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PANEL ON MANUFACTURING PROCESS CONTROLS
GARY A. BAUM (chair),
Institute of Paper Science and Technology, Atlanta, Georgia
THOMAS G. DEVILLE,
Bechtel Technology and Consulting, San Francisco, California
RICHARD J. EBERT,
Alcoa Technical Center, Alcoa Center, Pennsylvania
DENNIS K. KILLINGER,
University of South Florida, Tampa
STEVEN R. LECLAIR,
U.S. Air Force Research Laboratory, Wright-Patterson Air Force Base, Ohio
JAY LEE,
United Technologies Research Center, East Hartford, Connecticut
FRANCIS C. MCMICHAEL,
Carnegie-Mellon University, Pittsburgh, Pennsylvania
JORGE L. VALDES,
Bell Laboratories, Lucent Technologies, Murray Hill, New Jersey
National Materials Advisory Board Staff
THOMAS E. MUNNS, Senior Program Officer
AIDA C. NEEL, Senior Project Assistant
BONNIE SCARBOROUGH, Research Associate
National Materials Advisory Board Liaison
KATHLEEN C. TAYLOR,
General Motors Corporation, Warren, Michigan
Board on Manufacturing and Engineering Design Liaison
CHARLES W. HOOVER, JR.,
Polytechnic University, Brooklyn, New York
Government Liaison
TIMOTHY MCINTYRE,
U.S. Department of Energy, Washington, D.C.
COMMITTEE ON INDUSTRIAL TECHNOLOGY ASSESSMENTS
R. RAY BEEBE (chair), consultant,
Tucson, Arizona
GARY A. BAUM,
Institute of Paper Science and Technology, Atlanta, Georgia
PHILIP H. BRODSKY,
Monsanto Company, St. Louis, Missouri
JOHN V. BUSCH,
IBIS Associates, Wellesley, Massachusetts
NORMAN A. GJOSTEIN, consultant,
Dearborn, Michigan
FRANCIS C. MCMICHAEL,
Carnegie-Mellon University, Pittsburgh, Pennsylvania
MAXINE L. SAVITZ,
AlliedSignal Aerospace Corporation, Torrance, California
Government Liaisons
DENISE SWINK,
U.S. Department of Energy, Washington, D.C.
JAMES E. QUINN,
U.S. Department of Energy, Washington, D.C.
NATIONAL MATERIALS ADVISORY BOARD
ROBERT A. LAUDISE (chair),
Bell Laboratories, Lucent Technologies, Murray Hill, New Jersey
G.J. ABBASCHIAN,
University of Florida, Gainesville
MICHAEL I. BASKES,
Sandia/Livermore National Laboratory, Livermore, California
JESSE L. BEAUCHAMP,
California Institute of Technology, Pasadena
FRANCIS DISALVO,
Cornell University, Ithaca, New York
EARL DOWELL,
Duke University, Durham, North Carolina
EDWARD C. DOWLING,
Cleveland Cliffs, Inc., Cleveland, Ohio
THOMAS EAGAR,
Massachusetts Institute of Technology, Cambridge
ANTHONY G. EVANS,
Harvard University, Cambridge, Massachusetts
JOHN A.S. GREEN,
The Aluminum Association, Washington, D.C.
