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Suggested Citation:"Front Matter." National Research Council. 1995. Information Technology for Manufacturing: A Research Agenda. Washington, DC: The National Academies Press. doi: 10.17226/4815.
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Information
Technology
for
Manufacturing

A Research Agenda

Committee to Study Information Technology and Manufacturing

Computer Science and Telecommunications Board
Commission on Physical Sciences, Mathematics, and Applications

Manufacturing Studies Board
Commission on Engineering and Technical Systems

National Research Council

National Academy Press
Washington, D.C. 1995

Suggested Citation:"Front Matter." National Research Council. 1995. Information Technology for Manufacturing: A Research Agenda. Washington, DC: The National Academies Press. doi: 10.17226/4815.
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Page ii

NOTICE: The project that is the subject of this report was approved by the Governing Board of the National Research Council, whose members are drawn from the councils of the National Academy of Sciences, the National Academy of Engineering, and the Institute of Medicine. The members of the committee responsible for the report were chosen for their special competences and with regard for appropriate balance.

This report has been reviewed by a group other than the authors according to procedures approved by a Report Review Committee consisting of members of the National Academy of Sciences, the National Academy of Engineering, and the Institute of Medicine.

Support for this project was provided by the national Science Foundation (under Grant No.MIP-93/2296). Any opinions, findings, conclusions, or recommendations expressed in this material are those of the authors and do not necessarily reflect the views of the National Science Foundation.

Library of Congress Catalog Card Number 94-67789
International Standard Book Number 0-309-05179-7

Cover: The manufacturing "wheel" shown is intended to suggest the integration through information technology of manufacturing activities both among and across the four basic elements of an idealized process. The concept is discussed in Chapter 2 of this report.

Available from:

National Academy Press
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Box 285Washington, DC 20055
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Copyright 1995 by the National Academy of Sciences. All rights reserved.

Printed in the United States of America

Suggested Citation:"Front Matter." National Research Council. 1995. Information Technology for Manufacturing: A Research Agenda. Washington, DC: The National Academies Press. doi: 10.17226/4815.
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Page iii

Committee To Study Information
Technology And Manufacturing


PETER WILL, USC/Information Sciences Institute, Chair

BARBARA M. FOSSUM, University of Texas

DENNIS M. HOGAN, Dennis M. Hogan Associates

NEAL LAURANCE, Ford Motor Company

KEN J. LINDSAY, Northrop Aircraft Division

EUGENE S. MEIERAN, Intel Corporation

RAJ REDDY, Carnegie Mellon University

WYCKHAM D. SEELIG, AT&T Network Systems

GILBERT S. STAFFEND, Allied Signal Automotive

IVAN E. SUTHERLAND, Sun Microsystems Laboratories (through February 1994)

LOUISE H. TREVILLYAN, IBM T.J. Watson Research Center

DANIEL E. WHITNEY, Massachusetts Institute of Technology

EUGENE WONG, University of California at Berkeley

PAUL K. WRIGHT, University of California at Berkeley

RICHARD A. WYSK, Texas A&M University


ROBERT E. KAHN, Corporation for National Research Initiatives, Special Advisor


Staff

MARJORY S. BLUMENTHAL, Computer Science and Telecommunications Board

THOMAS C. MAHONEY, Manufacturing Studies Board (through September 1994)

MICHAEL A. McDERMOTT, Manufacturing Studies Board (through February 1994)

GREG MEDALIE, Computer Science and Telecommunications Board (through April 1994)

HERBERT S. LIN, Computer Science and Telecommunications Board (from April 1994)

LESLIE M. WADE, Project Assistant

Suggested Citation:"Front Matter." National Research Council. 1995. Information Technology for Manufacturing: A Research Agenda. Washington, DC: The National Academies Press. doi: 10.17226/4815.
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Page iv

Computer Science And Telecommunications Board

WILLIAM WULF, University of Virginia, Chair

FRANCES ALLEN, IBM T.J. Watson Research Center

JEFF DOZIER, University of California at Santa Barbara

DAVID J. FARBER, University of Pennsylvania

HENRY FUCHS, University of North Carolina

CHARLES M. GESCHKE, Adobe Systems Inc.

