Manufacturing, reduced to its simplest form, involves the sequencing of product forms through a number of different processes. Each individual step, known as an unit manufacturing process, can be viewed as the fundamental building block of a nation's manufacturing capability. A committee of the National Research Council has prepared a report to help define national priorities for research in unit processes. It contains an organizing framework for unit process families, criteria for determining the criticality of a process or manufacturing technology, examples of research opportunities, and a prioritized list of enabling technologies that can lead to the manufacture of products of superior quality at competitive costs. The study was performed under the sponsorship of the National Science Foundation and the Defense Department's Manufacturing Technology Program.
Manufacturing will unquestionably be a very different enterprise in 2020 from what it is today. This book presents an exciting picture of the profitable and productive potential of manufacturing two decades hence. This book takes an international view of future manufacturing that considers the leaps and bounds of technological innovation and the blurring of the lines between the manufacturing and service industries. The authors identify ten strategic technology areas as the most important for research and development and they recommend ways to address crosscutting questions. Representing a variety of industries, the authors identify six "grand challenges" that must be overcome for their vision to be realized, including the human/technology interface, environmental concerns, and miniaturization. A host of issues are discussed that will push and pull at manufacturing over the next 20 years: the changing workforce, the changing consumer, the rise of bio- and nanotechnology, the prospects for waste-free processing, simulation and modeling as design tools, shifts in global competition, and much more. The information and analyses in this book will be vitally important to everyone concerned about the future of manufacturing: policymakers, executives, design and engineering professionals, researchers, faculty, and students.
The activities of the Department of Defense (DOD) and its contractors in manufacturing, testing, maintaining, and disposing of military equipment make up a significant portion of the industrial processes conducted in the United States. As is the case with the commercial industries, some of these activities, such as metal plating, have resulted in industrial pollution and environmental contamination. With increasing environmental regulation of such processes in recent decades, defense facilities have been faced with growing compliance issues. Department of Defense efforts to manage, correct, and prevent these problems have included the establishment of the National Defense Center for Environmental Excellence (NDCEE) under the management of the U.S. Army Industrial Ecology Center (IEC). The National Research Council's Committee to Evaluate Transfer of Pollution Prevention Technology for the U.S. Army was formed to identify major barriers to the transfer of pollution prevention technologies and to recommend pathways to success. To address the study objectives, the committee (1) reviewed the NDCEE's technology transfer activities, (2) examined efforts to transfer technology in four areas, two of which were identified at the outset by the NDCEE as successful and two of which were identified as unsuccessful, and (3) identified opportunities for improving the transfer of pollution prevention technologies to maintenance and rework facilities in the Department of Defense and to industrial manufacturing facilities performing defense-related operations.
To maintain competitiveness in the emerging global economy, U.S. manufacturing must rise to new standards of product quality, responsiveness to customers, and process flexibility. This volume presents a concise and well-organized analysis of new research directions to achieve these goals. Five critical areas receive in-depth analysis of present practices, needed improvement, and research priorities: Advanced engineered materials that offer the prospect of better life-cycle performance and other gains. Equipment reliability and maintenance practices for better returns on capital investment. Rapid product realization techniques to speed delivery to the marketplace. Intelligent manufacturing control for improved reliability and greater precision. Building a workforce with the multidisciplinary skills needed for competitiveness. This sound and accessible analysis will be useful to manufacturing engineers and researchers, business executives, and economic and policy analysts.
Manufacturing process controls include all systems and software that exert control over production processes. Control systems include process sensors, data processing equipment, actuators, networks to connect equipment, and algorithms to relate process variables to product attributes. Since 1995, the U.S. Department of Energy Office of Industrial Technology 's (OIT) program management strategy has reflected its commitment to increasing and documenting the commercial impact of OIT programs. OIT's management strategy for research and development has been in transition from a technology push strategy to a market pull strategy based on the needs of seven energy-and waste-intensive industries-steel, forest products, glass, metal casting, aluminum, chemicals, and petroleum refining. These industries, designated as Industries of the Future (IOF), are the focus of OIT programs. In 1997, agriculture, specifically renewable bioproducts, was added to the IOF group.The National Research Council Panel on Manufacturing Process Controls is part of the Committee on Industrial Technology Assessments (CITA), which was established to evaluate the OIT program strategy, to provide guidance during the transition to the new IOF strategy, and to assess the effects of the change in program strategy on cross-cutting technology programs, that is, technologies applicable to several of the IOF industries. The panel was established to identify key processes and needs for improved manufacturing control technology, especially the needs common to several IOF industries; identify specific research opportunities for addressing these common industry needs; suggest criteria for identifying and prioritizing research and development (R&D) to improve manufacturing controls technologies; and recommend means for implementing advances in control technologies.
