Effects of Remanufacturable Product Design on Market Segmentation and the Environment

Despite documented benefits of remanufacturing, many manufacturers have yet to embrace the idea of tapping into remanufactured‐goods markets. In this article, we explore this dichotomy and analyze the effect of remanufacturable product design on market segmentation and product and trade‐in prices by studying a two‐stage profit‐maximization problem in which a price‐setting manufacturer can choose whether or not to open a remanufactured‐goods market for its product. Our results suggest that it is optimal for a manufacturer to design a remanufacturable product when the value‐added from remanufacturing is relatively high but product durability is relatively low and innovation is nominal. In addition, we find that entering a remanufactured‐goods market in and of itself does not necessarily translate into environmental friendliness. On the one hand, the optimal trade‐in program could result in low return and/or remanufacturing rates. On the other hand, a low price for remanufactured products could attract higher demand and thereby potentially result in more damage to the environment. Meanwhile, external restrictions imposed on total greenhouse gas emissions draw criticism in their own right because they risk stifling growth or reducing overall consumer welfare. Given these trade‐offs, we therefore develop and compare several measures of environmental efficiency and conclude that emissions per revenue can serve as the best proxy for emissions as a metric for measuring overall environmental stewardship.     

Rough-cut capacity planning for remanufacturing firms

Capacity planning is a critical element of any successful production planning and control system. A method of rough-cut capacity planning is developed, based on the bill-of-resources approach, that can be used to plan for capacity required for firms in a remanufacturing including overhaul repair operations environment. The modified bill-of-resources approach developed takes into account two major stochastic elements inherent in this environment; probabilistic material replacement factors and probabilistic routing files. A detailed example from an actual repair overhaul operation is presented to illustrate the technique.     

The compatibility of durable goods with contingent generic consumables

Many durable products provide value only when used together with contingent services or consumable components, e.g. light fixtures (bulbs), printers (ink), electronics (batteries). Consumers need only have access to the contingent consumable components to continue to derive service from a durable. In fact, many firms rely primarily upon the revenues generated from the contingent services or consumables as the primary source of profitability, e.g. giving away the razors to make money on the blades. Such firms often invest considerable effort into making sure that consumers of their durables are held captive to their own branded consumables by impeding their access to generically available consumables. They do so by designing their products in such a way that they are not readily compatible with the generic consumables. We consider the implications of competition from third-party manufacturers that can provide generic consumables and the manufacturer’s production decisions of a durable good under such contingencies. This allows us to draw managerial insights about how a firm should decide on his product compatibility and production quantity when the generic contingent consumables enter the market.     

OEM product design in a price competition with remanufactured product

An original equipment manufacturer (OEM) produces new products and often faces a dilemma when determining the level of interchangeability in its product design. The interchangeability is considered as a degree to which the product can be disassembled without force, and thus an increasing degree of interchangeability would decrease the OEM's production cost, but it would also lower a remanufacturer's cost in cannibalizing used items. Decreasing the level of interchangeability to deter the remanufacturer, on the other hand, would simultaneously increase the production costs of the OEM. We thus formulate a two-period supply chain model consisting of two chain members, an OEM and a remanufacturer, to investigate the product design decision of the OEM and both chain members' competitive pricing strategies. We then characterize the equilibrium decisions and profits with regard to costs and consumers' preference for the remanufactured product. We also evaluate a strategic game in which the OEM chooses the degree of interchangeability, and the remanufacturer determines its collection strategy. We find that the product-design strategy is effective for the OEM in competing with the remanufacturer, but it is not necessarily harmful to the remanufacturer.     

The closed-loop supply chain network with competition,distribution channel investment,and uncertainties

In this paper, a closed-loop supply chain network is investigated with decentralized decision-makers consisting of raw material suppliers, retail outlets, and the manufacturers that collect the recycled product directly from the demand market. We derive the optimality conditions of the various decision-makers, and establish that the governing equilibrium conditions can be formulated as a finite-dimensional variational inequality problem. We establish convergence of the proposed algorithm that can allow for the discussion of the effects of competition, distribution channel investment, yield and conversion rates, combined with uncertainties in demand, on equilibrium quantity transactions and prices. Numerical examples are provided for illustration.     

