Performance evaluation of the remanufacturing system prone to random failure and repair

Implementation of new environmental legislation and public awareness has increased the responsibility of manufacturers. Remanufacturing has been applied in many industries and sectors since its introduction. However, only 10% to 20% of the returned products pass through the remanufacturing process, and the remaining products are disposed in the landfills. Uncertainties like high failure rates of the servers, buffer capacities, and inappropriate preventive maintenance policies would be responsible for most of the delays in remanufacturing operations. In this paper, a simulation-based experimental methodology is used to determine the optimal preventive maintenance frequency and buffer allocation in a remanufacturing line. Moreover, an estimated relationship between preventive maintenance frequency and Mean Time Between Failure (MTBF), is presented to determine the best preventive maintenance frequency. The solution approach is applied to computer remanufacturing industry. Analysis of variance (ANOVA), and regression analysis are performed to denote the most influential factors to remanufacturing cycle time (performance measures). A case study is used to show the applicability of the modelling approach in assessing and improving the cycle time, and the profit of a remanufacturing line . Managerial insights are highlighted to support managers and decision-makers in their quest for more efficient and smooth operation of the remanufacturing system.