Reconditioning of Equipment 1

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AMBO UNIVERSITY

HACHALU HUNDESSA CAMPUS

School Of Mechanical and Industrial Engineering


Department of Mechanical Engineering
Projects of maintenance and installation of
machinery
Name of students ID.No

1) Baisa Daba Chala ……………………….…….A/UR27995/11


2) Bedasa Mengistu Ketema………………..……A/UR27522/11
3) Birhanu Tilahun Ayalewu…………… ….……BRT/0446/10
4) Dinkineh Debebe Dawit…………………...….A/UR27518/11
5) Dita Gemedo Gemechu………………………..A/UR27813/11

Submitted to: Jemal w.

January 11, 2023 GC

Ambo, Ethiopia
Maintenance project
Contents
STUDY RECONDITIONING PROCESSES IN MAINTENANCE OF MACHINERY ...................... 1
1. INTRODUCTION .............................................................................................................................. 1
1.1 Definition of Reconditioning of Equipment ................................................................................. 1
1.2 Steps of reconditioning processes ................................................................................................. 2
1.3 Reconditioning-process activities ................................................................................................. 2
1.4 Management of reconditioning process ........................................................................................ 3
1.5 Types of reconditioning process ................................................................................................... 5
1.6 Reconditioning process assessment .............................................................................................. 7
1.7 Machines to be reconditioned ....................................................................................................... 8
1.8 Cost Analysis of Reconditioning .................................................................................................. 8
1.9 Requirements for Reconditioning Undertakings ........................................................................... 9
1.9.1 Infrastructure requirements. ................................................................................................. 10
1.9.2 Technical Requirements:...................................................................................................... 10
1.10 Advantages of reconditioning processes ................................................................................... 12
Conclusions ........................................................................................................................................... 13

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STUDY RECONDITIONING PROCESSES IN MAINTENANCE OF


MACHINERY

1. INTRODUCTION

1.1 Definition of Reconditioning of Equipment


Reconditioning processes are the process of servicing, re-adjusting, and recalibrating
machines, equipment or instruments to bring them to near-new or original operational level.

This can include cleaning, inspecting, repairing, and replacing worn or damaged parts. The
goal of reconditioning is to bring the equipment back to its original specifications and extend
its useful life. Reconditioning of equipment plays a significant role in maintenance of
equipment, particularly in developing countries where increasing cost of new equipment
makes the acquisition of new Equipment difficult, the need for reconditioning arises from

a) Aging machinery with rapidly decreasing reliability and high risk of failure:

b) Increasing and prohibitive cost of new equipment; ,

c) Scarce capital;

d) Lack of adequate foreign exchange.

Reconditioning of worked out equipment after long use may be defined as a systematic
planned Active deigned to restore equipment to its original performance condition. With firm
commitment towards quality, it is needed to offer machine reconditioning services as per
specific requirements of the machines. These services are rendered in compliance with the set
international standards and norms. We can render these services using latest controllers and
upgrades technology, which help in improving the productivity and accuracy of the machines.
This process Involves repair. To certain problem areas in an equipment that may include:

 grinding app scrapping;


 removal of slackness due to wear; and
 Replacement of certain parts. Reconditioning is miniature version of the original
equipment manufacturing process.

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1.2 Steps of reconditioning processes
The reconditioning process typically involves several steps, which may vary depending on
the specific item being reconditioned and the method being used. However, many
reconditioning processes include the following steps:

Inspection: The item is thoroughly inspected to identify any damage or wear and to
determine the extent of the reconditioning that will be required.
Disassembly: If necessary, the item is disassembled to make it easier to recondition
and repair.
Cleaning: The item is thoroughly cleaned to remove dirt, grime, and other
contaminants.
Repair and Replacement: Any damaged or worn parts are repaired or replaced as
needed.
Reassembly: The item is reassembled, making sure all parts are securely in place and
functioning properly.
Testing: The item is tested to ensure that it is in proper working order.
Refinishing: The item is refinished if necessary to restore its appearance.
Packaging and Shipping: After reconditioning the item is packaged and shipped.

1.3 Reconditioning-process activities


The process of reconditioning is similar to the manufacture of a new machine and should be
approached in a logical and scientific manner. Reconditioning process involves the following
activities:

 Stripping of existing machine component-wise.