A flexibly structured lot sizing heuristic for a static remanufacturing system

An effective planning of lot sizes is a key strategy to efficiently manage a combined manufacturing/remanufacturing system in the presence of substantial setup costs. Due to its complex interdependencies, optimal policies and solutions have not been identified so far, but several heuristic approaches have been analyzed in recent contributions. The main heuristic shortcuts are forcing equally sized lot sizes over the planning horizon as well as imposing a specific cycle structure, i.e., a sequence of manufacturing batches is followed by a sequence of remanufacturing batches. We are instead proposing a flexibly structured heuristic that allows for differently sized remanufacturing batches. We show in a comprehensive numerical study that our approach outperforms other existing approaches in more than half of all instances by up to 17%.     

Closed‐Loop Supply Chains: A Critical Review,and Future Research*

In this article, I present a review and tutorial of the literature on closed‐loop supply chains, which are supply chains where, in addition to typical forward flows, there are reverse flows of used products (postconsumer use) back to manufacturers. Examples include supply chains with consumer returns, leasing options, and end‐of‐use returns with remanufacturing. I classify the literature in terms of strategic, tactical, and operational issues, but I focus on strategic issues (such as when should an original equipment manufacturer (OEM) remanufacture, response to take‐back legislation, and network design, among others) and tactical issues (used product acquisition and disposition decisions). The article is written in the form of a tutorial, where for each topic I present a base model with underlying assumptions and results, comment on extensions, and conclude with my view on needed research areas.     

When to Offer Lower Quality or Remanufactured Versions of a Product

We investigate the profitability of adding a lower quality or remanufactured product to the product portfolio of a monopoly firm, both in single‐period and steady‐state settings. Consumer behavior is characterized by a deterministic utility function for the original product and a nonlinear relative utility function for the lower quality product. We find a threshold for the cost of the low‐quality product below which it is optimal to add it to the firm's portfolio, and show that while a cost advantage is necessary to make the lower quality offering profitable under linear or convex relative utility functions, market segmentation alone can justify the addition of the lower quality product under concave relative utility functions. In particular, we characterize (i) the new product cost under which it is optimal to offer a lower quality version of the product even if it is as costly to produce as the original product; and (ii) the weighted average of new and remanufactured product costs in the steady state under which it becomes cost effective to offer new products under the remanufactured label. Finally, we also identify the maximum possible profits from customer segmentation and the form of the relative utility function that achieves them. We discuss the implications for the common marketing practices of branding and generics.     

On Core Sorting in RMTS and RMTO Systems: A Newsvendor Framework

Variation in core condition and uncertainty in market demand pose great challenges for remanufacturers to match supply with demand. This article investigates a firm that acquires and remanufactures cores of multiple quality conditions to satisfy demand. Both remanufacturing‐to‐stock (RMTS) and remanufacturing‐to‐order (RMTO) systems are considered. In each system, a sorting operation that resolves the core conditions before remanufacturing may or may not be adopted, leading to four possible sorting/remanufacturing strategies: (1) no sorting in RMTS; (2) sorting in RMTS; (3) no sorting in RMTO; and (4) sorting in RMTO. Under each strategy, we derive the optimal decisions on the acquisition and remanufacturing quantities, in two scenarios, respectively: (i) all acquired cores are remanufacturable and (ii) some cores are non‐remanufacturable. We find that sorting can be completely useless to RMTS system, and thus should never be adopted regardless of the sorting cost. We provide the analytical condition under which this ineffectiveness of sorting occurs. Nevertheless, sorting is always useful to RMTO system and should be adopted when the sorting cost is below a threshold value. We also conduct an extensive numerical study and show that the effects of sorting to RMTO system are more significant than that to RMTS system.     

Improving the efficiency of remanufacture through enhanced pre-processing inspection – a comprehensive study of over 2000 engines at Caterpillar remanufacturing,U.K.

Remanufacturing returns used product to an ‘as-new’ condition and is a key strategy in environmentally conscious manufacturing and waste management. However, strategies to improve the efficiency of the process are hampered by a lack of remanufacturing-specific industrial research. This paper presents the results of quantitative research, conducted in an industrial remanufacturing facility, to establish the relationship between pre-processing inspection levels and the subsequent remanufacturing process time for returned used products (known as cores). It concludes that for cores having either complex geometry (such as internal ports), a large number of sub-components or that are constructed from, or comprising of, multiple materials the remanufacturing process is shortened by increased inspection prior to processing. However, these benefits are currently limited by the amount of information that can be gained from the inspection methods used. The authors describes the practical use of these results in both a decision-making methodology for inspection and a cost assessment tool.