BBB is dedicated to continuous improvement and waste reduction. Our goal is to provide the highest quality product at the right price and at the right time. In order to accomplish these goals, we must continually innovate within our manufacturing operation. We must continually search for ways in which to work smarter, with more efficiency and with added effectiveness. In addition, BBB is a price leader in our industry and the competitive pressures in the market place force us to continually look for ways to reduce costs, while maintaining our world class quality position. This commitment, combined with our highly efficient state-of-the-art equipment and facility, allows us to deliver to our customers a cost effective, higher quality product in a shorter amount of time.
Lean manufacturing is the tool we have employed throughout the organization in order to eliminate waste. What is lean manufacturing? Simply stated, lean manufacturing is a series of techniques for identifying and eliminating waste. The goal of eliminating waste is achieved by continuously improving the flow of product at the demand of the customer. We deploy a team of Lean Champions throughout the organization who train, motivate and monitor team mates. All employees are trained on Lean and waste reduction and are encouraged to promote ideas that enhance our continuous improvement initiatives. Moreover, lean manufacturing is a system for satisfying customer requirements on delivery, quality, and price. The end goal of our Lean and continuous improvement initiatives is to meet and exceed a customers’ delivery and quality expectations.
According to the Automotive Parts Remanufacturers Association (APRA), remanufacturers have been “recycling” automotive parts for more than 80 years. During World War II, natural resources were scarce forcing the country to reuse automotive and truck parts in order to meet demand. This gave rise to what was later named the remanufacturing industry.
The financial impacts of remanufacturing are significant. Remanufactured components cost about 40 to 60 percent less than a new component. In the case of starters and alternators, remanufactured units are about half the cost of a new unit. The high quality, technical support and industry leading low warranty rates related to BBB products make the selection of a BBB remanufactured electric component not only “green” but also financially sound.
The environmental benefits of remanufacturing are significant. APRA stated that the car parts remanufacturing industry benefits the environment in various ways, including:
- Energy conservation – EBay Motors estimates that remanufacturing provides an 85% reduction in energy usage over the manufacturing of a new unit. In addition, automotive and truck parts are kept out of the re-smelting process longer leading to the conservation of millions of barrels of oil or comparable forms of energy.
- Pollution reduction – Remanufacturing helps keep components out of the re-smelting process for a longer time frame reducing air pollution generated by re-smelting. In addition, new part manufacturing increases pollution throughout the manufacturing process whereas remanufacturing eliminates new part requirements.
- Raw material use reductions – Remanufacturing gives a product numerous lives instead of just one, thereby saving non-renewable raw materials. Rebuilders annually save millions of tons of non- renewable natural resources, such as iron, aluminum and copper.
- Landfill space conservation – Landfills are spared from accepting millions of tons of metallic and nonmetallic waste because of the monetary value the industry places on parts. This value is referred to as a “core charge” and is returned to the source of the worn out parts, ensuring that parts are returned to be rebuilt.
In addition to carbon footprint reductions related to remanufacturing, BBB has implemented numerous initiatives to further enhance its GREEN position. BBB’s Lean Manufacturing Plan reduces various types of waste involved in the remanufacturing process, including material scrap, power usage, inventory management and more. Examples include reducing component waste through process improvements, reducing electrical usage by installing more efficient lighting systems in our facilities and obtaining very high first pass yield quality standards. In addition, our employees are searching daily for ways in which to lessen our impact on the planet.