Manufacturing firmsâ€"large and smallâ€"face massive change and adjustment as they move from a stable, fault-tolerant environment of long production runs to a volatile world in which production runs are short; product characteristics are changing constantly; and defect-free, on-time production at decreasing prices is a condition for survival. The necessary changes in the production organization include everything from the layout of the shop floor to the distribution of authority between managers and workers. The magnitude of these changes threatens to overwhelm the managerial capacities of firms, regardless of their size. This study examines the particularly vulnerable situation of small and mid-size manufacturers and considers ways in which to help them undertake the many changes and adjustments necessary. These include assimilating the new tools, disciplines, and philosophy of lean manufacturing; embracing new ways of delegating responsibilities; and developing new kinds of partnerships among customers, suppliers, and employees.
The Book of Majors 2014 by The College Board helps students answer these questions: What's the major for me? Where can I study it? What can I do with it after graduation? Revised and refreshed every year, this book is the most comprehensive guide to college majors on the market. In-depth descriptions of 200 of the most popular majors are followed by complete listings of every major offered at more than 3,800 colleges, including four-year and two-year colleges and technical schools. The 2014 edition covers every college major identified by the U.S. Department of Education—over 1,200 majors are listed in all. This is also the only guide that shows what degree levels each college offers in a major, whether a certificate, associate, bachelor's, master's or doctorate. The guide features: • insights—from the professors themselves—on how each major is taught, what preparation students will need, other majors to consider and much more. • updated information on career options and employment prospects. • the inside scoop on how students can find out if a college offers a strong program for a particular major, what life is like for students studying that major, and what professional societies and accrediting agencies to refer to for more background on the major.
The Book of Majors 2013 by The College Board helps students answer these questions: What's the major for me? Where can I study it? What can I do with it after graduation? Revised and refreshed every year, this book is the most comprehensive guide to college majors on the market. In-depth descriptions of 200 of the most popular majors are followed by complete listings of every major offered at over 3,800 colleges, including four-year, two-year and technical schools. The 2013 edition covers every college major identified by the U.S. Department of Education — over 1,100 majors are listed in all. This is also the only guide that shows what degree levels each college offers in a major, whether a certificate, associate, bachelor's, master's or doctorate. The guide features: • Insights — from the professors themselves — on how each major is taught, what preparation students will need, other majors to consider and much more! • Updated information on career options and employment prospects. • Inside scoop on how students can find out if a college offers a strong program for a particular major, what life is like for students studying that major, and what professional societies and accrediting agencies to refer to for more background on the major.
The managed flow of goods and information from raw material to final sale also known as a "supply chain" affects everythingâ€"from the U.S. gross domestic product to where you can buy your jeans. The nature of a company's supply chain has a significant effect on its success or failureâ€"as in the success of Dell Computer's make-to-order system and the failure of General Motor's vertical integration during the 1998 United Auto Workers strike. Supply Chain Integration looks at this crucial component of business at a time when product design, manufacture, and delivery are changing radically and globally. This book explores the benefits of continuously improving the relationship between the firm, its suppliers, and its customers to ensure the highest added value. This book identifies the state-of-the-art developments that contribute to the success of vertical tiers of suppliers and relates these developments to the capabilities that small and medium-sized manufacturers must have to be viable participants in this system. Strategies for attaining these capabilities through manufacturing extension centers and other technical assistance providers at the national, state, and local level are suggested. This book identifies action steps for small and medium-sized manufacturersâ€"the "seed corn" of business start-up and developmentâ€"to improve supply chain management. The book examines supply chain models from consultant firms, universities, manufacturers, and associations. Topics include the roles of suppliers and other supply chain participants, the rise of outsourcing, the importance of information management, the natural tension between buyer and seller, sources of assistance to small and medium-sized firms, and a host of other issues. Supply Chain Integration will be of interest to industry policymakers, economists, researchers, business leaders, and forward-thinking executives.
