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Manufacturing innovation   asa fall mtg 10-9-12 - morris
 

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  • Alexander Hamilton, 1st Secretary of the Treasury: In his celebrated "Report on Manufactures" in 1791, Hamilton offered a program whose central theme was the development of domestic industries for national security.

Manufacturing innovation   asa fall mtg 10-9-12 - morris Manufacturing innovation asa fall mtg 10-9-12 - morris Presentation Transcript

  • Manufacturing Innovation A National Defense Imperative Aerospace States Association Fall General Meeting October 9, 2012Ed MorrisNDIA Manufacturing Division ChairmanDirector, Mechanical Engineering & ManufacturingLockheed Martin Corporate Engineering & Technology "Delivering Value through Defense Manufacturing Technology"
  • Discussion Topics• NDIA & Manufacturing Division Overview• From a National Defense Perspective, What Is “Manufacturing Innovation” and Why Is It Important?• Barriers to Manufacturing Innovation• Manufacturing Innovations “In Work”• Closing Thoughts "Delivering Value through Defense Manufacturing Technology"
  • NDIA Overview• Vision: – America’s leading Defense Industry association promoting National Security• Mission: – ADVOCATE: Cutting-edge technology and superior weapons, equipment, training, and support for the War-Fighter and First Responder – PROMOTE: A vigorous, responsive, Government – Industry National Security Team – PROVIDE: A legal and ethical forum for exchange of information between Industry and Government on National Security issues• Motto: – Strength through Industry and Technology "Delivering Value through Defense Manufacturing Technology"
  • NDIA Overview (Cont’d)• About Us: – Over 1,780 corporate members, 87,700 individual members, 52 Chapters, 32 Divisions and 7 Industrial Working Groups – Work with industry, government, all military Services, and academia – Monthly journal National DEFENSE provides the latest developments in technology, arms and weaponry, and issues of concern to industry and the government – NDIA traces its history to the American Defense Preparedness Association (ADPA), founded in 1919, and the National Security Industrial Association (NSIA), founded in 1944 – The new NDIA, founded in March 1997, is a non- partisan, non-profit, educational association with offices in Arlington, Virginia "Delivering Value through Defense Manufacturing Technology"
  • NDIA Manufacturing DivisionMission: Enhance the security of the United States bypromoting communications and interaction between thedefense industry, academia, government and military inthe area of manufacturingSpecific Objectives:  Advocate national support for defense manufacturing  Promote defense manufacturing excellence  Support promising technologies, processes, and implementation methodologies  Support efforts to educate, recruit and train a highly skilled defense manufacturing workforce  Conduct research and analysis on manufacturing trends and policies  Conduct government-industry forums focused on defense manufacturing5 "Delivering Value through Defense Manufacturing Technology"
  • Today’s Global Keep-Awakes . . .• Current Conflicts – GWOT (Terrorism Anywhere) – Iraq & Afghanistan – Cyber Warfare – Piracy at Sea• Global Hot Spots – Iran – North Korea – Others . . .• The Global Economy• Energy Resources• Materials Availability• Counterfeit Parts• Pandemic Disease• Earthquakes?? "Delivering Value through Defense Manufacturing Technology"
  • National Defense Realities• Budget Control Act of 2011 Impact – Program Cancellations – Program Stretch-outs – Few New Starts• Aging, Worn-out Equipment – E-3A Airborne Warning And Control System aircraft (AWACS) are running two 12-hour missions/day in Afghanistan – they are 30 years old – B-52 has been in active service with the USAF since 1955; Current plan is to keep the B-52H in service until 2045 – 90 Years! "Delivering Value through Defense Manufacturing Technology"
  • DoD Warfighter Perspective• We are in a long, global war – perhaps measured in decades!• Our adversaries: – Place little or no value on human life, including their own – Are skilled at rapidly adapting “just good enough” technology at very low cost• IEDs are still a major threat• Energy demands for today’s equipment must be reduced• Weapon reliability is crucial “Need quality products on time” "Delivering Value through Defense Manufacturing Technology"
  • Defense Manufacturing Mandates• Rapidly field the very best new equipment• Upgrade & modernize existing systems• Rapidly incorporate new technologies into new and fielded systems MONAX 3G Wireless Communications SystemsWhile . . .• Adjusting to changing requirements and budgets• Maintaining a Viable Defense Industrial Base• Ensuring product affordability "Delivering Value through Defense Manufacturing Technology"
