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THE COMPETITIVE EDGE: Research Priorities for U.S. Manufacturing
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THE COMPETITIVE EDGE: Research Priorities for U.S. Manufacturing
Index
A
Accounting systems 17 , 74 , 131
Accreditation Board for Engineering and Technology (ABET) 133 , 139 n.9
Adaptive control 33 , 35 , 36–37
Advanced coatings 79
Advanced engineered materials (AEM) 9 , 12 , 21 ,78–80
educational infrastructure 82–83 , 94–96
knowledge-based systems 87–88 , 96–97
metal-matrix composites 81–82 , 91 , 92–93
polymer-based composites 80–81 , 92
potential of 83–85
process simulation and modeling 85–86 , 96–97 , 112
research needs 1 , 2 , 21 , 92–97
sensors 88–89
technical cost modeling 89–92
Advanced manufacturing technology
See also Technology
and competitiveness 1 , 3 , 5 , 17
data collection 11 , 13–14
development of 103–105
and organizational structure 10–11
work force skills and 2 , 7–9 , 17 , 18 , 120 , 126–127 , 132 , 138
Aircraft engine manufacturing 58 , 63–65 , 102
Aishin Seiki pump factory 59–60
Alcoa Research Laboratories 87
Alloys 79
aluminum 87 , 97 n.1
ceramic 84
polymer 81
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titanium 102
Aluminum, graphite-reinforced 91
Aluminum Alloy Design Inventor (ALADIN) 87 , 97 n.1
Analog-to-digital conversions 28
Annealing 84
Apprenticeship 125 , 127
Artificial intelligence 17 , 40 , 57 , 87 , 96–97 , 97 n.1, 116
Automation 109 , 116 , 124
Automobile part manufacturing 58–59 , 80 , 90
B
Bachelor's degree 137
Blacks 152
Blend (alloy) polymers 81
Breakdown maintenance 54 , 57
Business-related assumptions 34 , 35–36
C
Capacity utilization 19 , 74
Capital investment 77 n.3, 78
equipment reliability and maintenance and 9 , 54 , 56–57 , 58 , 61 , 74 , 75
Carnegie Mellon University 87
Ceramics 23
alloys 84
fibers 82 , 83
Chemicals industry 46–49
Closed-loop feedback control 39–40 , 42 , 51
Cognitive science 40
Communication 110
Competitiveness 1 , 9–11
barriers to 16–18
equipment reliability and 54 , 70 , 72
Computer-aided design (CAD) 46 , 48 , 95 , 102 , 115 , 117
Computer-aided engineering (CAE) 107 , 115
Computer-aided manufacturing (CAM) 115 , 131
Computer-integrated enterprising (CIE) 113 , 115
Computer-integrated manufacturing (CIM) 13 , 42 , 55–56
Computer simulation 85 , 89 , 102 , 112
Computer software in equipment reliability and maintenance 54–55 , 56 , 61 , 69 , 76
in intelligent manufacturing control 20 , 25 , 52
in materials production 88
Computer technology 28
Conceptual design 105–106
Conceptual thinking 136
Concurrent engineering 63 , 76 , 101
Contingencies 36 , 41
Control decisions 29 , 109–110 , 119.