 De-greasing and cleaning of equipment parts.
 Inspection of component parts and determining their residual life.
 Replacement of all parts which have a residual life less than some critical useful life
and replacing by matching parts. In Marty industrial applications the critical residual
life is 5 to 7 years.
 Replacement of all mandatory components.
 Inspection and repair of all castings.
 Grinding of guide-ways, etc and hardening.
 Assembly and testing of all sub-assemblies.
 Reassembling the machine and achieving specified standards of alignments.
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 Load testing of machine to specified standards.
 Repainting and change of name plate where necessary.
 Inspecting machine
 In general, reconditioning activities can be grouped into two categories:

1. Mechanical or technical activities, such as replacing worn parts, calibrating or testing


equipment, etc.

2. Cosmetic or appearance-related activities, such as cleaning, repainting, or detailing.

During reconditioning process, there is also the Evaluation process which will be done to
check the overall condition of the item and identify any issues that need to be addressed.

1.4 Management of reconditioning process


It's important to have dedicated and trained personnel to manage the reconditioning process
to ensure that the product or equipment is reconditioned to the highest possible standard and
is safe to use. The management of the reconditioning process involves several steps,
including:

Assessment: The first step in the reconditioning process is to assess the condition of
the product or equipment. This includes determining the extent of any damage or
wear, as well as any missing or broken parts.
Planning: Once the assessment is complete, a plan for the reconditioning process is
developed. This plan should include details such as the materials and tools that will be
needed, the estimated time required to complete the process, and any potential risks or
hazards.
Execution: The next step is to execute the plan, which may involve disassembling the
product or equipment, cleaning and inspecting each component, replacing any broken
or worn parts, and reassembling the product or equipment.
Testing and Quality Control: After the reconditioning process is complete, the
product or equipment should be thoroughly tested and inspected to ensure that it is in
good working condition. This step is critical to ensure that the product or equipment
performs as expected and meets quality standards.
Documentation: Throughout the reconditioning process, it is important to document
each step, including the condition of the product or equipment before and after
reconditioning, the materials and tools used, and any issues or problems that were

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encountered and resolved. This documentation can be used to improve the
reconditioning process in the future and as a reference for warranty, legal or insurance
claims.
Process improvement: Continual process improvement is important to improve the
efficiency, safety and quality of the reconditioning process. Regularly reviewing and
updating the process based on feedback, best practices and industry standards would
help to improve the reconditioning process.
 Maintenance management is often faced with the dilemma of replacement versus
reconditioning of existing equipment. Rule of thumb that can be applied in this case is:

1) Parts which require a considerable degree of specialized skills and costly processes are
best replaced.

2) If the repair facility available is limited then replacement of certain machines with
technologically superior equipment must take precedence over reconditioning.

3) If cheap and fast replacement parts are available, reconditioning is not a right alternative.

In general, maintenance management should resort to reconditioning if the following


situations arise.

a) Whenever the machine is imported, reconditioning is made compulsory for saving foreign
exchange as well as ensuring economy in consumption of spare parts.

b) Critical components like: hafts, gears, valves, pumps, etc. must retain dimensional and
structural integrity so that the desired performance is attained for maximum period of time
before re placement becomes necessary due to breakage. Such components even if they wear
out, they should be reconditioned and reused as long as possible.

c) Supply of machines/spare 3 is unreliable.

d) Equipment/part manufacture is discontinued and hence no supply is possible.

e) Replacement of machine is costly and new machine introduces compatibility problem with
existing set-up.

f) Budget shortage for replacement.

g) Original equipment is a special purpose machine and cannot be reordered.

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h) Rejection of output, reworking and scrap is beyond a predetermined level.

i) Reconditioning of an equipment should be considered at the end of a predetermined


trouble-free operating life of equipment.

1.5 Types of reconditioning process


I. Reconditioning Process without identity loss

In the context of reconditioning without identity loss, it likely refers to a process by which a
person or system can be returned to a desired state without losing their unique characteristics
or identity. It is might involve software updates and maintenance that improve the system's
performance and security without altering its core functionality.

It's important to note that there is not a set methodology, process or even definition of
reconditioning that has a common agreement across the field or industry. The definition and
goals of reconditioning might vary depending on the context and the nature of the item being
reconditioned. In any case, the goal of reconditioning without identity loss is to maintain the
integrity of the item or person being reconditioned while still addressing any issues or
problems that need to.