Unified life-cycle engineering (ULCE), or concurrent engineering, is a design engineering environment in which computer-aided design technology is used to assess and improve the quality of a productâ€"not only during the active design phases but throughout its entire life cycle. This is achieved by integrating and optimizing the design attributes for producibility and supportability as well as for performance, operability, cost, and schedule. This book addresses ULCE approaches to design, manufacture, and application of structural componentsâ€"especially for advanced military systems. Conclusions and recommendations to support the development of an effective ULCE design engineering environment are presented.
Computational mechanics is a scientific discipline that marries physics, computers, and mathematics to emulate natural physical phenomena. It is a technology that allows scientists to study and predict the performance of various productsâ€"important for research and development in the industrialized world. This book describes current trends and future research directions in computational mechanics in areas where gaps exist in current knowledge and where major advances are crucial to continued technological developments in the United States.
America is changing. Many of the most noticeable changes in day-to-day life are associated with the advancing capabilities of computer systems, the growing variety of tasks they can accomplish, and the accelerating rate of change. Advanced engineering environments (AEEs) combine advanced, networked computer systems with advanced modeling and simulation technologies. When more fully developed, AEEs will enable teams of researchers, technologists, designers, manufacturers, suppliers, customers, and other users scattered across a continent or the globe to develop new products and carry out new missions with unprecedented effectiveness. Business as usual, however, will not achieve this vision. Government, industry, and academic organizations need to make the organizational and process changes that will enable their staffs to use current and future AEE technologies and systems. Design in the New Millennium: Advanced Engineering Environments: Phase 2 is the second part of a two-part study of advanced engineering environments. The Phase 1 report, issued in 1999, identified steps the federal government, industry, and academia could take in the near term to enhance the development of AEE technologies and systems with broad application in the U.S. engineering enterprise. Design in the New Millennium focuses on the long-term potential of AEE technologies and systems over the next 15 years. This report calls on government, industry, and academia to make major changes to current organizational cultures and practices to achieve a long-term vision that goes far beyond what current capabilities allow.
Accelerating the transition of new technologies into systems and products will be crucial to the Department of Defenses development of a lighter, more flexible fighting force. Current long transition times-ten years or more is now typical-are attributed to the complexity of the process. To help meet these challenges, the Department of Defense asked the National Research Council to examine lessons learned from rapid technology applications by integrated design and manufacturing groups. This report presents the results of that study, which was based on a workshop held to explore these successful cases. Three key areas emerged: creating a culture for innovation and rapid technology transition; methodologies and approaches; and enabling tools and databases.
This is the most recent report of the National Research Council's Standing Committee to Review the Research Program of the Partnership for a New Generation of Vehicles (PNGV), which has conducted annual reviews of the PNGV program since it was established in late 1993. The PNGV is a cooperative R&D program between the federal government and the United States Council for Automotive Research (USCAR, whose members are DaimlerChrysler, Ford Motor Company, and General Motors) to develop technologies for a new generation of automobiles with up to three times the fuel economy of a 1993 midsize automobile. The reports review major technology development areas (four-stroke direct-injection engines, fuel cells, energy storage, electronic/electrical systems, and structural materials); the overall adequacy of R&D efforts; the systems analysis effort and how it guides decisions on R&D; the progress toward long-range component and system-level cost and performance goals; and efforts in vehicle emissions and advanced materials research and how results target goals. Unlike previous reports, the Seventh Report comments on the goals of the program, since the automotive market and U.S. emission standards have changed significantly since the program was initiated.
The selection of the proper materials for a structural component is a critical activity that is governed by many, often conflicting factors. Incorporating materials expert systems into CAD/CAM operations could assist designers by suggesting potential manufacturing processes for particular products to facilitate concurrent engineering, recommending various materials for a specific part based on a given set of characteristics, or proposing possible modifications of a design if suitable materials for a particular part do not exist. This book reviews the structural design process, determines the elements, and capabilities required for a materials selection expert system to assist design engineers, and recommends the areas of expert system and materials modeling research and development required to devise a materials-specific design system.