SIEGFRIED S. HECKER,
Los Alamos National Laboratory, Los Alamos, New Mexico
JOHN H. HOPPS,
Morehouse College, Atlanta, Georgia
MICHAEL JAFFE,
Rutgers University, Piscataway, New Jersey
LISA KLEIN,
Rutgers University, Piscataway, New Jersey
SYLVIA M. JOHNSON,
SRI International, Menlo Park, California
HARRY A. LIPSITT,
Wright State University, Dayton, Ohio
ALAN G. MILLER,
Boeing Commercial Airplane Group, Seattle, Washington
RICHARD S. MULLER,
University of California, Berkeley
ROBERT C. PFAHL, JR.,
Motorola, Schaumburg, Illinois
ELSA REICHMANIS,
Bell Laboratories, Lucent Technologies, Murray Hill, New Jersey
KENNETH L. REIFSNIDER,
Virginia Polytechnic Institute and State University, Blacksburg
JAMES WAGNER,
Case Western Reserve University, Cleveland, Ohio
BILL G.W. YEE,
Pratt and Whitney, West Palm Beach, Florida
RICHARD CHAIT, Director
BOARD ON MANUFACTURING AND ENGINEERING DESIGN
F. STAN SETTLES (chair),
University of Southern California, Los Angeles
ERNEST R. BLOOD,
Caterpillar, Inc., Mossville, Illinois
JOHN BOLLINGER,
University of Wisconsin, Madison
JOHN CHIPMAN,
University of Minnesota, Minneapolis
DOROTHY COMASSAR,
GE Aircraft Engines, Cincinnati, Ohio
ROBERT A. DAVIS,
The Boeing Company, Seattle, Washington
GARY L. DENMAN,
GRC International, Inc., Vienna, Virginia
ROBERT EAGAN,
Sandia National Laboratories, Albuquerque, New Mexico
MARGARET A. EASTWOOD,
Motorola, Inc., Schaumburg, Illinois
WILLIAM C. HANSON,
Massachusetts Institute of Technology, Cambridge
JAMIE C. HSU,
General Motors Corporation, Warren, Michigan
CAROLYN W. MEYERS,
North Carolina A&T State University, Greensboro
FREDERICK J. MICHEL, consultant,
Alexandria, Virginia
PAUL S. PEERCY,
SEMI/SEMATECH, Austin, Texas
FRIEDRICH B. PRINZ,
Stanford University, Stanford, California
DANIEL P. SIEWIOREK,
Carnegie-Mellon University, Pittsburgh, Pennsylvania
GORDON A. SMITH,
Vanguard Research, Inc., Fairfax, Virginia
JOSEPH WIRTH,
Raychem Corp. (retired), Los Altos, California
RICHARD CHAIT, Director
Acknowledgments
The Panel on Manufacturing Process Controls would like to thank the participants in the workshops, which were the principal data-gathering sessions for this study. The information and insight from these sessions were invaluable to the committee.
Presenters at the first workshop on Industries of the Future (IOF) included C. Philip Ross of Creative Opportunities, Inc.; Mel Koch of the University of Washington's Center for Process Analytical Chemistry; William Walkington of Walkington Engineering, Inc.; Robert Bareiss of Bareiss Associates; John A.S. Green of The Aluminum Association; and Barry Brusey and Mike Dudzic of Dofasco Steel.
Presenters at the second workshop on technology opportunities included Tariq Samad of Honeywell; Yoh-Han Pao of AIWARE, Inc.; Frederick Proctor of the National Institute for Standards and Technology; Rush Robinett of Sandia National Laboratories; David Holcomb of Oak Ridge National Laboratory; Arlene Garrison of the University of Tennessee 's Measurement and Engineering Control Center; Michael Carrabba of EIC Laboratories; and Mel Koch of the University of Washington's Center for Process Analytical Chemistry.
The panel is particularly grateful to Timothy McIntyre of the U.S. Department of Energy Office of Industrial Technology for his assistance in identifying representatives of IOF industries to participate in the first workshop and for his participation in both workshops.
This report has been reviewed by individuals chosen for their diverse perspectives and technical expertise, in accordance with procedures approved by the National Research Council's (NRC) Report Review Committee. The purpose of this independent review is to provide candid and critical comments that will assist
the authors and the NRC in making the published report as sound as possible and to ensure that the report meets institutional standards for objectivity, evidence, and responsiveness to the study charge. The content of the review comments and draft manuscript remain confidential to protect the integrity of the deliberative process. We wish to thank the following individuals for their participation in the review of this report: James J. Solberg, Purdue University; John A.S. Green, The Aluminum Association; Arlene A. Garrison, University of Tennessee; Daniel J. Maas and Tony Haynes, National Center for Manufacturing Sciences; Karen Markus, MCNC; and James Wagner, Case Western Reserve University.
