50 Years of Cat® Reman: An Overview
With more than 50 years of remanufacturing experience, Caterpillar has established itself as a leader in the industry and set an example for others to follow.
Caterpillar’s remanufacturing efforts started with a single-series engine in 1973 and has evolved into the Cat Reman Program, which provides customers with access to like-new parts at a fraction of the cost of new parts. This program enables us to keep resources in circulation and has been instrumental in reducing total ownership and operating costs for our customers.
By offering remanufactured parts at Boyd CAT, we have been able to add value to our offerings and extend the lives of many machines.
About Remanufacturing
The fundamental remanufacturing concept is a great example of how companies can be more efficient by conserving resources and reducing their consumption of raw materials. At Boyd CAT, we aim to make our customers more successful with our products and services, and remanufacturing couldn’t be a better fit for ensuring this success.
Remanufacturing provides customers with a cost-saving alternative to buying new components. Not only does this help save on cost, but it reduces downtime, allowing machine owners to easily swap a leaking cylinder or broken pump with a high-quality rebuilt cylinder or pump.
Our world-class Cat Reman process is rooted in data, using analytics to reduce process variability and increase productivity. The analytics team transforms data into actionable information to guide decisions and improve processes – allowing for less waste, increased efficiency, and enhanced customer value. Plus, remanufacturing is good for the planet because it conserves raw materials and reduces energy use during production.
The Start of Cat Reman
On March 7, 1973, Caterpillar established its diesel engine remanufacturing plant—a first for any U.S. company. “That was before 3208s came on the scene. At that time, we were going to start building all the 3100 series engines, the 1100 series engines, and a Marine engine,” said Steve Stark, former technical resource manager and one of the first people to work on the Cat Reman program.
By the mid-1970s, Caterpillar had begun selling remanufactured turbos and even the first 3406 engine. In addition to selling 240 of these turbos through authorized Cat dealers in America, Caterpillar also moved its operations to Corinth in 1982. After Caterpillar launched the Cat Reman production line, it expanded to encompass most industries we serve today.
With one such expansion in 1985 – involving a new removal-and-installation process for cylinder components – Caterpillar created technology to help engine manufacturers increase efficiency and reduce maintenance costs across their entire range of products. This change allowed Caterpillar to provide customers with pre-assembled liners, pistons, and connecting rods. This single, pre-assembled kit was known as the Cat Reman Cylinder Pack. Today, this has evolved to our Engine Overhaul Kits with four different precious metals to choose from.
One challenge the program faced early on was the existing focus on new parts and components, leaving few resources available for testing and remanufacturing used products. Steve Stark said this was why he “started the technical resources group in Corinth. We developed our own salvage techniques and did a lot of our own testing.” Despite this challenge, Cat Reman provided customers with quality remanufactured engines ready to be installed into their equipment within hours of delivery – dynamometer tested to ensure quality performance.
Today, the Cat Reman Program, now global in scope, provides customers with over 8,000 unique parts and components. These sustainably remanufactured products can cost as much as 60 percent less than new ones – giving equipment a second life at a fraction of the price.
Follow Along The Remanufacturing Process
The Caterpillar remanufacturing process is a highly advanced and efficient system that begins with the customer’s used core. Once the core nears its end of life, customers can return it to their local Boyd CAT dealership for core credit.
The accepted core is then sent to one of our global core processing facilities, where it undergoes a thorough inspection before transport to a Cat Reman factory. Once there, the skilled technicians disassemble the component into its smallest parts, wiping away any trace of its previous identity.
After that step, we utilize advanced techniques such as laser cladding, machining, metal deposition, and other sophisticated salvage procedures to restore each piece to like-new condition meticulously. Following the salvage process, the part is methodically reconstructed to become just as good as the new component. Our technicians ensure it adheres to the same OEM specs and includes all recent Caterpillar engineering advancements.
Each unit undergoes stringent testing to meet the same high standards as new Cat parts. The unit is then reintroduced into the supply chain as a Cat Reman product – complete with a 12-month Caterpillar Parts Warranty identical to a brand-new part.
The Sustainability of Remanufacturing
The Cat Reman process is a groundbreaking method of sustainable manufacturing that not only benefits the environment, but also provides cost-effective solutions to our customers. Because this process involves remanufacturing used cores, it effectively reduces waste produced during the manufacturing process and simultaneously offers valuable, high-quality parts to customers.
In addition to being eco-friendly, this approach requires less energy and raw materials, and produces fewer greenhouse gasses than traditional manufacturing methods. A focus on sustainability is deeply ingrained in our values and business model, which places a strong emphasis on ecological responsibility in all of our operations.
By prioritizing sustainability efforts, Caterpillar can meet regulatory requirements, support customer uptime, and achieve shareholder objectives. As a result, the Cat Reman program is a win-win for all stakeholders involved, providing both economic and environmental benefits. Boyd CAT remains committed to sustainability and efficiency and we are proud of our remanufacturing efforts for the good of our planet and our customers.
The Cat Reman Difference
Over the years, our Cat Reman Program has evolved into a comprehensive system that gives customers access to like-new parts at an unbeatable value. This program has helped many customers reduce ownership and operating costs and promote sustainability by preserving valuable resources.
We continuously invest in research and development to improve remanufactured parts’ performance, durability, and quality. As we move ahead, we will continue to provide top-quality, like-new parts for our customers, allowing them to reduce their environmental impact while also improving their bottom line.
Get Started with Cat Reman Today
Reach out to our team here about Cat Reman and how it can help your business save money and reduce its environmental impact.