Royal Reman Process ™

 

Royal Equipment Reman (Remanufacturing) Process™

  • One of the leading global suppliers of remanufactured equipment for the surface mining industry
  • All brands of electric mining equipment are eligible for Reman
  • Reman products are 35-65% of the cost of new products
  • Reman partners and subcontractors strategically located around the world

Introduction:

Due to its substantial capital investment, mineral mining companies can't afford the less-than-optimal production of its equipment fleet, and much less the downtime caused by equipment failures. That's why we remanufacture products to operate reliably and efficiently for as long as there is useful life left in an existing piece of equipment and component. And mining equipment usually comes with a long useful life built in from the factory!

We take previously owned pieces of mining equipment and completely transform them into highly productive machines. It's a remarkable concept for the value and quality minded mining company and mining contractor who, like us, are driven by nothing less than the safest and very best performance for their hard earned income.

The 10 Steps in the Royal Reman Process™ are shown below. Let's take a closer look at the remanufacturing of a mining truck.

  1. Receiving
  2. Disassembly & Sand Blasting
  3. Detailed Inspection & Testing
  4. Evaluation
  5. Structural Repairs Made to OEM Standards
  6. Electrical Wiring Inspection & Reworking
  7. Reassembly
  8. Final Assembly Testing
  9. Jobsite Reassembly & Commissioning
  10. Equipment Placed in Service

Environmental Benefits of Remanufacturing

According to studies performed at the Fraunhofer Institute in Stuttgart, Germany, energy savings by remanufacturing world-wide in a year equals the electricity generated by 5 nuclear power plants or 10,744,000 barrels of crude oil which corresponds to a fleet of 233 oil tankers. The Fraunhofer Institute also determined that raw materials saved by remanufacturing worldwide in a year would fill 155,000 railroad cars forming a train 1,100 miles long. Because products that are remanufactured are kept out of the waste stream longer, landfill/junk yard space is preserved and air pollution is reduced from products that would have had to be smelter again or otherwise reprocessed. A product can always be recycled. Extending product life through remanufacturing is the key to leveraging the earth's natural resources.

Royal Reman Process™

  1. Receiving: Royal disassembles and remanufactures machines from the inside out, discarding and replacing every part that no longer deliver its intended purpose with new and upgraded OEM parts.
  2. Disassembly & Sand Blasting: After a rigorous strip down, machines are thoroughly washed and sand blasted to ensure the complete removal of dirt, grease, oil and other impurities. Frame is independently magnetic-particle tested for cracks.
  3. Detailed Inspection & Testing: Independent testing is initially performed on major structural components to determine the repair scope of the work. Components that are magnetic-particle tested include:
    • Main Frame
    • Rear Axle Housing
    • Front Spindles
    • Dog Bone; and,
    • Nose Cone
    • Upon completion an inspection report is issued.
  4. Evaluation: At this stage all the critical subassemblies and parts are evaluated for soundness and compliance with OEM's specifications. Non compliant parts are discarded, with the remaining parts passing on to be remanufactured by experts, using new, upgraded, OEM parts.
  5. Structural Repairs Made to OEM Standards: All the required structural repairs are performed per the latest OEM guidelines and procedures.
  6. Electrical Wiring Inspection & Reworking: A very important aspect of the remanufacturing process is the electric wiring. Electrical 24 volt system wiring and high voltage cabling are enhanced during the remanufacturing process. Royal reworks the electrical diagrams to include the following:
    • Remove components and circuits no longer utilized
    • Revise all circuits for upgraded components
    • Add new circuits for new components and new optional equipment
    • Incorporate new spare wires, in new wiring harnesses, for future product improvements or new equipment options
    • Improve major wiring harness to include cannon plug design and a simplified wiring routing
  7. Reassembly: We then start reassembling the equipment.
    • Cab is fully remanufactured from the inside out
    • The latest upgrades are incorporated.
    • Superior craftsmanship and attention to detail are the hallmark of our work
    • Genuine parts are used to RemanTMcomponents.
  8. Final Assembly Testing: We then proceed to test the final product.   A Royal Equipment representative in conjunction with a General Electric representative, and the new engine OEM representative perform full load test on the remanufactured truck at the RemanTMfactory location. Test reports will be supplied to customer.
  9. Jobsite Reassembly & Commissioning: Final commissioning process includes road test performed after reassembly at the mine site.


  10. Equipment Placed in Service: The end result...a remanufactured machine that looks andfunctions like a new machine. We guarantee our work, and we provide the required data to support our claim.


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 Printed: Wed, March 10, 2010 - 2:25:28:pm
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