Aftermarket refers to various services around the after-sales use of construction machinery. With the substantial increase in the sales and holdings of domestic construction machinery, it is imperative to find a sustainable production and consumption model for the promotion of energy conservation and emission reduction in the construction machinery industry. Affected by the "One Belt, One Road" and other policies, the export volume of my country's construction machinery products has grown rapidly, and foreign merchants have put forward clear remanufacturing requirements for the construction machinery products sold in my country.
Multi-party demand forces the remanufacturing of construction machinery to become a market opportunity that all parties focus on, and it also faces problems that need to be overcome.
Remanufacturing is guided by the theory of product life cycle, with the goal of improving the performance of waste products, with the criteria of high-quality, high-efficiency, energy-saving, material-saving and environmental protection, and using advanced technology and industrialized production as the means to repair and transform The general term for a series of technical measures or engineering activities of waste products.
Statistics show that the annual losses caused by equipment shutdown and scrap due to wear and corrosion in my country's industrial industry account for about 10% of the annual GDP, and the loss is as high as 100 billion yuan. The data also shows that as of the end of 2014, the number of main products of construction machinery was about 6.5 million to 7.04 million. It is estimated that by 2020, the number of construction machinery scrapped every year will reach 1.2 million, which means that a large number of projects will be produced every year. Mechanical waste parts are not conducive to environmental protection and sustainable development.
Zhang Guosheng, deputy chief engineer of Tianjin Construction Machinery Research Institute, said at the Shell Cup CMIIC2015 China Construction Machinery Industry Internet Conference and Brand Event held not long ago, the cost of remanufacturing is only about 50% of new products, energy saving 60%, and material saving 70%. The adverse impact on the environment has been significantly reduced, which has effectively promoted the construction of a resource-saving and environment-friendly society.
According to statistics, the utilization rate of old parts of construction machinery products can reach more than 80%.
On the other hand, as my country's economy enters a new normal, the traditional equipment manufacturing industry is facing problems such as insufficient demand and overcapacity, and product remanufacturing has become an increasingly emerging industry.
According to statistics, the current global remanufacturing output value has exceeded 100 billion U.S. dollars, 75% of which come from the United States, of which automobile and construction machinery remanufacturing accounted for more than 2/3. In my country, the remanufacturing industry has just started and has not yet been launched on a large scale, and the market has huge room for improvement. Experts predict that the scale of China's remanufacturing industry will reach US$10 billion per year in the future.
China attaches importance to the development of remanufacturing industry, and the remanufacturing of construction machinery is included in the national development strategy. The Circular Economy Promotion Law of the people's Republic of China, which came into effect on January 1, 2009, points out that the State supports enterprises to carry out remanufacturing and tire retreading of motor vehicle parts, construction machinery, machine tools and other products; In May 2010, the national development and Reform Commission and other 11 departments jointly issued "opinions on promoting the development of remanufacturing industry", which listed construction machinery as one of the key support areas to promote the development of remanufacturing industry.
In 2009, seven construction machinery enterprises including XCMG, Qianlima, Liugong (8.99-0.22%, buy), caterpillar remanufacturing industry Shanghai, Tianjin Construction Machinery Research Institute, Zoomlion (5.46-1.09%, buy) and sany group were selected as the first batch of pilot units for remanufacturing of mechanical and electrical products by the Ministry of industry and information technology of the people's Republic of China, which explicitly supported construction machinery enterprises to develop remanufacturing industry.
However, when China realized the value of remanufacturing and vigorously advocated it, the remanufacturing industry of construction machinery countries represented by the United States, Japan and Europe, which started earlier, has developed relatively mature and has formed large-scale production. The remanufacturing industry of caterpillar, Komatsu, case and other enterprises has a history of more than 40 years, with hundreds of patented technologies. Remanufacturing industry is one of the main sectors of the output value of these enterprises.
Caterpillar is the world's largest and most powerful remanufacturing giant. Its remanufacturing company has 19 factories and nearly 4000 employees in 8 countries; In China, caterpillar remanufacturing has more than 100 employees. In the mature market, 20% of the parts sold by caterpillar worldwide are remanufactured parts.
In China, the remanufacturing industry is still in its infancy, according to Grude, Caterpillar's global vice president in charge of remanufacturing.
Although China's remanufacturing industry started late, it has developed rapidly.
According to reports, XCMG, Zoomlion, Sany, Liugong, Xiagong, Shantui, Tianjin Construction Machinery Research Institute and other enterprises and scientific research institutes have invested a lot of human and material resources to carry out research and industrialization of construction machinery remanufacturing technology in different modes. It is reported that Liugong has built a remanufacturing line for the remanufacturing and production of hydraulic cylinders, hydraulic valves, box bridges and other products, with an annual output of 6000 hydraulic cylinders, which can be mass produced; Xiagong has carried out the remanufacturing production of double transformer assembly, overrunning clutch assembly and main drive assembly of construction machinery. At present, the production line of box and Bridge disassembly and remanufacturing has been built and has been mass produced. At the same time, advanced technologies have been developed and applied to the remanufacturing process of products, including not only the technologies in the remanufacturing process such as parts nondestructive disassembly technology and parts cleaning technology, but also the evaluation technologies such as residual life assessment, Remanufacturability assessment and remanufactured product surface quality assessment.
At present, the development of remanufacturing in China also meets some problems.
Firstly, the laws and regulations on Remanufacturing need to be further improved.
Shi Peijing, deputy director of the Key Laboratory of Defense Science and technology for Equipment Remanufacturing Technology, which is famous for Chinese remanufacturing, pointed out that developed countries such as Europe and the United States have successively established relatively perfect remanufacturing technology standards, regulations and instruction systems, and have strict requirements on the quality assurance of remanufactured products. At present, the domestic remanufacturing industry is still in its infancy, and the understanding of remanufacturing from all walks of life is not unified enough.
Secondly, it has not formed a certain scale and system, and has little technology accumulation.
Zhang Guosheng said that the remanufacturing of construction machinery in China is mainly concentrated in several domestic main engine manufacturing enterprises and relevant agent enterprises, and the remanufacturing products are mostly the key parts produced by themselves or the whole machine and key parts recycled by agents, with a low remanufacturing rate and a small scale of remanufacturing industry.
Shi Peijing said that the lack of standards for remanufacturing technology, quality control and qualification management restricted the wide application of remanufacturing technology and the healthy development of the remanufacturing industry.
GERD also believes that the main resistance to the further development of the remanufacturing industry is the reverse logistics system, that is, how to return the core to the original manufacturer for remanufacturing. A challenge that is easily underestimated is how to manage the reverse logistics system of core recycling so as to effectively recycle the cores and ensure that the cores can be effectively reused.
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