See also Intelligent manufacturing control;
Process control
Cooperative behavior 136–137
Cooperative Hierarchical Image Learning Dynamics (CHILD) 31–32
Copolymers 79
Copper-clad Invar (CIC) 91
Copper-clad molybdenum (CMC) 91
Cornell University 95
Cost accounting systems 17 , 131
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Cost models 68
cost-of-ownership models 112
technical cost modeling 89–92
Cost reduction 69
Costs
education and training 135
equipment reliability and maintenance and 55 , 67 , 68 , 74 , 75
of machine downtime 19–20 , 59 , 74
nonproduction 17
production 17 , 55 , 109 , 110
in product realization process 14 , 101 , 109 , 110
semiconductor manufacturing equipment 61 , 62 , 63
Crystal growth techniques 84 , 102
Customer needs 9
and advanced engineered materials 85
and product realization process 98 , 99 , 100 , 105 , 106 , 107 , 110 , 111 , 115 , 116
D
Data
acquisition and analysis 31 , 32
in advanced manufacturing technology 11 , 13–14
on equipment reliability and maintenance 68
in intelligent manufacturing control 1 , 14 , 15 , 29 , 30 , 38 , 39 , 42 , 44 , 49
for product realization images 115 , 119
Decision making
in cost modeling 90
intelligent manufacturing control 6 , 26–27 , 28–29 , 30 , 35
Least Commitment 97 n.1
manufacturing 73 , 74 , 117
Defense Advanced Research Projects Agency (DARPA) 95 , 133
Design 26 , 40
advanced engineered materials 2 , 93
detailed processes 107–108
for manufacturability 78 , 101 , 102 , 109
for product quality 106–107
and product realization process 14 , 100 , 112–113 , 115–116 , 118
for reliability 63–65 , 74
Diesel locomotives 33
Display technologies 116
Distribution systems 26 , 110–111
Downtime costs 19–20 , 59 , 74
Drafting 107
Drucker, Peter 17
E
E-beam submicron lithography 95
Economist 18 , 122
Education 50 , 126
attainment levels 5 , 6 , 120
continuing 124–125
education and training consortia 134–135
faculty 133 , 137
funding 128 , 133 , 134 , 135 , 136 , 137
managerial 133–134
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manufacturing 73 , 97 , 120–122 , 123 , 127 , 128 , 130–131 , 132–133 , 138
materials processing 82–83 , 94–96
microelectronics 128 , 129
paraprofessional 135
teaching factories 94–95 , 96 , 97
teaching methods 137
U.S., inadequacy of 2 , 18 , 22 , 122–123 , 138
Electromechanical equipment 69
Electron beams 84
Electronic materials 84
Electronics manufacturing equipment 8
Employees 99 , 117 .
See also Work force
educational attainment 5 , 6 , 120
performance assessment 17–18 , 122–123
Employment 3–5 , 122 , 148–153
Engineering
advanced manufacturing technology and 10 , 11
of advanced materials 79 , 83 , 87 , 90
education 22 , 124–125 , 130–131 , 133 , 136
and equipment reliability and maintenance 57 , 69 , 72–73
in product realization process 100 , 101 , 107 , 108 , 109 , 115
Engineering Research Centers 135
Engineers, manufacturing 18 , 69 , 73 , 128
Environmental conditions 36
Environmental Research Institute of Michigan 53 n.3
Equipment reliability and maintenance (ERM) 1–2 , 9 , 12 , 15 , 20–21 , 54–57 , 112
automobile parts industry 58–59
barriers to progress 66–70
and competitiveness 54 , 70 , 72
current practice 57–58
potential of 63–66
pump production 59–60
research needs 70–77
semiconductor industry 61–63 , 64 , 65
steam turbine generators 60–61
Etching and deposition 84
Europe 117–118
Expert systems 15 , 17 , 116
and advanced engineered materials 87 , 94
in equipment maintenance 61
and intelligent manufacturing control 33 , 40 , 46 , 47–48
Expertise 41
F
Facility systems 26
Factory as laboratory 18–19 , 22 , 33 , 49 , 50 , 51
Factory yields 63
Faculty 133 , 138
Failure modes and effects criticality analysis (FMECA) 62 , 63
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Feedback
closed-loop control 39–40 , 42 , 51
open-loop control 39 , 49
time 20 , 25 , 26
Feldberg, Meyer 124
Fiber optic sensing 46 , 47
Fiber-reinforced composites 79
Fiber-reinforced polymers 80
Fiber-reinforced thermoplastics 81
Flexibility 10 , 119
Flexible manufacturing systems 7 , 8 , 78 , 93 , 95 , 100 , 109 , 130