JAMES GRAY, San Francisco, California

BARBARA J. GROSZ, Harvard University

DEBORAH A. JOSEPH, University of Wisconsin

RICHARD M. KARP, University of California at Berkeley

BUTLER W. LAMPSON, Digital Equipment Corporation

BARBARA H. LISKOV, Massachusetts Institute of Technology

JOHN MAJOR, Motorola Inc.

ROBERT L. MARTIN, AT&T Network Systems

DAVID G. MESSERSCHMITT, University of California at Berkeley

WILLIAM H. PRESS, Harvard University

CHARLES L. SEITZ, Myricom Inc.

EDWARD SHORTLIFFE, Stanford University School of Medicine

CASMIR S. SKRZYPCZAK, NYNEX Corporation

LESLIE L. VADASZ, Intel Corporation


MARJORY S. BLUMENTHAL, Director

LOUISE A. ARNHEIM, Senior Staff Officer

HERBERT S. LIN, Senior Staff Officer

JAMES E. MALLORY, Staff Officer

RENEE A. HAWKINS, Staff Associate

GLORIA P. BEMAH, Administrative Assistant

LESLIE M. WADE, Project Assistant

Suggested Citation:"Front Matter." National Research Council. 1995. Information Technology for Manufacturing: A Research Agenda. Washington, DC: The National Academies Press. doi: 10.17226/4815.
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Page v

Manufacturing Studies Board

CHARLES P. FLETCHER, Aluminum Company of America, Chair

SARA L. BECKMAN, University of California at Berkeley

LESLIE A. BENMARK, E.I. Du Pont de Nemours & Co. Inc.

STEVEN J. BOMBA, Johnson Controls Inc.

BRIAN E. BOYER, Northrop Aircraft Division

GARY L. COWGER, General Motors Corporation

HAROLD E. EDMONDSON, Hewlett-Packard (retired)

THOMAS G. GUNN, Gunn Associates Inc.

ALISTAIR M. HANNA, McKinsey & Co. Inc.

GEORGE J. HESS, The Ingersoll Milling Machine Co.

CHARLES W. HOOVER, JR., Polytechnic University

STEPHEN C. JACOBSEN, University of Utah

RAMCHANDRAN JAIKUMAR, Harvard University

J.B. JONES, Virginia Polytechnic Institute and State University

DONALD KENNEDY, International Association of Machinists and Aerospace Workers

THOMAS L. MAGNANTI, Massachusetts Institute of Technology

JOE M. MIZE, Oklahoma State University

JACOB T. SCHWARTZ, New York University

HERBERT B. VOELCKER, Cornell University

PAUL K. WRIGHT, University of California at Berkeley


ROBERT SCHAFRIK, Acting Director

Suggested Citation:"Front Matter." National Research Council. 1995. Information Technology for Manufacturing: A Research Agenda. Washington, DC: The National Academies Press. doi: 10.17226/4815.
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Page vi

Commission On Physical Sciences,
Mathematics, And Applications

RICHARD N. ZARE, Stanford University, Chair

RICHARD S. NICHOLSON, American Association for the Advancement of Science, Vice Chair

STEPHEN L. ADLER, The Institute for Advanced Study

SYLVIA T. CEYER, Massachusetts Institute of Technology

SUSAN L. GRAHAM, University of California at Berkeley

ROBERT J. HERMANN, United Technologies Corporation

RHONDA J. HUGHES, Bryn Mawr College

SHIRLEY A. JACKSON, Rutgers University

KENNETH I. KELLERMANN, National Radio Astronomy Observatory

HANS MARK, University of Texas at Austin

THOMAS A. PRINCE, California Institute of Technology

JEROME SACKS, National Institute of Statistical Sciences

L.E. SCRIVEN, University of Minnesota

A. RICHARD SEEBASS III, University of Colorado

LEON T. SILVER, California Institute of Technology

CHARLES P. SLICHTER, University of Illinois at Urbana-Champaign

ALVIN W. TRIVELPIECE, Oak Ridge National Laboratory

SHMUEL WINOGRAD, IBM T.J. Watson Research Center

CHARLES A. ZRAKET, The MITRE Corporation (retired)