II. Reconditioning Process by recoating of worn machine parts

It is a process of recoating, which involves applying a new layer of material to the surface of
the part to protect it from further wear and tear. This can be done using a variety of
techniques, depending on the type of material and the condition of the surface.

One method of recoating is thermal spray coating, which involves heating a material (such as
metal or ceramics) to a high temperature, and then spraying it onto the surface of the part
using a high-pressure gun. This can create a very hard, durable coating that can protect the
part from wear and tear.

Other coating methods include electroplating, in which a metal is deposited onto the surface
of the part using an electric current, and painting or powder coating, in which a paint or
powder is applied to the surface and then heated to create a protective coating.

In addition to recoating, worn machine parts may also be reconditioned by machining or


grinding to remove damaged or worn areas, and by polishing or lapping to restore a smooth
surface finish.

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III. Repetitive Reconditioning Process without identity loss.

It is a process in which an individual repeatedly experiences a particular stimulus or situation


in order to change their response to it. This can be used to reduce anxiety, phobias, and other
negative reactions.

It's also important to keep in mind that an individual's identity is not fixed, but rather, it's
constantly evolving throughout their lifetime. Therefore, the goal of repetitive reconditioning
should not be to change or erase an individual's identity, but rather, to help them learn to live
with and make peace with their thoughts and emotions in a way that aligns with their core
values and allows them to live a fulfilling.

There are several types of reconditioning processes depending on the specific equipment
or product being reconditioned. Some examples include:

1. Mechanical reconditioning: This process involves restoring mechanical components,


such as gears, bearings, and shafts, to their original specifications. This can be done by
cleaning, polishing, and replacing worn or damaged parts.

2. Electrical reconditioning: This process involves restoring electrical components, such as


motors, generators, and control systems, to their original specifications. This can be done by
cleaning, repairing, and replacing worn or damaged parts, as well as rewinding and testing
motors.

3. Hydraulic reconditioning: This process involves restoring hydraulic components, such as


pumps, cylinders, and valves, to their original specifications. This can be done by cleaning,
repairing, and replacing worn or damaged parts, as well as testing and adjusting the system.

4. Thermal reconditioning: This process involves restoring the heat-resistance properties of


equipment, such as furnace or boilers, by removing build-up of ash and corrosion, inspecting
and replacing refractory and other related components.

5. Pneumatic reconditioning: This process involves restoring pneumatic components, such


as compressors, actuators, and valves, to their original specifications. This can be done by
cleaning, repairing, and replacing worn or damaged parts, as well as testing and adjusting the
system.

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6. Surface reconditioning: This process is used to remove corrosion, rust, and other forms of
surface damage from metal components. This can be done using chemical treatments,
sandblasting, or other methods.

1.6 Reconditioning process assessment


When conducting a Reconditioning Process assessment, the manager or the Engineer is
tasked with the following:

 Advice the types of tooling or machine reconditioning program is designed to handle.


 Calculate the economical lot sizes that will save the customer money.
 Describe when to pull used tools from operation before they are excessively damaged.
 Review minimum flute and diameter specifications that the customer requires.
 Review acceptable margin wear or damage with the customer.
 Suggest alternate point grinds to help save money.
 Review corner radius blend requirements to reduce cost.
 Provide information about our scrap carbide program.
 Explain how best to properly package worn tools.
 Review shipping options such as totes, van pick-up, and priority mailing.

Generally when assessing the effectiveness of a reconditioning process, there are several
factors to consider. Here are a few key things to keep in mind:

1. Goals: The first step in assessing the effectiveness of a reconditioning process is to


determine whether the individual's goals have been met. This might include things like
reducing anxiety, overcoming a phobia, or learning a new skill.

2. Progress: It's important to track the individual's progress over time in order to determine
whether they are making progress towards their goals. This might involve measuring changes
in symptoms, such as reductions in anxiety levels or improvements in social interactions.

3. Participation: The individual's engagement and participation in the process is another


important factor to consider. If the individual is not fully invested in the process, it is less
likely to be effective.

4. Quality of the therapist-client relationship: The quality of the therapeutic relationship is


also an important factor in determining the effectiveness of a reconditioning process. A

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therapist who is able to establish a strong and positive rapport with the individual is more
likely to be able to guide them through the process and help them make progress.