While the individuals listed above have provided many constructive comments and suggestions, responsibility for the final content of the report rests solely with the authoring committee and the NRC.
Finally, the panel gratefully acknowledges the support of the staff of the National Materials Advisory Board and the Board on Manufacturing and Engineering Design, including Thomas E. Munns, study director, Aida C. Neel, senior project assistant, and Bonnie Scarborough, research associate.
Preface
In 1993, the U.S. Department of Energy (DOE) Office of Industrial Technology (OIT) established a group of seven industries designated as Industries of the Future (IOF). These industries were selected for their high energy use and large waste generation. The original IOF included the aluminum, chemicals, forest products, glass, metal castings, petroleum refining, and steel industries. Each industry was asked to provide a future vision and a road map detailing the research required to realize its vision. In November 1994, the forest products industry was the first of the IOF industries to enter into an agreement with DOE. At this writing, six of the IOF industries have prepared vision statements and signed agreements with DOE.
OIT asked the National Research Council's National Materials Advisory Board (NMAB) to evaluate their program strategy and to provide guidance for OIT's transition to the new IOF strategy. A Committee on Industrial Technology Assessments (CITA) was formed for this purpose with the specific tasks of reviewing and evaluating the overall OIT program, reviewing selected OIT-sponsored research projects, and identifying cross-cutting technologies (i.e., technologies applicable to more than one industry). CITA was asked to focus on three specific areas: intermetallic alloys, manufacturing process controls, and separations. A separate panel was formed to study each area and publish the results in a separate report. This report describes the activities and recommendations of the Panel on Manufacturing Process Controls (MPC).
The MPC panel's objectives are listed below:
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identify key processes that would benefit most from improved manufacturing process controls for each of the IOF
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identify control technology needs that are common among the IOF industries
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identify research opportunities to address these needs
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suggest criteria for identifying and prioritizing research and development to develop improved manufacturing controls technology
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suggest means for transferring advances in control technology to the IOF industry sectors
The MPC panel was composed of experts knowledgeable in sensors, measurement technology, and/or process control. The panel held two meetings. At the first meeting, on October 22, 1996, representatives of six of the IOF industries discussed the needs of their industries for sensing and process controls. As a result of this meeting, the panel was able to identify common needs among the IOF industries. On May 29, 1997, the MPC panel met with experts on cutting-edge sensing and control technologies to identify opportunities for the development of technologies to meet the IOF industries' needs. The conclusions and recommendations of the MPC panel can be found in Chapter 4 of this report. In general, the panel found ample opportunities for research on cross-cutting technologies, in both sensing and manufacturing control, that apply to several IOF industries.
The chair wishes to thank the MPC panel members for their enthusiasm and dedication, as well as the experts from the IOF industries and experts on process control and sensors for their excellent presentations. The chair thanks all of the participants for their insights and stimulating discussions and the staff of the NMAB for their coordination and assistance throughout the entire process, including the publication of this report.
Comments and suggestions can be sent via electronic mail to nmab@nas.edu or by FAX to NMAB (202) 334-3718.
GARY A. BAUM, chair
Panel on Manufacturing Process Controls
Tables, Figures, and Boxes
TABLE
1-1 |
Status of IOF Vision Documents, |
FIGURES
1-1 |
Manufacturing energy use (1994), |
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1-2 |
Research issues, engineering focus, and attributes of process sensors and controls, |
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1-3 |
Research needs and technical challenges for intelligent sensors and control systems, |
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2-1 |
Three-level classification scheme for process control technologies, |
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3-1 |
Continuous annealing process roller sequence, |
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3-2 |
Decision support hierarchy for plant-wide optimization, |
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3-3 |
Monitoring system for finishing mill electric motors, |