Fortune 100 companies 51
Fortune 500 companies 122
Functional integration 14 , 39
Funding, education and training 128 , 133 , 134 , 135 , 136 , 137
G
Gallium arsenide single crystals 84 , 102
Generally accepted accounting principles 74
Germany 120
Global information systems 102
Government 130 , 139
Graphite-reinforced aluminum 91
Great Lakes Manufacturing Technology Center 139 n.7
H
Hierarchical organization 35
High modulus materials 79
High-pressure oxidation 84
High school 138
High-temperature structural materials 79
Hispanics 152
Hot isostatic pressing 102
Hudson Institute 123
Human decision making 28–29
Human knowledge 14 , 31 , 39 , 40 , 42
Human-machine integration 16–17 , 20 , 23 , 25 , 32 , 34 , 49 , 75 , 136–137
Human plane 101
Human resource development 8 , 126
I
Illinois Institute of Technology 95
Imaging techniques 116
Implanter equipment 62–63 , 64
Industrial Technology Institute 31 , 53 n.3
Industry
competitiveness 1 , 9 , 16–18 , 70
design practices 118
education and training in 124–125 , 127 , 130
research in 50–51 , 52
Information
in advanced manufacturing technology 11 , 13–14
in manufacturing control 33 , 35 , 38 , 39 , 40
in product realization process 102
Information plane 101 , 102 , 103 , 118–119
Infrastructure processes 112–113
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Instrumented Factory Gear Center 95
Integrated circuits 8 , 30 , 84 , 95 , 96
Integration
in advanced engineered materials 94 , 96
in advanced manufacturing technology 11 , 14
human-machine 16–17 , 20 , 23 , 25 , 32 , 34 , 49 , 75 , 136–137
in intelligent manufacturing control 31 , 39
sensor 17 , 49 , 50
Intel Corporation 61–63
Intelligence
human-machine 25 , 32 , 34 , 36
machine 14 , 20 , 40–42 , 44 , 49
management 1 , 51
organizational 11 , 14–15
Intelligent manufacturing control (IMC) 6 , 9 , 11 , 13 , 23 , 25–34
and advanced engineered materials 14 , 86 , 87 , 88
in chemicals industry 46–9
data requirements and analysis 14 , 15 , 29–30 , 31
and equipment reliability and maintenance 65–66 , 75
manufacturing assumptions 34–36
and product realization 109–110 , 112
research needs 1 , 20 , 33 , 49–52
in wire-drawing industry 42–45
world model of 36–42 , 49 , 51
Intelligent processing of materials (IPM) 85 , 86 , 87 , 88
Intelligent product realization images 2 , 15 , 21 , 101–102 , 115–116 , 119
International standards 111
Inventory 111
Ion implantation 84
J
Japan 117–118
automotive industry 58–59
education and training 122
equipment reliability and maintenance in 57 , 58–60 , 69 , 76
flexible manufacturing systems 7 , 8
Institute for Plant Maintenance 60 , 70
management skills 18 , 124 , 130 , 134
metalworking industry 7 , 8
pump production 59–60
quality control practices 119 n.1
semiconductor industry 9 , 61
Just-in-time (JIT) 57 , 77 n.1, 111
K
Knowledge, process 34 , 35 , 38 , 39–40 , 41 , 51 , 120
Knowledge-based systems 15 , 33 , 87–88 , 96–97
Knowledge bases 1 , 16 , 32 , 49 , 51
L
Labor utilization 7 , 17 .
See also Work force
Language translators 46 , 48
Laser ablation 96
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Lasers 84 , 89
Lead times 55
Learning
economies of 35
in intelligent control 25 , 32 , 33 , 37 , 38 , 39 , 40 , 49
organization 10
and work force skills 18–19 , 23 , 51
Lehigh University 132
Liquid crystalline polymers 80 , 81
Literacy 2 , 22 , 128
Low-skill jobs 122
M
Machine intelligence 14 , 20 , 40–42 , 44 , 49
Machine-machine integration 39
Machine-related assumptions 34–35 , 36
Machine tools 8
Machine utilization 7 , 66 , 130
Maintenance 54 , 57 , 59 , 60 , 63 , 67 , 74 , 111–112
Make-versus-buy decision 105
Management
advanced manufacturing technology and 10 , 11 , 18–19 , 120
and equipment reliability and maintenance 1–2 , 21 , 23 , 57 , 59 , 67–68 , 71–73
and intelligent control 30 , 43 , 51 , 53
and manufacturing skills 124 , 127 , 130 , 133–134 , 138–139
and product realization process 99 , 108 , 110 , 113 , 115 , 117 , 118
Manufacturing 24 n.1, 50 , 76 , 136
advanced technology 22–24 , 28 , 105 , 117 , 130
competitiveness 1 , 2 , 9–11
decision making 74