5. Measurement tool: It's important to use validated and reliable measurement tools to assess
the progress and goals.

6. Follow-up: Finally, it's important to follow up with the individual after the reconditioning
process has ended to see if the changes that were made have been maintained over time. This
can give you a sense of the long-term effectiveness of the process.

1.7 Machines to be reconditioned


 CNC Machines
 Robotics and Automation equipment
 Heavy-duty equipment and vehicles such as forklifts and cranes
 Car battery
 Transformers
 Steel Drums
 Machine tool spindle
 Conventional lathes
 Milling machines
 Vertical and horizontal boring machines
 Radial, pillar and multi spindle drilling machines
 Surface and cylindrical grinding machines
 Hydraulic and mechanical press
 Plate rolling machines
 For hydraulic

1.8 Cost Analysis of Reconditioning


The cost of reconditioning a machine will vary depending on the type of machine, its
condition, and the extent of the reconditioning.

The cost of reconditioning will depend on a number of factors, including the type of
equipment or product being reconditioned, the extent of the repairs required, and the labor
and materials required to complete the reconditioning process.

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Some common costs associated with reconditioning include the cost of labor, parts, and
materials, as well as any costs associated with testing or certifying the equipment or product
after it has been reconditioned.

It is also important to consider the costs associated with not reconditioning such as lost
production time, costly replacement, and possible safety hazards. A cost-benefit analysis may
be helpful in determining whether reconditioning is the most cost-effective option for a
particular piece of equipment or product. the cost of reconditioning can vary widely
depending on the scope of work, but it's important to consider long term benefits and costs
saved.

In general, some organizations consider that cost of reconditioning up to 30% of the price cf
anew machine to be acceptable, where the reconditioning cost should include: material, labor,
depreciation and any other contracted service required in the reconditioning process. This
level is acceptable if there are no other adverse effects on the performance of the machine
after reconditioning. The performance after reconditioning can be assessed through

 trouble-free service hours after reconditioning


 out-put rate
 Expected life of equipment after reconditioning.

In cost analysis of reconditioning, the reconditioning process will be approved only if a


critical cost-benefit analysis favors reconditioning to replacement.

In performing cost-benefit analysis is one to consider the cost of replacement versus that of
reconditioning. Replacement costs should include: spares cost; installation; service costs; cost
of ordering end transporting; labor; utilities, etc. Reconditioning costs should include:
material, labor, depreciation, outside contracted services.

Inhere, one thing should be noted which may not be quantified in terms of dollars; and that is,
the experience gained locally in the process of reconditioning. Performing a reconditioning
activity develops local capabilities which leads to increased design and fabrication capability.

1.9 Requirements for Reconditioning Undertakings


There are two aspects to the requirements that must be fulfilled to undertake a reconditioning
Action. These are the infrastructure and technical requirements.

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1.9.1 Infrastructure requirements.
For proper reconditioning adequate infrastructure facilities must be available include:

Workshop or facility: This could include a building or space with enough room to
accommodate the equipment or machinery being reconditioned, as well as the tools
and equipment needed to complete the work.
Tools and equipment: This could include basic hand tools such as wrenches and
sockets, as well as specialized tools such as lathes, milling machines, and welding
equipment.
Materials and supplies: A wide range of materials and supplies may be needed for
reconditioning equipment or machinery. This could include replacement parts,
lubricants, cleaning supplies, and protective gear such as safety goggles and gloves.
Personnel: Reconditioning equipment or machinery typically requires specialized
knowledge and skills, so it may be necessary to have a team of trained technicians or
engineers to handle the work.
Safety equipment: Safety should be a top priority during any reconditioning
undertaking. Adequate safety equipment such as face masks, goggles, gloves, hearing
protection and safety shoes are necessary to protect the personnel working on the
machinery.
Inspections and certifications: Depending on the type of equipment or machinery
being reconditioned, it may be necessary to meet certain inspection or certification
standards before the equipment can be put back into use. This would require necessary
inspection tools, documentations and certification that should be kept on record
 reconditioning shop;
 machines
 skilled manpower
 coordination between design, planning, purchase, inspection, sales and These
engineering
 Training of person.

