Retrofit vs. rebuild vs. remanufacture: which is right for you?

When it comes to machine tools, confusion regarding the use of the terms retrofit, rebuild, and remanufacture is quite common. In fact, the terms are often used differently to describe the various services being offered, according to Wayne Baldwin of machine rebuilder Phoenix, Inc. (Seekonk, MA).

"This may lead to unhappy customers and to a degree of mistrust of the machine tool industry as a whole," Baldwin says. "Customers may be confused by lengthy, line-by-line offerings that simulate a shopping list," says Baldwin.

To avoid misunderstandings, he advises customers to develop comprehensive specifications in consultation with a reputable manufacturer. And, he proposes the following definitions to further eliminate confusion.

• A retrofit is a replacement of an existing machine tool control system, often including drives, axis motors, and spindle motor. It is commonly performed at the customer site. The process of adding a CNC control and drive system to a manual machine goes far beyond a retrofit, and requires substantial engineering in both the design and construction of machine tools.
  
• The term rebuilding traditionally has been a catch-all for a wide variety of operations from partial repair to full restoration. In general, quotations for rebuilding a machine tool will include restoration or replacement of many, but not all, of the systems and components. It is not unusual for a rebuild quote to include a long list of items with specific mention of what will be replaced/restored and what will be reused. These items could be as important as a major way system or as simple as limit switches, hoses, and belts. It's up to the customer to assure that all needed components are listed.
  
• Remanufacturing attempts to return a new machine to the customer. Remanufacturing includes the replacement of all major systems, and may include engineered improvements and alterations to increase the functionality and productivity of the machine. Larger working travels, conversion from manual to CNC, increased spindle speeds, the addition of a toolchanger, increased table size, and the addition of fourth or fifth axes are just some of the factors involved in remanufacturing a machine. Unlike rebuilding, remanufacturing shifts all of the responsibility from the customer to the supplier.

At first glance, the remanufacture of a machine tool may seem more expensive than other approaches, but is often the most cost-effective option when a detailed analysis is done by someone familiar with machine tools. Important questions to consider in such an analysis include:

• Will the supplier be able to make the necessary changes and provide comprehensive professional documentation necessary to maintain the machine?
  
• Does the supplier have the in-house expertise necessary to accept complete, single-source responsibility?
  
• Will the machine be covered by a warranty?

Phoenix Inc., 257 Pine Street, Seekonk, MA 02771 USA. Phone (508) 399-7100.