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New Directions in Manufacturing: Report of a Workshop (2004)
Board on Manufacturing and Engineering Design (BMED)

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. "2 Challenges Facing U.S. Manufacturing Today." New Directions in Manufacturing: Report of a Workshop. Washington, DC: The National Academies Press, 2004.

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New Directions in Manufacturing: Report of a Workshop

domestic manufacturers. This has been the result of a 30-year trend of outsourcing by large automotive, aerospace, and heavy equipment manufacturers. Since the early 1980s, manufacturing employment has become increasingly concentrated in smaller plants and decreasingly concentrated in larger companies. The number of manufacturing plants with fewer than 500 employees in the United States fell in 2000 and 2001 for the first time since 1978.14 The influence of this small-manufacturer segment is exemplified by the fact that in large manufacturing plants that have experimented with a variety of ways to empower employees, it is routine today for small work units to operate independently within a larger plant. In other words, large firms are trying to emulate the productivity factors of small firms, which are perceived as being better.

Small and medium-sized manufacturers face specific issues, including a small client base and a greater dependence on revenue from each client; small management teams; limited access to capital for improvements; and difficulties in providing service overseas. In order for these enterprises to prosper, increased integration of their supply chain is important, as is easier access to technology and capital. The manufacturing sector needs to find a way to modernize and strengthen small and medium-sized manufacturing enterprises. Support from federal and state governments can be very effective, and the committee noted broad support for the Manufacturing Extension Partnership program. It is key that this type of support be sustained and that it be coordinated among the stakeholders: employers, educators, students, and government leaders.

RISK

The bottom line for many manufacturers today is risk. Decisions on manufacturing domestically or overseas, to adopt innovations or evolutionary improvements, or to hire and train new workers or to invest in more productive technology are all based on the perception or measurement of risk. In many cases, the United States does not offer a least-risk environment to start or expand a manufacturing enterprise.

14  

Daniel Luria. 2003. U.S. component manufacturing at a crossroads: Region-loyal production and global manufacturing deflation. Available at http://www.cows.org/supplychain/pdf/present/luria.pdf. Accessed November 2003.

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Front Matter (R1-R10)
Executive Summary (1-4)
Part I Summary of the Workshop Sessions1 Manufacturing in the United States (5-10)
2 Challenges Facing U.S. Manufacturing Today (11-20)
3 New Directions (21-22)
Part II Presented Papers: Manufacturing in the U.S. Economy4 Keynote Address: The Administration's Manufacturing Policy (23-27)
5 U.S. Manufacturing at the Crossroads (28-33)
6 Innovation and U.S. Manufacturing (34-38)
Part III Presented Papers: View from Three Manufacturing Sectors7 Trends in Rural Manufacturing (39-45)
8 Issues for Small Manufacturing Enterprises (46-48)
9 Drivers and Challenges for U.S. Aerospace Manufacturing (49-54)
Part IV Presented Papers: Manufacturing Globalization10 Manufacturing Globalization: Is the Glass Half Full or Half Empty? (55-60)
11 Manufacturing Globalization at United Technologies Corporation (61-64)
12 Insights on Outsourcing (65-72)
Part V Presented Papers: The Human Element in Manufacturing13 Keeping America Competitive (73-81)
14 Economic Challenges to American Manufacturing (82-87)
15 The Crisis in U.S. Manufacturing: A Union View (88-90)
16 The Human Component in Manufacturing (91-94)
Part VI Presented Papers: The Way Forward17 Standards and Infrastructure (95-99)
18 Collaborating to Meet Manufacturing Challenges (100-104)
19 Manufacturing, Energy, and the Future of New Technology (105-107)
20 Army Manufacturing Technology Program Responds to 21st Century Challenges (108-111)
21 Turning New Technologies into Products at Sandia National Laboratories (112-114)
Part VII Presented Papers: New Manufacturing Paradigm22 Manufacturing in a Digital Era (115-129)
23 Manufacturing Knowledge and the Arrow of Time (130-134)
Appendix A Biographical Sketches of Committee Members (135-140)
Appendix B Workshop Agenda (141-143)
Appendix C Acronyms and Abbreviations (144-146)