design for manufacturability 78 , 101 , 102 , 109
education 73 , 130–131 , 133–134
employment 3–5 , 22
engineering and 109 , 128
factory as laboratory 18–19 , 22 , 33 , 49 , 50 , 51
flexible systems 7 , 8 , 78 , 93 , 95 , 100 , 109 , 130
lack of career esteem 18 , 22 , 124 , 126 , 128 , 131
models of 115
of product images 119
as a science 3
Manufacturing assumptions 34–36
Manufacturing capacity 67
Manufacturing control 25 , 38
Manufacturing Educational Centers 135
Manufacturing engineers 18 , 69 , 73 , 128
Manufacturing skills improvement 3–5 , 13 , 120–122
barriers to 126–130
educational deficiencies 2 , 22 , 122–123
necessity of 7 , 9 , 120 , 124–126
research needs 1 , 22 , 130–139
Marketing 102 , 108 , 110–111
time to market 6–7 , 9
Market strategy 100–101 , 105
Martian Rover 30–31
Massachusetts Institute of Technology 132
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Materials composition 102
Materials engineers 85
Materials-specific research 92–93
Mechanization 34
Mechatronic equipment 52 , 55 , 56 , 69
Metal-matrix composites (MMC) 81–82 , 91 , 92–93
Metal oxide chemical vapor deposition 95–96
Metal Oxide Semiconductor Implementation System (MOSIS) 95
Metals 23 , 83–84
Metalworking industry 7 , 8
Microelectronics manufacturing 128 , 129
Microprocessor control systems 25 , 38 , 42 , 43 , 44
Microstructural modeling 86 , 93 , 94
Minorities 124
Model-based reasoning 110
Modularity 111
Molecular beam epitaxy (MBE) 84 , 95 , 96
Multi-attribute utility analysis 89
Multilayered heterostructures 79 , 84
Multiobjective problems 90–91
Multiphase alloys 79
N
National Aeronautics and Space Administration (NASA) 53 n.3, 130
National Center for Research in Vocational Education 125
National defense 126
National Institute of Standards and Technology 130 , 139 n.7
National Research Council 72
National Science Foundation (NSF) 130 , 131 , 138
recommended research funding 132 , 133 , 134 , 136 , 137
National security 8
National Submicron Center 95
National Technological University 132 , 137
Near net shape processes 78 , 102
New York Times 124
Nishio pump factory 59–60
Nonproduction costs 17
Nonvalue-added activities 101
O
Open-loop control systems 39 , 49
Optical materials 79
Order entry 26
Organizational structure 16 , 18–19
compression of hierarchy 6–7 , 20 , 24 , 25 , 26 , 27
and product realization process 2 , 98 , 99–100 , 111 , 117–119
Organometallic chemical vapor deposition 84
Output 55
Overhead 69
P
Paraprofessional education 135
Performance measurement 17–19 , 73–74
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Personal computers 52–53
Personnel systems 26
Photolithography 63 , 65 , 84
Physical plane 101
Piezoelectric transducers 88
Plasma-enhanced etching and deposition 84
Polymer-based composites 80–81
Polymers 23 , 83 , 92
Predictive maintenance 23 , 54–55 , 57
Preventive maintenance 54 , 57 , 60 , 69
Printed circuit boards 91
Problem solving 40–41 , 44
Process complexity 30
Process control 9 , 14 , 132
advanced engineered materials 79 , 85 , 87 , 102
costing 19 , 20
data bases 29 , 42
feedback loops 37 , 38 , 39–40 , 42
intelligent manufacturing control 25 , 26 , 33 , 109–110
wire-drawing industry 43 , 44
Process design 72–73 , 86
Process disruptions 30
Process industries 51
Process knowledge 34 , 35 , 38 , 39–40 , 41 , 51 , 120
Process simulation models 15 , 17 , 85–86 , 94 , 96–97 , 102
Process variance 43 , 44
Product cost of ownership 112
Product development life cycle 15 , 115 , 118–119
acceleration of 99 , 100 , 101 , 117
customer requirements and 98
life-cycle design 107–108
life-cycle support 111–112
product design and 109 , 112
simulation 23 , 112
Production 108–110
Production capacity development 108
Production control 131
Production costs 17 , 55 , 109 , 110
Production monitoring system 19 , 74
Productivity 119 , 134
advanced manufacturing technology and 7 , 10
of capital investment 9 , 54
equipment maintenance and 9 , 23 , 54 , 58 , 66 , 76
intelligent manufacturing control and 45
product design and 109 , 112
Product quality 9 , 25 , 28 , 106–107 , 110
Product realization process (PRP) 9 , 12 , 14 , 15 , 23 , 100–103