Mechanical engineering is critical to the design, manufacture, and operation of small and large mechanical systems throughout the U.S. economy. This book highlights the main findings of a benchmarking exercise to rate the standing of U.S. mechanical engineering basic research relative to other regions or countries. The book includes key factors that influence U.S. performance in mechanical engineering research, and near- and longer-term projections of research leadership. U.S. leadership in mechanical engineering basic research overall will continue to be strong. Contributions of U.S. mechanical engineers to journal articles will increase, but so will the contributions from other growing economies such as China and India. At the same time, the supply of U.S. mechanical engineers is in jeopardy, because of declines in the number of U.S. citizens obtaining advanced degrees and uncertain prospects for continuing to attract foreign students. U.S. funding of mechanical engineering basic research and infrastructure will remain level, with strong leadership in emerging areas.
Effective design and manufacturing, both of which are necessary to produce high-quality products, are closely related. However, effective design is a prerequisite for effective manufacturing. This new book explores the status of engineering design practice, education, and research in the United States and recommends ways to improve design to increase U.S. industry's competitiveness in world markets.
Integrated computational materials engineering (ICME) is an emerging discipline that can accelerate materials development and unify design and manufacturing. Developing ICME is a grand challenge that could provide significant economic benefit. To help develop a strategy for development of this new technology area, DOE and DoD asked the NRC to explore its benefits and promises, including the benefits of a comprehensive ICME capability; to establish a strategy for development and maintenance of an ICME infrastructure, and to make recommendations about how best to meet these opportunities. This book provides a vision for ICME, a review of case studies and lessons learned, an analysis of technological barriers, and an evaluation of ways to overcome cultural and organizational challenges to develop the discipline.
As the Department of Defense continues development of the future warrior system, the difficulty of moving rapidly from design to manufacturing for complex technologies is becoming a major concern. In particular, there are communication gaps between design and manufacturing that hinder rapid development of new products important for these future military developments. To help address those concerns, DOD asked the NRC to develop a framework for "bridging" these gaps through data management, modeling, and simulation. This report presents the results of this study. It provides a framework for virtual design and manufacturing and an assessment of the necessary tools; an analysis of the economic dimensions; an examination of barriers to virtual design and manufacturing in the DOD acquisition process; and a series of recommendations and research needs.
The mission of the Manufacturing Engineering Laboratory (MEL) of the National Institute of Standards and Technology (NIST) is to promote innovation and the competitiveness of U.S. manufacturing through measurement science, measurement services, and critical technical contributions to standards. The MEL is organized in five divisions: Intelligent Systems, Manufacturing Metrology, Manufacturing Systems Integration, Precision Engineering, and Fabrication Technology. A panel of experts appointed by the National Research Council (NRC) assessed the first four divisions. Overall, this book finds that the four individual divisions are performing to the best of their ability, given available resources. In many areas in all four divisions, the capabilities and the work being performed are among the best in the field. However, reduced funding and other factors such as difficulty in hiring permanent staff are limiting (and are likely to increasingly limit) the degree to which MEL programs can achieve their objectives and are threatening the future impact of these programs.
Traditionally, engineering education books describe and reinforce unchanging principles that are basic to the field. However, the dramatic changes in the engineering environment during the last decade demand a paradigm shift from the engineering education community. This revolutionary volume addresses the development of long-term strategies for an engineering education system that will reflect the needs and realities of the United States and the world in the 21st century. The authors discuss the critical challenges facing U.S. engineering education and present a plan addressing these challenges in the context of rapidly changing circumstances, technologies, and demands.
