Defense Manufacturing in 2010 and Beyond Meeting the Changing Needs of National Defense (1999) / Chapter Skim
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3 Leveraging Advances in Commercial Manufacturing
3 Leveraging Advances in Commercial Manufacturing
Pages 47-72
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From page 47... ...
The increased emphasis on low cost has led DOD to promote the use of COTS products and to investigate the possible manufacture of defense products on commercial production lines. Because commercial industry is much larger than the defense industry, it has a correspondingly stronger base for technology development and manufacturing advances.
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From page 48... ...
and invited speakers to assess advances anticipated in manufacturing. The committee then identified the following areas of management and technology advances that defense manufacturing can expect to draw on: industry collaboration adaptive enterprises high-performance organizations life-cycle perspectives advanced manufacturing processing technology environmentally compatible manufacturing shared information environments These advances are interactive, rather than being independent of each other (i.e., shared information environments may support the goals of high-performance organizations and adaptive enterprises may promote industry collaboration)
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From page 49... ...
LEVERAGING ADVANCES IN COMMERCIAL MANUFACTURING TABLE 3-1 Commercial Manufacturing Advances and Elements 49 Advance Elements Industry collaboration Adaptive enterprises High-performance organizations Life-cycle perspective Advanced manufacturing technology Environmentally compatible manufacturing Shared information environment Electronic commerce Teaming among organizations Long-term supplier relationships Virtual enterprises Agile enterprises Reduced lead time Reduced cycle time Activity-based accounting Lean enterprises Knowledge-based and learning enterprises Virtual co-location of people High performance work teams Cross-functional teams Standardization of parts and reduction in number of parts Integrated product and process development Life-cycle design Cost as an independent variable accounting Flexible assembly Soft tooling Single piece fabrication Rapid prototyping Three-dimensional digital product models High-speed machining Simulation and modeling Predictive process control technologies Adaptive machine control Tool-less assembly Nanotechnology Biotechnology Embedded sensors Generative numerical control Flip chips Cleaning systems Coating systems Material selection, storage, and disposal Data interchange standards Internet, intranets, and browser technology Intelligent agents Seamless data environment Telecommunications Distance learning
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From page 50... ...
emphasizes the timely collaboration of stakeholders, including customers and key suppliers, in a systematic development process. IPPD encompasses new business development, research and development, product and process development, transition to production, and continuous product improvement.
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From page 51... ...
Three-Dimensional Digital Product Models A three-dimensional digital model of a product fully describes the geometry of the product, materials to be used, the attributes of its parts, and the relationship between its parts. In other words, such a model includes all critical information regarding a product's physical dimensions.
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From page 52... ...
Work is being done on using prototypes to create molds for castings. Technically complex products could be built in quicker development cycles and at lower cost if soft tooling, threedimensional digital product data, and generative numerical control were used.
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From page 53... ...
GNC on the factory floor can be coupled with other knowledge bases to reduce flow times and configured to automatically generate the manufacturing plan or process concurrently from the three-dimensional data set. GNC will be able to generate the numerical control program to coordinate measuring machines for quality assurance.
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From page 54... ...
Parts could be designed to take advantage of the reduced flow time and the use of single-piece fabrication with HSM. Flexible Tooling and Soft Tooling Flexible tooling is tooling that can be used to assemble more than one product and can thereby reduce nonrecurring costs by eliminating the cost of dedicated tooling.
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From page 55... ...
For use in advanced military applications, the thermal shock resistance, thermal cycling fatigue strength, temperature and humidity bias, and resistance to mechanical shock and vibration of flip-chip technology will have to be established. Nanotechnology and Biotechnology Nanotechnology, which involves the precise control of materials architecture at the molecular or atomic level, has great potential for the development of manufacturing processes that can vary material composition throughout a structure.
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From page 56... ...
The use of paints containing chrome may soon be eliminated. Problems associated with environmentally compatible coatings include the fact that water-based paints must be applied in lower humidity environments.
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Although substantial efforts are being made to develop and use alternative materials, some manufacturing processes will continue to require hazardous materials. The most significant environmental concern for defense manufacturing is the storage and disposal of these hazardous materials.
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High-speed communications have enabled the development of virtual enterprises worldwide. Significant barriers remain, however, to the optimal functioning of virtual enterprises, including impediments to the rapid and full exchange of information such as a lack of robust information infrastructure and data exchange standards.
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From page 59... ...
At the same time, they apply lean business principles to reduce cycle times, improve quality, and lower costs. Agile enterprises provide customized products by working adaptively, responding to marketplace opportunities, exploiting technology, and entering into strategic alliances.
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From page 60... ...
Visualization via three-dimensional modeling and rapid prototyping can also be used, and product data can be transferred to manufacturing sites to accelerate product delivery. Technologies for virtual co-location include intelligent agents to notify individuals when they are needed and mobile video and voice communications.
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From page 61... ...
Seamless Data Environment In the seamless data environment, information sources will be transparent to the user, who will only need to know what information is required, not where to find it. Information has been stored in databases based on organizational structures, business processes, or other rationales, but access to information has been predicated on knowing where the information is stored and how it can be retrieved.
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From page 62... ...
