Remanufactured Air Starters Improve Supply Chain Reliability

This remanufacturing program helped improve product availability while reducing cost and environmental impact

A global manufacturer of large diesel and gas engines required dependable starting solutions that met strict quality requirements while remaining cost-effective for dealers and end users. Through a comprehensive remanufacturing program for air starters, the supplier achieved industry-leading delivery and quality performance while supporting sustainability objectives.

At a Glance

Supports construction, mining, marine, rail, oil & gas, and off-road industries
Products distributed through a 1.5 million sq. ft. North American parts distribution hub
Supplies 2,300+ authorized service locations worldwide
Supports 21 global parts distribution centers
Achieved 100% delivery and quality performance metrics
Significant reductions in material use, energy consumption, and process emissions

A large global service network needed dependable, cost-effective engine starting solutions

The organization serves customers operating critical equipment across multiple industries where equipment uptime is essential. Dealers and end users required reliable air starter solutions that delivered original-equipment performance at a lower cost than new replacement components.

In addition to meeting demanding quality expectations, supply chain performance was critical. Components needed to be available when customers required them, with minimal lead times and consistent on-time delivery performance.

The challenge extended beyond product availability. The customer also sought solutions that aligned with broader sustainability goals by reducing material consumption, manufacturing energy requirements, and greenhouse gas emissions.

A remanufacturing program delivered like-new performance while extending product life

Rather than relying on traditional rebuilding or refurbishment methods, the supplier implemented a comprehensive remanufacturing process designed to return air starters to like-new condition using original-engineering specifications and manufacturing expertise.

The program leverages existing component cores, reducing the need for new raw materials while maintaining performance, reliability, and quality standards expected from original-equipment parts.

Products are remanufactured, tested, and supplied through a large-scale distribution network that supports thousands of dealer locations and multiple global distribution centers. This approach ensures parts availability while helping reduce total ownership costs for customers.

Key Elements of the Solution

OEM-standard remanufacturing process
Reuse of serviceable component cores
Rigorous quality inspection and testing
Forecast-driven production planning
Global distribution support
Continuous supplier performance management

Consistent delivery, quality, and sustainability gains strengthened supply chain performance

The remanufacturing program delivered measurable operational and environmental benefits.

Business Results

100% Delivery and Quality Performance

According to customer performance metrics, delivery and quality performance reached 100%, representing a significant improvement from the previous year.

Improved Dealer and Customer Confidence

Reliable product availability and consistent quality improved confidence throughout the dealer network and among end users operating mission-critical equipment.

Reduced Costs

The remanufactured option provided a cost-effective alternative to new components while maintaining expected reliability and performance standards.

Sustainability Benefits

Compared to manufacturing new components, the remanufacturing process achieved:

65–87% reduction in greenhouse gas process emissions
80–90% reduction in new material usage
65–87% reduction in process energy consumption

These improvements support both environmental objectives and long-term operating cost reductions.