advanced technology development 103–105
conceptual design 105–106
customer needs and 98 , 99 , 100 , 105 , 106 , 107 , 110 , 111 , 115 , 116
detailed design process 107–108
distribution and marketing 110–111
end-to-end infrastructure processes 112–113
intelligent product images 2 , 15 , 21 , 101–102 , 115–116 , 119
life-cycle support 111–112
organizational framework
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and, 21 , 98 , 99–100 , 117–118
production 108–110
product quality development 106–107
research needs 1 , 2 , 21 , 105 , 106 , 113–119
technological feasibility 21 , 98 , 99
Product specifications 23 , 106 , 115
Profitability 69
Purdue University 132
Q
Quality 9 , 25 , 28 , 106–107
equipment maintenance and 55 , 66 , 76
management and 110 , 134
Quality control 85
Quality loss function 104 , 119 n.1
R
Reliability 3 , 9 , 14 , 68 , 69 , 70 , 76
design for reliability 63–65 , 74
Research needs
advanced engineered materials 1 , 2 , 21 , 92–97
equipment reliability and maintenance 70–77
factory as laboratory 18–19 , 22 , 33 , 49 , 50 , 51
intelligent manufacturing control 1 , 20 , 33 , 49–52
manufacturing skills improvement 1 , 22 , 130–139
product realization process 1 , 2 , 21 , 105 , 106 , 113–119
Risk and value analysis 113
Robotics 131
S
Scale economies 35
Science
manufacturing as 3
technology as 41
Sematech 96
Semiconductor industry 138
equipment reliability and maintenance in 61–63 , 64 , 65
Semiconductors 9
advanced engineered materials in 23 , 79 , 84 , 95–96
Sensor integration 17 , 49 , 50
Sensor technology 1 , 27–28 , 31 , 39–40 , 51
in equipment reliability and maintenance 56 , 63 , 75
in intelligent processing of materials 88–89
in machine intelligence 20 , 25
Simulation 72–73 , 89
process models 15 , 17 , 85–86 , 94 , 96–97 , 102
product life cycle 23 , 112
Simultaneous design 63
Southwestern Bell 122–123
Statistics 132
Steam turbine generators 33 , 60–61
Supermodulus materials 95
Synchrotron radiation 84
T
Taguchi, Genichi 104 , 119 n.1
Taxation 127 , 128
Teaching factories 94–95 , 96 , 97
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Team concept 118
Technical cost modeling 89–92
Technological feasibility, product 21 , 98 , 99
Technology 16–17.
See also Advanced manufacturing technology
and decision making 26–27 , 28
diffusion of 50 , 51–52
and equipment reliability and maintenance 70
and materials development 84–85
and product realization 98 , 99 , 100 , 102 , 117–118 , 119
as science 41
transfer of 105 , 139 n.7
Technology management 72 , 130 , 134 , 138–139
Theoretical capacity 55 , 74
Thermoplastics 80–81
Thermostatic control 36–37
Tiger teams 101
Time-based competition 100
Time to market 6–7 , 9
Titanium alloys 102
Training programs 125 , 127–128
education and training consortia 134–135
Transducers 28 , 88
Transfer press 58
U
Unified Technology Center 139 n.7
United States
design practices in 107
educational system 2 , 18 , 22 , 73 , 122–123 , 131 , 138
flexible manufacturing systems in 7 , 8
industrial competitiveness 1 , 9 , 16–18 , 70
management practices in 69 , 124–126 , 127 , 134
manufacturing technology in 2 , 29 , 57–58 , 65–66 , 117–118
quality improvement in 119 n.1
semiconductor industry 61
utilities industry 60
U.S. Department of Commerce 134
U.S. Department of Defense 8 , 124 , 126 , 128
U.S. Department of Labor 123
Universities 128–130 , 132 , 134 , 136
University of Southern California 95
University of Wisconsin 132
User training 30
Utilities industry 60
V
Very large scale integration (VSLI) chips 83
Village industry 118
Vocational education 135
W
Wafer etch equipment 62–63 , 64
Wall Street Journal 122
Wave-soldering machines 33
Wire-drawing industry 42–45
Women 124
Work force 25
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educational attainment 5 , 6 , 120
employment trends 3–5 , 122 , 148–153
labor utilization 7 , 17
skills improvement 2 , 3–5 , 9 , 30 , 122 , 124–125 , 127–128 , 130–131 , 138
Work organization 117
Work-in-process inventory 63
Work teams 99–100 , 119 , 126–127
World War II 126
X
X-rays 84
Z
Zero defects 3 , 59
