Improvement and Standardization of Forklift Remanufacturing : Action Research on Toyota Material Handling Sweden forklift remanufacturing

Abstract: The current production field operates on linear resource flows, characterized by known supply and consistent manufacturing materials. In contrast, a remanufacturing system experiences variable process flows for each produced unit, even though the end product remains the same. The uncertainty surrounding the quality of cores can impact tactical decisions. This variability is influenced by factors such as the quality and condition of the core upon arrival at the facility, leading to uncertainties in cost and production times. The purpose of this research is to develop a cost estimation method for product recovery decision-making processes and enhance the flow efficiency of remanufacturing processes. To achieve this goal, the study identifies and investigates the factors that affect the condition of the core, represented by processing time. Subsequently, the analysis focuses on processing time and spare parts cost, and introduces a cost estimation method based on historical data. Finally, the current process flow is examined, and suggestions for improvements are provided. This research employs two distinct approaches: statistical and quantitative analysis, as well as qualitative inquiry that considers the experiences and perceptions of employees and other non-numerical aspects. Therefore, an action research methodology has been used, combining scientific knowledge with existing expertise within an organization to address real organizational problems. The study develops a new inspection process that combines a prediction model for processing times with a thorough inspection of important parts identified through spare part analysis. Additionally, suggestions are made to improve the flow of the remanufacturing process by prioritizing critical inventory items and introducing a new inspection and cleaning station where necessary spare parts are ordered before the remanufacturing process begins.