NORMAN METZGER, Executive Director

Suggested Citation:"Front Matter." National Research Council. 1995. Information Technology for Manufacturing: A Research Agenda. Washington, DC: The National Academies Press. doi: 10.17226/4815.
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Page vii

Commission On Engineering And Technical Systems

ALBERT R.C. WESTWOOD, Sandia National Laboratories, Chair

H. KENT BOWEN, Harvard University

NAOMI F. COLLINS, NAFSA: Association of International Educators

NANCY R. CONNERY, Consultant

RICHARD A. CONWAY, Union Carbide Corporation

SAMUEL C. FLORMAN, Kreisler Borg Florman Construction Company

TREVOR O. JONES, Libbey-Owens-Ford Company

NANCY G. LEVESON, University of Washington

ALTON D. SLAY, Slay Enterprises Inc.

JAMES J. SOLBERG, Purdue University

BARRY M. TROST, Stanford University

GEORGE L. TURIN, Teknekron Corporation

WILLIAM C. WEBSTER, University of California at Berkeley

DEBORAH A. WHITEHURST, Arizona Community Foundation

ROBERT V. WHITMAN, Massachusetts Institute of Technology

CHARLES E. WILLIAMS, Toll Road Investors Partnership II


ARCHIE L. WOOD, Executive Director

Page viii Cite
Suggested Citation:"Front Matter." National Research Council. 1995. Information Technology for Manufacturing: A Research Agenda. Washington, DC: The National Academies Press. doi: 10.17226/4815.
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Page viii

The National Academy of Sciences is a private, nonprofit, self-perpetuating society of distinguished scholars engaged in scientific and engineering research, dedicated to the furtherance of science and technology and to their use for the general welfare. Upon the authority of the charter granted to it by the Congress in 1863, the Academy has a mandate that requires it to advise the federal government on scientific and technical matters. Dr. Bruce Alberts is president of the National Academy of Sciences.

The National Academy of Engineering was established in 1964, under the charter of the National Academy of Sciences, as a parallel organization of outstanding engineers. It is autonomous in its administration and in the selection of its members, sharing with the National Academy of Sciences the responsibility for advising the federal government. The National Academy of Engineering also sponsors engineering programs aimed at meeting national needs, encourages education and research, and recognizes the superior achievements of engineers. Dr. Robert M. White is president of the National Academy of Engineering.

The Institute of Medicine was established in 1970 by the National Academy of Sciences to secure the services of eminent members of appropriate professions in the examination of policy matters pertaining to the health of the public. The Institute acts under the responsibility given to the National Academy of Sciences by its congressional charter to be an adviser to the federal government and, upon its own initiative, to identify issues of medical care, research, and education. Dr. Kenneth I. Shine is president of the Institute of Medicine.

The National Research Council was organized by the National Academy of Sciences in 1916 to associate the broad community of science and technology with the Academy's purposes of furthering knowledge and advising the federal government. Functioning in accordance with general policies determined by the Academy, the Council has become the principal operating agency of both the National Academy of Sciences and the National Academy of Engineering in providing services to the government, the public, and the scientific and engineering communities. The Council is administered jointly by both Academies and the Institute of Medicine. Dr. Bruce Alberts and Dr. Robert M. White are chairman and vice chairman, respectively, of the National Research Council.

Suggested Citation:"Front Matter." National Research Council. 1995. Information Technology for Manufacturing: A Research Agenda. Washington, DC: The National Academies Press. doi: 10.17226/4815.
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Page ix

Preface

At the request of the National Science Foundation, the National Research Council's Computer Science and Telecommunications Board (CSTB) and Manufacturing Studies Board (MSB) formed the Committee to Study Information Technology and Manufacturing in April 1993. The committee of 16 individuals from academia and industry was charged with determining the computer science and engineering research needed to support advanced manufacturing.

