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“The No. 1 priority given to all suppliers is the reduction of unscheduled downtime.“
Global director of fab operations from a worldwide leading semicon company

Benefits of ARPQP in detail

High quality

  • Highly reliable vacuum pump remanufacturing
  • World-class automotive quality standard IATF 16949:2016
  • Defined process to ensure that every vacuum pump receives the same treatment

Fast and predictable

  • Fast and predictable remanufacturing lead times and on-time delivery by the Busch lean flow system of remanufacturing and RFID tracking
  • Online real-time monitoring of the remanufacturing process
  • Push notifications on mobile devices

Savings potential

  • Predictable reliability helps eliminate unscheduled downtimes
  • Lower costs per wafer

ARPQP vs. standard service

Value featuresThird partyOriginal manufacturerBusch ARPQP
Vacuum pump repair onlyx  
True remanufacturing xx
ISO 9001:2015 certificationxxx
Compliance with IATF 16949:2016  x
Process engineering xx
Structured risk analysis of whole process  x
Analysis of vacuum measurement system  x
Statistical analysis of process data  x
Charting of process capability  x
Standard tool calibrationxxx
2D measuring of vacuum pumpxxx
3D measuring of vacuum pump  x
Lean processes xx
RFID real-time tracking of entire remanufacturing process  x
Push notifications on mobile devices during remanufacturing process  x
Spare parts inventory managed by Busch  x
RFID spare parts inventory control  x
Single-piece flow remanufacturing  x
Real-time balanced flow monitoring  x

Annual savings: $900,900

Assumption: 2% returned capacity buffer allowed for even just 0.1% increased production capacity

See complete calculation

ARPQP principles

ARPQP (Advanced Remanufactured Product Quality Planning) uses the four core principles of the world-class automotive standards of APQP in the world of remanufacturing vacuum pumps.

The remanufacturing of each vacuum pump follows exactly these four principles. Thus, every vacuum pump receives the same treatment. Eliminating any variations within the remanufacturing process delivers products with the same quality every time. Still, every remanufactured vacuum pump is subjected to three-dimensional measuring using certified methods to make sure everything is within exact tolerances.

These four core principles are:

  • 1. Failure mode effects analysis

    A formalized and structured method of proactive risk analysis of each process and component, completed before the respective process is executed and the component is mounted.

    ARPQP failure mode effects analysis

  • 2. Measurement system analysis

    A formalized and structured method of evaluating not only the performance of the vacuum measurement equipment but also the environment and the users to make sure that all measurements taken are within the APQP standard (Variation caused by the overall measurement method is 10% or less of the allowable tolerance).

    ARPQP measurement system analysis

  • 3. Statistical process control

    A formalized and structured method of statistical analysis of process data. A higher-level way to know that all processes and components are meeting the required results and remains in control. Allows for proactive adjustments and corrections well before defects occur. Very early warning method of process drift.

    ARPQP statistical process control

  • 4. Production part approval

    A formalized and structured method for strict quality control of all components. Seeks to eliminate defects created by supplier products.

    ARPQP production part approval

ARPQP success story

arpqp_success_story

13% increase in the average time in production with zero capital investment

ARPQP has already proven to be successful among many of our customers. The reasons why customers decide to use ARPQP vary. Yet, they all have the same objectives: avoid unscheduled downtime and improve performance.

One of our customers had the service performed by a third-party vacuum pump service provider. However, the customer was no longer satisfied with the provided service. The third parties’ lower pricing did not make up for the high cost of unscheduled downtime caused by the poor rebuild quality, which inevitably and adversely affected production.

After implementing ARPQP, our customer was able to achieve a 13% increase in the average time in production for their vacuum pump fleet, with zero capital investment.

FAQ

What could a transition plan look like if I want to switch from a previous service plan to ARPQP?

We have a tested and proven transition plan that ensures a smooth transition from the previous supplier to Busch - with no service interruptions.

We are flexible on the time frame we require to take over your vacuum pump service (less than 30 days, 60 days, or 90 days). In the process, we have defined three phases: planning, knowledge transfer, service launch.

The following steps are completed per phase:

1. Planning

  • Awarding of contract
  • On-site badge and training
  • Information on required shipping procedures

2. Knowledge transfer
  • Familiarization with our shipping requirements
  • Declaration of contamination documents
  • Understanding of PO issue procedures and approval chain

3. Service launch
  • Completion of reporting procedures and criteria
  • Tracking of KPIs and reporting to POCs
  • Quarterly scheduled meetings to ensure and align on cost goals, ROI, warranties and performance

What are the seven steps in remanufacturing?

At Busch, we use a 7-step process for vacuum pump remanufacturing. For each step, we allocate two hours that affords managed capacity, consistent turn time, and high-quality product. These steps include:

1. Disassembly
2. Decontamination
3. Final cleaning
4. Presentation
5. Module assembly
6. Final assembly
7. Testing

Our lean flow process delivers to our customers an expected level of performance, quality and delivery every time.

What does the Busch lean flow system mean in detail?

The Busch lean flow system is designed to be a fully flexible, fast and scalable remanufacturing system. RFID tracking of the entire production process allows for reliable remanufacturing lead times and on-time delivery. Thanks to this, you get:

  • Online real-time monitoring of the remanufacturing process
  • Push notifications on mobile devices

Can ARPQP only be used for Busch vacuum pumps?

No, ARPQP can be used for nearly any vacuum pump brand.

Is Busch IATF-certified?

Our production company Ateliers Busch S.A. in Chevenez, Switzerland, is already certified according to IATF 16949:2016. The official certification for ARPQP is pending.

Can ARPQP only be used when upgrading to a new fleet of vacuum pumps?

No, ARPQP can be used not only for a new fleet of vacuum pumps, but also for your already existing one.

What are the details of the ARPQP value calculation?

How can better availability and its value be calculated?

1. Better availability calculation

With ARPQP, the number of vacuum pumps sent back for repair can be reduced by a minimum of 14%. What does that mean for the production capacity of the fab?
In a fab that runs crash to crash, 14% fewer repairs would mean 14% fewer crashes.

  • With 14% fewer crashes at an avg. of 20 hours for MTTR, the fab’s operational time increases by 680 hours:
    250 – 216 = 34 * 20 hrs. = 680 hrs
  • Total available production time annually is 8,760 hrs.
    680 hrs. / 8760 hrs. = 8% improved equipment availability.
  • If we assume quadruple redundancy of the entire fab = 8% ÷ 4 = 2.0% better availability.

2. What is the value of this 2% improved availability?

Assumptions:
  • Semi fab has $1,000,000,000 revenues
  • The net profit of the fab is 10% EBIT
  • Total fab costs are $900,000,000
  • The fab manufactures 1,000,000 wafers annually
  • Cost per wafer=Total fab costs /# wafers produced = 900,000,000/1,000,000= $900 per wafer cost

3. ARPQP value calculation:

  • Assumption: 2% returned capacity buffer allowed for even just 0,1% increased production capacity
  • Cost per wafer=Total fab costs /# wafers produced = 900,000,000/1,001,000= $899,1 per wafer cost ($0,90 saving)
  • Annual saving: $0,90 x 1,001,000 = $900,900