1.9.2 Technical Requirements:


For proper reconditioning of equipment the technical level must be commensurate with the
practical aspect.

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 Involved engineers should be conversant with the design features of the equipment
which include: equipment performance, assemblies, components, lubrication system,
material specifications, etc.
 Adequate machine history should be available which includes operating conditions
and working shifts, maintenance system, frequency of breakdowns, etc.

There are several technical requirements that must be met to ensure that the machines are
reconditioned properly. These technical requirements may include:

Inspection: A thorough inspection of the machine is required to identify any damage


or wear and to determine the extent of the reconditioning that will be required. This
will typically include checking for wear on mechanical components, inspecting
electrical systems and controls, and testing the machine to ensure that it is in proper
working order.
Cleaning and Disassembly: The machine should be cleaned thoroughly to remove
dirt, grime, and other contaminants. If necessary, the machine may need to be
disassembled to make it easier to recondition and repair.
Repair and Replacement: Any damaged or worn parts should be repaired or
replaced as needed. This will typically include replacing bearings, seals, gaskets, and
other wear items, as well as repairing or replacing electrical and electronic
components.
Reassembly and testing: The machine should be reassembled and tested to ensure
that it is in proper working order. This will typically include running the machine
through a series of tests to check for proper operation, alignment, and calibration.
Calibration: The machine should be calibrated to ensure that it is working to the
correct specifications. Depending on the machine, this may include calibrating
sensors, measuring devices, and controls to ensure that they are working within
acceptable tolerances.
Updating and Modernizing: Reconditioning could include modernizing the
equipment to make it more efficient, reliable and to bring it up to the latest industry
standards.
Safety: Safety measures should be implemented to ensure that the reconditioned
machine is safe to operate. This may include installing safety guards, interlocks, and
other safety devices to prevent accidents.

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Maintenance: The reconditioned machine should be provided with a maintenance
schedule, to ensure that the machine is always in a good working condition.
Quality control: Quality control measures should be in place to ensure that the
reconditioned machine meets the standards and specifications. This may include
carrying out inspections and testing before and after the reconditioning process, as
well as maintaining detailed documentation of all the steps involved in the
reconditioning process.

1.10 Advantages of reconditioning processes


 Cost savings: Reconditioning can be significantly less expensive than purchasing
new equipment or replacement parts. This is especially true for industrial equipment
and machinery, which can be quite costly to replace.
 Sustainability: Reconditioning helps to reduce the amount of waste generated by
manufacturing and consumption, as well as to prolong the life of a product and reduce
the need to extract new raw materials.
 Quality: Reconditioned items can often be restored to their original specifications,
ensuring that they function as well as new items. This can be particularly important
for critical equipment or machinery.
 Access to older parts: As technology advances, it can be difficult to find new
replacement parts for older equipment. Reconditioning can provide an alternative
solution by restoring older parts to working condition.
 Preservation of historical equipment: in some cases preserving historical
equipment is important for heritage and culture, reconditioning can give new life and
make equipment safe to use again.
 Increased productivity: Reconditioned equipment can function as well as new
equipment, and can often be returned to service more quickly than new equipment,
which can increase productivity and reduce downtime.
 Longer life: Reconditioning can help extend the life of equipment and machines,
which can save money over the long term and help to ensure that resources are used
more efficiently.
 Creates more jobs (e.g. in Garage) and increases inventory.
 Challenges the questions of liability, risk and quality for manufacturers.
 Maximize sustainability and re-using of machines.

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 Converts old products into raw materials, and then manufactures into finished new
products again
 reduces the amount of energy and pollution from manufacturing
 Have positive consequences for manufacturers, the labor force and the environment.

Conclusions
 The main goal of reconditioning is to extend the lifespan of the equipment and
improve its overall performance.
 Reconditioning may not be suitable for all types of equipment; it also depends on how
well the equipment is maintained initially.
 The best practice is to consult the manufacturer and an experienced technician to
determine if reconditioning is the best option for your equipment.
 The opportunity to increase efficiency and sustainability through reconditioning
process now sits alongside the provision of good lubrication and the establishment of
preventative maintenance programs as a powerful tool with which to protect
profitability.
 Generally Reconditioning machines can save money and extend the useful life of the
equipment; it can also bring the machine up to the latest industry standards, improve
its performance and make it more reliable.

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