In preparing this report, the committee reviewed and synthesized relevant material from recent reports and initiatives, interviewed a number of researchers and practitioners in the field, and met five times to discuss the input from these sources as well as the independent observations and findings of the committee members themselves. (Contributors to this report are listed in Appendix A.) It shared its preliminary thinking with a broad community in an interim report.1 Reviewers of that document noted a number of issues as deserving of further study that are addressed in this final report. The committee included experts from the information technology (IT) and the manufacturing domains, individuals involved in research and development as well as implementation, and individuals experienced in the manufacture of mechanical and electronic products.2 In short,

1 Computer Science and Telecommunications Board and Manufacturing Board, National Research Council. 1993. Information Technology and Manufacturing: A Preliminary Report on Research Needs. National Academy Press, Washington, D.C.

2 In the interests of keeping this project manageable, the committee concentrated on discrete manufacturing. In did not address continuous manufacturing (the production of substances and materials) to any significant degree.

Suggested Citation:"Front Matter." National Research Council. 1995. Information Technology for Manufacturing: A Research Agenda. Washington, DC: The National Academies Press. doi: 10.17226/4815.
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the committee was by design highly heterogeneous, a characteristic intended to promote discussion and synergy among its members.

The committee focused on articulating a vision of IT-enabled manufacturing in the 21st century, identifying the obstacles to achieving the vision, and identifying research topics that address the obstacles. Its deliberations centered on the three thrusts outlined by the former Federal Coordinating Council for Science, Engineering, and Technology in its Advanced Manufacturing Technology initiative:

''Intelligent" manufacturing equipment and systems;

Integrated tools for product, process, and enterprise design; and

Advanced manufacturing technology infrastructure.

Since these thrusts were outlined, the present administration has emphasized to a much greater degree the importance of a national information infrastructure that would support many activities of national importance, including manufacturing. That issue was considered by the committee as well.

The range and combination of research topics recommended by the committee are an essential feature of this report. Some of the topics chosen by the committee have been proposed by others in prior reports; the need for work in some areas is enduring. Some topics fall into areas of long-standing need but are advanced with new emphases. Because of limited time, the committee was unable to assess in depth the topics it identified. Moreover, it did not specifically address areas other than information technology that might prove beneficial to manufacturing; such areas include new physical processes that might be developed to shape and fabricate discrete components. In preparing this final report, the committee drew heavily on the preliminary report it issued in late 1993. Its efforts in subsequent meetings served to develop more fully, validate, and complement the ideas presented in that earlier report. A site visit to an engine plant in March 1994 (described in Appendix B) provided a firsthand demonstration of the productive use of current information technology in manufacturing. In addition, a National Science Foundation workshop in May 19943 (attended by some committee members) helped to crystallize some of the ideas presented in the material on the design process.

The CSTB and MSB are grateful to the National Science Foundation, to those who made presentations and/or submitted written material to the committee, and to those who reviewed this report and its predecessor. CSTB will be glad to receive comments on this report. Please send them via Internet e-mail to CSTB@NAS.EDU, or via regular mail to CSTB, National Research Council, 2101 Constitution Avenue NW, Washington, DC 20418. The committee, of course, remains responsible for the report's content.

3 See Mukherjee, Amar, and Jack Hilibrand (eds.). 1994. New Paradigms for Manufacturing. NSF 94-123. National Science Foundation, Washington, D.C.

Suggested Citation:"Front Matter." National Research Council. 1995. Information Technology for Manufacturing: A Research Agenda. Washington, DC: The National Academies Press. doi: 10.17226/4815.
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Page xi

Contents

EXECUTIVE SUMMARY

1

1 VISION AND RECOMMENDED AREAS OF RESEARCH

12

Introduction

12

Information Technology and the Increasing Complexity of Manufacturing

13

Purpose, Scope, and Content of This Report

15

Flexibility for the Future

16

Recognizing Information Technology's Increasing Capability in a Changing World

17

Balancing Current Needs and the Development of Future Capabilities

23

Looking Ahead

25

The Potential Impact of Information Technology on the Manufacturing Enterprise

26

The Broad Vision

26

Nearer-Term Prospects for Improvement

28

Product and Process Design

28

Shop Floor Production

30

Business Practices

33

New Manufacturing Styles

34

The Virtual Factory

35

The Programmable or Reconfigurable Factory

36

The Networked Factory

38

Microfactories

39

Suggested Citation:"Front Matter." National Research Council. 1995. Information Technology for Manufacturing: A Research Agenda. Washington, DC: The National Academies Press. doi: 10.17226/4815.
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Page xii

