Assembly tools often lead hard lives on busy plant floors. When these tools begin to perform poorly, the first thought is to replace them, but restoring a tool through reconditioning or refurbishment can provide significant cost savings. Done professionally, these processes can add several years of productive life to an assembly tool for much less than the cost of a new one.

Opting for reconditioning or refurbishing also:

  • Avoids the productivity hit when operators have to learn to use new replacement tools.
  • Allows continued use of any spare parts in inventory.
  • Ensures consistent operation, preventing quality problems and warranty expenses.

Both processes can be beneficial, but the process that’s best for your tool will vary depending on its condition.

Reconditioning

Man working with tools

Reconditioning restores a tool to a like-new condition and level of performance and involves four steps:

  1. Cleaning & Inspection: Stripping the tool down to its core components, removing grease and debris, and carefully examining each part for chips, wear, cracking, and other damage.
  2. Part Replacement: Any parts deemed damaged or in poor condition will be replaced with OEM components to ensure a better fit and performance.
  3. Calibration: An essential part of every assembly tool rebuild that ensures the tool delivers the correct torque and rotation.
  4. Final Testing: The tool is tested against OEM specifications to verify performance.

Benefits

  • The repaired tool provides the same level of accuracy in service as a new tool.
  • Breakdowns due to failed components are avoided.
  • Extended lifespan.

Best Use Cases

  • When operators are comfortable with a particular style and type of tool.
  • When there are concerns that switching to new tools could affect product quality, perhaps requiring new process approval.
  • When working with a reduced maintenance budget.

Refurbishing

A technician is displaying a reconditioned Stanley E33 electric nutrunner

Refurbishment differs significantly from reconditioning; it involves cosmetic restoration and functional repairs. During this process, the tool is cleaned, and severely damaged components, such as frayed cables, are replaced. However, worn components that aren’t creating obvious problems may not be replaced. The tool may look new, but won’t perform as well as it did when new. The tool may also not undergo the same level of calibration and verification, though this varies by service provider.

Benefits

  • Typically less costly than buying reconditioned.
  • Major faults are addressed and resolved.
  • Looks like a new tool.

Best Use Cases

  • Backup tools that are deployed only if a production tool fails.
  • For non-safety-critical fastening applications or when a process does not require customer approval.
  • When the budget won’t allow the purchase of reconditioned equipment.

Which One Do You Need?

  • Does the tool have to meet OEM specs and/or need a performance guarantee? If so, reconditioning is the best solution.
  • Does it just need to be functional and reliable? In this case, refurbished tools are acceptable.
  • Are you interested in upgrading the tool? Reconditioning can provide access to updated OEM features.
  • Is resale value a concern? A reconditioned tool will be worth more.
  • What is the tool’s current condition? If it has only cosmetic damage, refurbishment may be the right approach; if it has been out of spec for a while, reconditioning may be better.
  • How old is the tool, and are replacement components available for it? OEM parts can be hard to obtain for older equipment, limiting the amount of reconditioning that’s possible.

When Replacement Is the Only Option

When a tool is in very poor condition, the cost of reconditioning or refurbishing may make replacement worth considering. A general rule of thumb is to replace when restoration costs more than 50% of the cost of a new item.

Other factors to consider are:

  • The age of the tool/how much work it has done. If it is nearing the end of its life, replacement may be a better option.
  • The availability of replacement parts.
  • Newer features or capabilities that could improve quality and productivity.

Please read Should You Repair or Replace Your Assembly Tools? for more guidance.

Restore Your Tool With Help From Encore Systems

Product quality and safety depend on the performance of your assembly tools, so it’s critical that you partner with a service provider committed to carrying out the highest standards.

Encore Systems is proud to be a leader in assembly tool repair and calibration. We follow a stringent reconditioning process compliant with ISO 9001:2015 quality management standards, ensuring every tool that leaves our facility meets or exceeds OEM performance specifications. To further help our customers, we back every repair with a warranty and can provide loaner tools to prevent downtime.

Start the reconditioning process today with a free evaluation.