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Understanding the remanufacturing process - 07.05.2019

Quality and adherence to industry standards are key factors that distinguish a remanufactured automotive major unit from an inferior reconditioned or refurbished product.  The complex process of remanufacturing an engine or component back to OEM standard requires significant investment in skills and capital equipment, let alone technical expertise and rigorous inspection procedures. IVS0164-Remanufacturing-Process-Flow.jpeg

All remanufactured Ivor Searle engines are built to exceed the BS AU257:2002 Code of Practice.  This crucial standard sets out the difference between a high quality remanufactured engine to an inferior reconditioned unit.  A remanufactured engine is exactly that, an engine which has been returned to the manufacturer’s specification to provide levels of performance and reliability equivalent to the original engine.
The standard fully details how petrol and diesel engines and components should be inspected and checked against OEM tolerances.  BS AU257:2002 also dictates that key components, including piston assemblies, big and small end bearings, as well as bushes, gaskets, seals, timing chains and drive belts are completely renewed.
Important additional operations, such as crack testing and machining components, are undertaken to ensure original performance is achieved with reliability.  In addition to having all key clearances and tolerances inspected during assembly.  Ivor Searle also fully tests and inspects all engines as the final stage of the remanufacturing process.
From the arrival of old core through to the delivery of a high quality finished major unit, the Ivor Searle engine remanufacturing process is based around these ten steps:

Step One: Core engine stripped, cleaned and checked.  All old pistons, bearings and gaskets etc. removed and scrapped.
Step Two: Engine components put into stores, ready for remanufacturing.
Step Three: Complete component machining: Crank grinding, full cylinder head machining, block machining, piston boring and honing etc.
Step Four: All engine parts picked and grouped from stores ready for assembly.
Step Five: Engine assembly in accordance with BS AU 257:2002.
Step Six: Engine test cell to check correct operation.
Step Seven: Quality inspection to ISO 9001:2015.
Step Eight: Engine painted in signature Ivor Searle black.
Step Nine: Installation parts and instructions added.
Step Ten: Engine placed into stock ready for next day customer delivery.
Thanks to this rigorous approach, customers purchasing a quality Ivor Searle remanufactured engine can be confident that they are investing in a unit that is built to a specific standard. 

In contrast, a reconditioned engine is a unit that has been stripped or disassembled and cleaned - and may have had some damaged components replaced.  Put simply, reconditioning is an entirely subjective process that offers little or no reassurance to the customer in terms of longevity, warranty protection or performance to OEM standards.
Compare this to the remanufacturing process which aims to return a product to at least its original specification and performance with a warranty that is equivalent or better than that of its brand-new equivalent.  At Ivor Searle, all engines have a 12-month, unlimited mileage parts and labour warranty and each has a unique serial number. 
In terms of other products, Ivor Searle also applies the same quality-focused ethos from engine remanufacturing when it comes to cylinder heads, gearboxes and turbochargers, all of which are remanufactured under a quality management system certified to ISO 9001:2015.  Again, this approach enables us to ensure customers are provided with quality products remanufactured to a consistent standard at a price that can be 40% less than brand new.
Ivor Searle holds comprehensive engine stocks to ensure first class customer service and minimum vehicle downtime and also provides free next day UK mainland delivery for stock items ordered before 3.30pm.  Ivor Searle has an extensive distributor network, so no matter where you are, you’re never far away from a quality product. To find out more, please call us on 01353 720531.

Filed under: engine, process, reman