Getting From Here to There—The Need for Balance and a Considered Approach

40

The Research Agenda

42

Technology Research

42

Product and Process Design

42

Shop Floor Control

43

Modeling and Simulation

45

Enterprise Integration and Business Practices

47

Non-Technology Issues

47

2 MANUFACTURING: CONTEXT, CONTENT, AND HISTORY

49

The Economics of Manufacturing

49

The Nature of Manufacturing

50

The Historical Context of Manufacturing

56

Early Paradigm Changes

56

Recent Changes and Their Effects

58

3 INTEGRATED PRODUCT AND PROCESS DESIGN

60

Introduction

60

Design Paradigms

62

Electronic Design

62

Application to Mechanical Design

65

Needs and Research for Mechanical Design

66

Research for Product Description

70

Research for Process Description

76

Research for Tools to Support Integrated Product and Process Design

79

Research Areas Not Specific to Manufacturing

80

Geometric Reasoning

80

Knowledge and Information Management

81

Specific Research Questions

82

4 SHOP FLOOR PRODUCTION

84

Introduction

84

Scheduling Factory Activities

85

Centralized Control

85

Decentralized Control

92

Autonomous Agents

92

Work and Logistics Flow

94

Controlling Individual Factory Activities

95

Equipment Controllers

96

Sensors

102

Page xiii Cite
Suggested Citation:"Front Matter." National Research Council. 1995. Information Technology for Manufacturing: A Research Agenda. Washington, DC: The National Academies Press. doi: 10.17226/4815.
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Facilitating Continuous Improvement

105

Controlling and Managing Product Configuration

106

Specific Research Questions

107

5 MODELING AND SIMULATION FOR THE VIRTUAL FACTORY

109

Introduction

109

Considerations in the Development of Virtual Factories

110

Learning from Past Problems

110

Determining the Requirements for Effective Factory Models

111

Modeling Technology

113

Representing and Capturing Manufacturing Expertise

116

Research Areas Not Specific to Manufacturing

118

6 INFORMATION INFRASTRUCTURE ISSUES

119

Introduction

119

Architectures and Standards

121

Integration

123

Redesign of Business Practices

123

Intra-enterprise Integration

124

Inter-enterprise Integration

128

Non-manufacturing-specific Research

130

Information Retrieval Systems

131

Software Engineering

132

Dependable Computing Systems

134

Collaboration Technology and Computer-supported Cooperative Work

135

7 ORGANIZATIONAL AND SOCIETAL INFRASTRUCTURE

136

Targeting the Decision Maker

137

Motivating Technology Transfer and Academic-Industrial Interaction

137

Motivating Introduction and Implementation of Information Technology

142

Understanding Organizational Issues

142

Human Resources

142

Communications

143

Organization for Ad Hoc Tasks

143

Informal Hierarchies of Status

144

Overcoming History and Managing Risk

144

Providing for Technology Demonstrations

147

Stimulating the Adoption of Open Standards

149

Suggested Citation:"Front Matter." National Research Council. 1995. Information Technology for Manufacturing: A Research Agenda. Washington, DC: The National Academies Press. doi: 10.17226/4815.
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Developing Better Metrics of Performance

151

Developing New Models for Accounting and Valuation

152

Emphasizing Education, Training, and Retraining

153

BIBLIOGRAPHY

156

APPENDIXES

 

A List of Contributors

163

B Site Visit to Romeo Engine Plant, March 23, 1994

165

C Illustrative Advanced Long-range Technology Demonstrations

169

Suggested Citation:"Front Matter." National Research Council. 1995. Information Technology for Manufacturing: A Research Agenda. Washington, DC: The National Academies Press. doi: 10.17226/4815.
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This book describes a vision of manufacturing in the twenty-first century that maximizes efficiencies and improvements by exploiting the full power of information and provides a research agenda for information technology and manufacturing that is necessary for success in achieving such a vision. Research on information technology to support product and process design, shop-floor operations, and flexible manufacturing is described. Roles for virtual manufacturing and the information infrastructure are also addressed. A final chapter is devoted to nontechnical research issues.

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