LEVERAGING COMMERCIAL ADVANCES Although advances in the commercial sector can be leveraged to meet many aspects of the defense manufacturing challenges identified in Chapter 1, some required capabilities will have to be developed specifically by the defense community. Low-Cost Rapid Product Realization Opportunities Rapid (and flexible)
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From page 63... ...
Both costs and cycle times for product realization will be reduced. The merging of commercial and defense production lines would facilitate the production of weapons systems on largely commercial production lines.
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From page 64... ...
A number of design capabilities will not be achieved by advances in commercial manufacturing and will therefore require initiatives by the defense community. These include the integration of COTS into defense systems, multiservice functionality, extended-life weapons systems, improved maintainability, technology insertion, the customization, remanufacture, and reconfiguration of defenseunique products, and the use of commercial processes in defense manufacturing.
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From page 65... ...
Adaptation of Information Technologies Opportunities Defense manufacturing will need the capability to develop enabling technologies for specific applications, the capability to participate in the development of standards to ensure compatibility between defense and commercial systems, and the capability to develop product and process databases that incorporate design history, as well as worker rationale and know-how. New approaches to manufacturing processes.
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From page 66... ...
Flexible processes will increase the number of manufacturers for a given part. Flexibility will be aided by rapid prototyping, three-dimensional product models, high-speed machining, improved simulation and modeling, production process controls, adaptive machine controls, and tool-less assembly, as well as flexible tooling and soft tooling.
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From page 67... ...
Use of Commercial Manufacturing Capacity Opportunities Defense manufacturing will need the capability to use commercial manufacturing capacity, including the use of and design for commercial processes, the incorporation of COTS parts and subsystems into defense products, the production of complete defense weapons systems on commercial lines, the reform of acquisition procedures to accommodate commercial practices, the monitoring of industry developments through technology road maps, the development of surge production capability, the avoidance of parts obsolescence, the qualification of commercial parts for military environments, and incentives for commercial industry to manufacture defense parts. Commercial manufacturing will have the ability to design some defense products for commercial production.
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From page 68... ...
The easy transfer of commercial process data to defense designers will help them accommodate commercial processes. Seamless access to product and process information will help.
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From page 69... ...
Defense manufacturing capabilities that will not be met by the advances listed above include: extended-life designs for weapons systems; designs for maintainability; designs for technology insertion; more efficient maintenance and depot operations; the development of product and process databases; and improved diagnostics. DOD will have to support the development of methods for quantifying the ability of commercial parts to withstand harsh military environments.
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From page 70... ...
The production of military parts on commercial production lines also raises concerns. Because system, subsystem, and component designs would have to be appropriate to modern commercial processes, defense manufacturers must keep abreast of advances in commercial processes, accommodate them in their designs, and pursue enabling technologies and practices that would facilitate the use of commercial production lines.
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From page 71... ...
LEVERAGING ADVANCES IN COMMERCIAL MANUFACTURING TABLE 3-2 Defense Manufacturing Challenges Supported by Commercial Advances 71 Challenge Supporting Commercial Advances Elements Low-cost rapid product Industry collaboration Activity-based accounting realization High-performance organizations Cost-as-an-independent-variable Adaptive enterprises Advanced manufacturing processing technology accounting Integrated product and process design Three-dimensional digital product models Simulation and modeling Tool-less assembly Teaming among organizations Virtual enterprises Long-term supplier relationships Lean, adaptive, and agile enterprises Knowledge-based and learning enterprises Simulation and modeling Expanded design Life-cycle perspectives Simulation and modeling capabilities Advanced manufacturing Three-dimensional digital product processing technology models Life-cycle design Cost-as-an-independent-variable accounting Environmentally Sharedinformation Seamless date environment compatible environments Life-cycle design manufacturing Life-cycle perspectives Coating systems Environmentally compatible Cleaning systems manufacturing Material selection, storage and disposal Adaptation of Sharedinformation Simulation and modeling information technology environments Datainterchange standards Adaptive enterprises Seamless data environments Advanced manufacturing Knowledge-based enterprises processing technology Simulation and modeling Security of product Advanced manufacturing Data exchange standards and process data processing technology Seamless data environment Three-dimensional product models continued
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From page 72... ...
72 TABLE 3-2 continued DEFENSE MANUFACTURING IN 2010 AND BEYOND Challenge Supporting Commercial Advances Access to production Industry collaboration Rapid prototyping sources Shared information Three-dimensional product models environments High-speed machining Adaptive enterprises Simulation and modeling Advanced manufacturing Adaptive machine controls processing technology Tool-less assembly Agile enterprises Teaming among organizations Use of commercial Sharedinformation Rapid prototyping manufacturing capacity environments Simulation and modeling Life-cycle perspectives Tool-less assembly Adaptive enterprises Data interchange standards Advanced manufacturing Seamless data environment processing technology Life-cycle design Cost-as-an-independent-variable accounting Agile enterprises Sustainment of Life-cycle perspectives High-speed machining weapons systems Advanced manufacturing Embedded sensors processing technology Cleaning systems Shared information Coating systems environments Life-cycle design Environmentally compatible Cost-as-an-independent-variable manufacturing accounting Seamless data environments Data interchange standards
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