bearing 2 to 3 years
• The lead-time of new bearing 12 to 24 months
• The above bearings has been refurbished and in
  operation for more than 10000 Hrs.
• The cost of refurbishment of two bearings -
  61462
• Customer has not purchased any set in year 2008.
• Value Created
• 40,898 Direct savings
• No Mill downtime because of bearing availability

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Bearing Repair - Essar Steel Hot Strip Mill

• Application Hot Coil Box Mandrel
• Bearing Part No. M272749Assy902B3 and M268749
  Assy90118
• Value of two bearing - 27,500
• The lead-time of new bearing 12 months
• Customer could remove bearing from the mandrel.
  Would need to gas cut bearing with potential risk
  to mandrel
• Timken Service Engineer designed the fixture and
  dismantled the bearing without damaging it.
• Bearings are being refurbished for 13,475
• Value Created
• 14,075 Direct savings
• No damage to shaft
• Mandrel was assembled and put back in service

15
Chock Rebuild Tinplate Company of India

• 4 Hi Skin Pass Mill Chock Rebuilding
• The chocks were scraped by the customer
• The cost of 4 new chock will be 60,000
• Operated in mill for more than 12 years
• New chocks delivery will be 12 to 24 months
• Set of 4nos. of chocks rebuilt
• The turn around time is 4 months
• The cost of rebuilding is 14,000
• The chocks were sent to customer with UST
  Magnaflusk Test report. Currently in Operation

Value Created 46,000 Direct savings No Mill
downtime because of chock availability Improved
finish over other chocks in operations Customer
will be sending balance 4 sets in schedule.
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Usha Martin

• Procured used bar Mill from US. (15 to 20 years
  old)
• Customer wanted available bearings and chocks
  refurbished and put back in operation
• Refurbishment order value 50,000

Value Created 75,000 Direct savings Mill stand
will be commissioned using existing chocks and
bearings as per project schedule