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2012/CTI2/MAG/WKSP/002

Remanufacturing Research and Development

Submitted by: Komatsu Ltd

Workshop on Remanufacturing Research and Development in APEC Economies

Singapore28 March 2012

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RemanufacturingRemanufacturing Research and Development

March 28, 2012 K t LtdKomatsu Ltd.

Product Support Div. Reman dept.Takafumi TAKENAKA

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ContentsContents

1)Construction Equipments2)Reman Operation & Activity3)Remanufacturing Research & Development4)Reman Facility （KRI）4)Reman Facility （KRI）

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Crawler Dozers Crawler Excavators

Main Products

Model Operating wgt.(ton) Capacity (HP)

D155 - D475 39.5 – 113.2 354 - 890Model Operating wgt.(ton) Capacity (HP)

PC1000 - PC8000 103.0 – 744.0 611 - 3863

Dump TrucksModel Operating wgt.(ton) Capacity (HP)

HD465 – 960E 42.8 – 249.5 739 - 3500

Wheel Loaders Motor GradersModel Operating wgt.(ton) Capacity (HP)

WA500 – WA1200 32.9 – 205.2 353 – 1715Model Operating wgt.(ton) Capacity (HP)

GD825 26.4 280

4Overburden treatment in mining

Electric Dump Truck(wgt. 140.6 ton, 2,000HP) Excavator (wgt. 398.0ton, 1,775HP)

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Engine Transmission Piston Pump Motor (PPM)

Reman Components

Engine subcomponent:F l I j ti P T b h

Wheel MotorHydraulic Cylinder:SuspensionFuel Injection Pump, Turbocharger Suspension

6Komatsu Reman Operation

Komatsu is helping to create a resource recycling society by promoting the reuse and recycling of used components and by improving the recyclability rate of construction machinery through its Reman Activity.

1. Concept

Komatsu to provide Quality Assurance Responsibility for Reman as a manufacture to maximize Customer Machine Availability and O&O Cost Reduction and create Reliable Relationship with Customer.

2. Basic Policy

1.Quality : Quality & Performance guaranteed to be the same level as for new component

2.Cost : Lower cost for Reman component3.Delivery : Reduced idle time for machines through sufficient Inventory 4.Efficiency : Centralized by Komatsu Reman Facility can avoid

duplicate investment by customer

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7Reman Potential

Reman Activity has been growing

Large size machine global population(Population history and estimation) Lots of

PotentialPotentialin future with machine population increase

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Global Supply NetworkGlobal Supply Network

Komatsu Global Reman Operation Network① Komatsu has Large size Global Reman Operation Facilities in Indonesia & Chile② Komatsu establish Regional Reman Facilities in Emerging area

(Difficult Core Trade ; China, Russia, India & Brazil)

① Komatsu has Large size Global Reman Operation Facilities in Indonesia & Chile② Komatsu establish Regional Reman Facilities in Emerging area

(Difficult Core Trade ; China, Russia, India & Brazil)

Engine

Transmission

Wheel Motor

Hydraulic Cylinder

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Research Center

Development Center - Dozer- Excavator

D T k

Remanufacturing Research & Development

Components development

Products development - Dump Trucks- ICT, Others

- Engines- Transmissions- Hydraulic Pumps,

Cylinders- Electronic, Others

Material development

Production Engineering development

Co-Working for development

- Metal spraying- Others

Remanufacturing Engineering development

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Shaft

GearImpeller

Core Situation

The Shaft of Engine Water Pump

WearWater Pump

Corrosion

Spec. of the shaft

Scratches

Metal Spraying

・Material ： SUS・Surface hardness ： HRC30～35・Surface hardness Oil seal contacted-part: HRC40～50

Remanufactured parts the same quality assurance methodsas Komatsu newly developed parts

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Test ResultTest Equipment

(1)Durability Test(Breaking Test)

Durability Test for the layer of Metal spraying

島津サーボパルサ

200mm

±17.4kg･m

(2)Torsion Fatigue TestFrequency Number ;10 million times.

Torq

ue

Time

The part of Impeller

Stress GaugesDurability Test : Pass

<without any damage such asabrasion or crack on the layerof Metal spraying>

12Corrosion Evaluation after Operation Test in Actual Vehicle

Appearance after Operation Test in Actual Vehicle

B ond-coat

Top-coat(13C rｽ ﾃﾝﾚｽ)

表面および内部に腐食は認められない

Inspection of the Seal-Contacted part

(13 Cr stainless)

Top-coat

Bond-coat

ｼｰﾙ部

Adherent matters

B ond coat(N i5Al)

基材（SUS431）

Seal contacted part Base layer

No corrosion on the surface and in the inner part of Metal Spraying

Base layer

OK

Corrosion Evaluation Test : Pass

<after Operation Test in Actual Vehicle >

Energy dispersion X-ray Spectroscopic Analysis：EDX

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13Examples of Remanufacturing Engine Parts

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Cylinder Block by Metal Spraying Valve, Crank Shaft by Grinding & Polishing

Cylinder Head by Cutting & Grinding

Examples of Remanufacturing Engine Parts

Fuel Injection Pump

Turbocharger

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Remanufacturing ProcessClutch Plate by Tempering & Grinding

Tempering Grinding

Finished Good

Examples of Remanufacturing TransmissionParts

Heat Spot

T/M Case by Insert CollarCross Section of T/M Hub by Metal Spraying

Wear ; Mounting Part Wear ; Bearing Part

T/M CaseHub

16Global Reman Factory - Komatsu Reman Indonesia （KRI）

①General view ②Location

③Products□ Reman Engines (Large)

Jakarta, Indonesia

Establishment：Jan., 2007

16.5 K Sq. M.

g ( g )

□ Reman T/C & T/M (Large)

□ Reman Piston & Pump Motor （Large）

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17Remanufacturing Process

Inspection Upon Receipt Core Cleaning Dis-Assembly Parts Inspection

Parts Cleaning Salvaging AssemblyParts Cleaning Salvaging Assembly

Performance Test Painting ShipmentFinished Goods

18Quality Assurance same as New Component

④ Measuring Equipments ④ Measuring Equipments ① ISO9001-2000 Certification② STD Procedure （Check Sheet ）③ 100% In-House Machining & Salvaging④ Measuring Equipments （Partsevaluation）⑤ Component Traceability Control

① ISO9001① ISO9001 ② Check Sheet ② Check Sheet

⑤ Component Traceability Control⑥ Testing Equipments （Performance）

③ In-house Salvaging: ex Boring machine③ In-house Salvaging: ex Boring machine ⑤ Component Traceability ⑤ Component Traceability

□ IC Tag□ Second Dimension Bar Code

Coordinate Measuring Machine

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⑥Testing Equipments⑥Testing Equipments

HYDRAULIC TEST BENCHENGINE DYNAMOMETER

Quality Assurance same as New Component

ENGINE DYNAMOMETER CERTIFICATE

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Issues ！！

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Thank you very much