The Committee on Modeling and Simulation Enhancements for 21st Century Manufacturing and Acquisition was formed by the NRC in response to a request from the Defense Modeling and Simulation Office (DMSO) of DOD. The committee was asked to (1) investigate next-generation evolutionary and revolutionary M&S capabilities that will support enhanced defense systems acquisition; (2) identify specific emerging design, testing, and manufacturing process technologies that can be enabled by advanced M&S capabilities; (3) relate these emerging technologies to long-term DOD requirements; (4) assess ongoing efforts to develop advanced M&S capabilities and identify gaps that must be filled to make the emerging technologies a reality; (5) identify lessons learned from industry; and (6) recommend specific government actions to expedite development and to enable maximum DOD and U.S. commercial benefit from these capabilities. To complete its task, the committee identified relevant trends and their impact on defense acquisition needs; current use and support for use of M&S within DOD; lessons learned from commercial manufacturing; three cross-cutting and especially challenging uses of M&S technologies; and the areas in which basic research is needed in M&S in order to achieve the desired goals for manufacturing and defense acquisition.
Conventional wisdom holds that high wages, high capital costs, and worker inflexibility have cost America its ability to compete in the world manufacturing marketplace. This book demonstrates that U.S.-based manufacturing can compete in terms of quality, product features, and timely deliveryâ€"the real measures of competitiveness in the 1990s. The committee identifies attributes that attract manufacturers to given locations and assesses the attractiveness of the United States as a location for different kinds of manufacturing. The volume dispels myths that have guided management decision making in the past and offers recommendations to promote the United States as a manufacturing site. The volume discusses new approaches to understanding and controlling costs. With case studies from three important industriesâ€"consumer electronics, semiconductors, and automobilesâ€"the book explores factors in site location decisions, highlighting advantages the United States can offer as a manufacturing site over low-cost rivals.
Construction productivity-how well, how quickly, and at what cost buildings and infrastructure can be constructed-directly affects prices for homes and consumer goods and the robustness of the national economy. Industry analysts differ on whether construction industry productivity is improving or declining. Still, advances in available and emerging technologies offer significant opportunities to improve construction efficiency substantially in the 21st century and to help meet other national challenges, such as environmental sustainability. Advancing the Competitiveness and Efficiency of the U.S. Construction Industry identifies five interrelated activities that could significantly improve the quality, timeliness, cost-effectiveness, and sustainability of construction projects. These activities include widespread deployment and use of interoperable technology applications; improved job-site efficiency through more effective interfacing of people, processes, materials, equipment, and information; greater use of prefabrication, preassembly, modularization, and off-site fabrication techniques and processes; innovative, widespread use of demonstration installations; and effective performance measurement to drive efficiency and support innovation. The book recommends that the National Institute of Standards and Technology work with industry leaders to develop a collaborative strategy to fully implement and deploy the five activities
In order to ensure effective military operations and continued warfighter safety, the functionality and integrity of the equipment used must also be ensured. For the past several years, the Nondestructive Evaluation Branch at the Air Force Research Laboratory (AFRL) has focused actively on the development of embedded sensing technologies for the real-time monitoring of damage states in aircraft, turbine engines, and aerospace structures. These sensing technologies must be developed for use in environments ranging from the normal to the extreme, confronting researchers with the need to understand issues involving reliability, wireless telemetry, and signal processing methods. Additionally, there is a need to develop science and technology that will address the sensing of a material state at the microstructure level, precursor damage at the dislocation level, and fatigue-crack size population. To address these issues, the National Research Council convened a workshop at which speakers gave their personal perspectives on technological approaches to understanding materials state and described potential challenges and advances in technology. This book consists primarily of extended abstracts of the workshop speakers' presentations, conveying the nature and scope of the material presented.
New York's Nanotechnology Model: Building the Innovation Economy is the summary of a 2013 symposium convened by the National Research Council Board on Science, Technology, and Economic Policy and members of the Nano Consortium that drew state officials and staff, business leaders, and leading national figures in early-stage finance, technology, engineering, education, and state and federal policies to review challenges, plans, and opportunities for innovation-led growth in New York. The symposium participants assessed New York's academic, industrial, and human resources, identified key policy issues, and engaged in a discussion of how the state might leverage regional development organizations, state initiatives, and national programs focused on manufacturing and innovation to support its economic development goals. This report highlights the accomplishments and growth of the innovation ecosystem in New York, while also identifying needs, challenges, and opportunities. New York's Nanotechnology Model reviews the development of the Albany nanotech cluster and its usefulness as a model for innovation-based growth, while also discussing the New York innovation ecosystem more broadly.
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