The Remanufacturing Process

 

 

 

Remanufacturing a Core

 

There is a vast difference between a rebuilt part (sometimes referred to as a spray and pray) and a part that is truly remanufactured.  At AAE, all our products are remanufactured to meet the strictest standards in the industry; Best-In-Class or scrap.  Going beyond OEM specifications, AAE aims to improve the performance of every part we produce. But remanufacturing goes far beyond just replacing worn or failed components.  It requires a complete understanding of how the part must fit and perform on the vehicle.

Vital to the remanufacturing process is the initial core.  The core is the old or failed part that enters the remanufacturing process.  As the life blood of any remanufacturer, the core is the raw material from which the process can begin. 



 


 

AAE’s remanufacturing process includes 8 critical process steps:

 

Step # 1 Core Receiving & Inspection


The remanufacturing process begins with the identification and inspection of cores.  To the untrained eye, it would be easy to over look small yet critical differences between what on the surface would appear to be the same part.  In fact, many parts look virtually the same.  However, to the trained eye there are many distinguishing features allowing the technicians to correctly identify every part before entering the remanufacturing process. Secondly, the inspection process is to ensure that each part is free from structural damage and missing parts which would compromise the physical integrity of the part and its ability to be remanufactured.  If a part fails inspection, it will be removed from the accepted core inventory and will be disassembled in an effort to retain components which can be salvaged.  These spare parts will be consumed during the manufacturing process to replace parts which fail at later stages of production. 

 

Once the part has been identified and passes inspected, it is appropriately labeled, entered into the core inventory system, and placed in its assigned bin location.  AAE uses identification technology and labeling systems to assist technicians with this process.   

Step #2 - Disassembly

 

AAE’s production scheduling system with determine what parts are needed for production.  Once identified, the appropriate number of cores will be pulled from their bin locations and put into the disassembly process. 

 

The disassembly process begins with the external components being removed from the part.  All non essential components such as boots, clamps, remaining cut hoses, or pot plugs will be removed.  Any residual oils remaining inside the unit will be drained.  All hard fluid lines are removed as are the inner tie rods.  These parts are retained and placed into holding bins.  In the second stage of disassembly, all the internal components are removed and disassembled.  Every component of a core is completely disassembled and individually inspected.  All wearable components, such as oil seals, o-rings, and bearings, are removed and will be replaced with new parts during the assembly process.  A complete Anatomy breakdown of racks and pumps can be found in the reference section at the end of this document. 

 

As part of AAE’s green manufacturing processes, all paper, cardboard, oils, scrap metals, and plastic materials resulting from the disassembly process are properly sorted and prepared to be recycled for protection of the environment.  

Step # 3 - Cleaning

 

Following disassembly, each part enters a deep cleaning process that includes a high pressure degreasing wash.  The part is then submerged into a vibrator which shakes aluminum media around the part to clean the exterior housing back to its original surface.  If required, shot blast processes are used to achieve the desired surface appearance standards.  All materials used in AAE’s cleaning processes are environmentally friendly and bio degradable.  

Step # 4 - Component Prep

 

During component prep, hard components are being reconditioned back to their original specifications.  All rack and pump shafts are polished to precise measurements and finishes using automated centerless grinders.  New seals and replacement components are gathered and inspected.  All fluid lines are tested for pin holes leaks.  Port threads are inspected and chased if necessary for clean and proper fitment.  

Step # 5 - Assembly

 

The process of re-assembly, the part is assembled using with the highest quality new and replacement parts available. AAE’s assembly specialists are master craftsmen with years of intense, specialized training. Only new seal and o-ring packs are installed with precision and care to insure no cuts or tears occur.  Pinion clocking positions are measured and set to OE specifications ensuring properly centered racks.  All bearings and gears are properly adjusted and lubricated during the assembly process. New o-rings are used as fluid lines are installed. Every part has a detailed build recipe along with specific assembly steps which insures repeatability and consistency across production runs. 

Step # 6 - Quality Control

 

100% of all products produced by AAE are air and hydraulically vehicle simulation tested under load to insure proper seal seating and that the unit is leak free.  Computer aided testers measure pressure ranges, fluid flow controls, and steering power assist as compared to control standards specific to vehicle make and model.  Test data is collected and retained for every unit and can be recalled in the event of a warranty claim.  Each part is uniquely marked with a specific identifier denoting production run, the production date and assembly technician.  

Step # 7 - Finishing Part Prep

 

As inspected and approved parts are released from quality control, the part moves into finishing prep.  During this final stage of production, goes through an additional inspection process where removal of any residual testing fluids is cleaned from the rack.  It is at this point that the inner tie rod installation, boot and clamp assembly, and port plug installation occurs.  Each unit is then processed for painting using a black high heat and element resistant premium surface paint.  As it leaves the paint booth, the part now has that showroom quality appearance and durability. Paint plugs are removed and replaced with new port protectors.  The AAE system flush warning label is applied and the part is now ready for the final process step of packaging.  

Step # 8 - Packaging

 

The AAE packaging system ensures uniformity and security of the part while in transition.  As AAE realizes that a part make potentially be shipped beyond the customers counter, it has designed its packaging to endure the ride. 

 

Every part is visually inspected for appearance issues as well as correct labeling.  The part is then placed on an insert which will be ultimately placed inside the packaging container.  The insert is processed through an orbital wrapper where a spinning cylinder head wraps the part with a heavy 8ml plastic wrap.  By securing the part to the insert, the part is stabilized during the shipping process and cannot come through the end of the box.  This plastic wrapping also protects the finish of the part as well as making an attractive view for the customer’s inspection.  AAE uses an attractive, printed, double-wall corrugated packaging box specifically designed for our operation.   Each part is appropriately labeled on the end of the package with a scan able barcode label.  AAE can provide custom labeling as requested to include specific customer cross reference part numbers. 

 

Inventory control and shipping accuracy is as important to AAE as the overall part quality.  AAE’s finished inventory area is well organized and utilizes an automated inventory control system for accurate inventory records.  The system directs our shipping technicians to the specific location where the parts are stored.  Utilizing specialized software, known as Order Verifier, AAE is able to ensure a 99.9 % order shipment accuracy rate.  Pallets are neatly stacked and secured to the pallet with shipping straps and a plastic pallet wrap.  Packing slips and shipping labels are attached.   Most volume orders are shipped within 24 hours of purchase order receipt.  Single item orders placed by 4pm will ship same day.