  • Manufacturing Innovations Enable Disruptive Warfare• Disruptive Warfare Technologies – Castles, ladders, hot tar & motes, catapults . . . – Night Vision, Laser target designation, Low Observable technologies . . . – IEDs, MRAPs, Bigger IEDs . . .• Disruptive Engineering Technology Shifts – Computing Power – Engineering Computing and CAD – Portable Computer Storage Media "Delivering Value through Defense Manufacturing Technology"
  • Some Definitions• Production versus “Big M” Manufacturing• “Advanced Manufacturing” is a family of activities that: – Depends on the use and coordination of information, automation, computation, software, sensing, and networking – Makes use of cutting edge materials and emerging capabilities enabled by the physical and biological sciences, for example nanotechnology, chemistry, and biology – Involves both new ways to manufacture existing products, and the manufacture of new products emerging from new advanced technologies Innovation, the Process & Product of IntroducingSomething New, Is the Engine for Advanced Manufacturing "Delivering Value through Defense Manufacturing Technology"
  • Barriers to Manufacturing Innovation• Fixated on the Past & Present – “We’ve always done it this way”• Fear of Failure – “Too risky”• Finances – “Not the first investment choice for Venture Capitalists”• “Tipping Point” Barriers – “Can engineers use the innovation in new product designs?”• Surviving the “Valley of Death” – “How can we bridge the gaps?” Technology Readiness Level (TRL) and Manufacturing Readiness Level (MRL) Must Stay in Sync "Delivering Value through Defense Manufacturing Technology"
  • Innovative Manufacturing Game-Changers In-Work• Robot Technology Including Machine Vision• Machine Communication Standards (like MTConnect)• Embedded Sensors for In-Process Inspection, Feedback & Heath Monitoring• Automated Creation of More Efficient Machine Tool Paths based on In-House Capability and Geometric Component Features• Reductions in Consumables Such as Coolant and Development of Longer Cutting Tool Life• Friction Stir Welding "Delivering Value through Defense Manufacturing Technology"
  • Innovative Manufacturing Game-Changers In-Work (Cont’d)• Friction Stir Welding "Delivering Value through Defense Manufacturing Technology"
  • Innovative Manufacturing Game-Changers In-Work (Cont’d)• Advanced Composites Manufacturing Direct Digital Manufacturing / Additive Manufacturing 1997 Manufacturing Modeling & Simulation Integrated Computational Materials Science & Engineering Several Are Still Short of Their “Tipping Point” "Delivering Value through Defense Manufacturing Technology"
  • National Network for Manufacturing Innovation (NNMI)• FY13 President’s Budget – a $1B, one-time investment to create the new National Network for Manufacturing Innovation Program – “Public-Private Partnership”• National Additive Manufacturing Innovation Institute (NAMII) pilot institute established – 1st of 15 institutes• $30 million in federal funding, matched by $40 million from the winning team led by the National Center for Defense Manufacturing and Machining (NCDMM) "Delivering Value through Defense Manufacturing Technology"
  • Additive ManufacturingSample Technique: Electron Beam Direct Manufacturing "Delivering Value through Defense Manufacturing Technology"
  • eBDM Process Flow"Delivering Value through Defense Manufacturing Technology"
  • eBDM Unit Cost Comparison Forging Process Direct Manufacturing First Part Learning CurveMachining Reduction Unit Cost Near-Net Forgings (average cost over many parts)Forging Predicting the futureProcessing 12% Rate Improvements Machining First Titanium Pricing & Improved Forgings Forging Learning Curve Part Processing ReductionRaw MachiningMaterial,Actual Raw Machining Material Deposition Deposition (LTA) Raw Material Raw Material (LTA) (LTA)LTA: Long-Term Agreement "Delivering Value through Defense Manufacturing Technology"
  • eBDM Lead Time Comparison • Lead time with ingot, plate and wire in stock • Faster machining due to nearer net partForging Process • Forging lead times are approximately 16 weeks for small parts, large parts are up Machining to 30 weeks Inspection Forging Processing Direct Heat Treat Manufacturing Machining Deposition "Delivering Value through Defense Manufacturing Technology"
  • Innovative Manufacturing Modeling & Simulation Discrete Event Simulation Digital Work Instructions Robotic Simulation Ergonomic SimulationAugmented Reality Human Factors Human Immersive Lab Assembly Simulation Risk Modeling Virtual Development Center Visualization DFX Simulation "Delivering Value through Defense Manufacturing Technology"
  • Innovative Materials Approach for Design & Manufacturing• Integrated Computational Materials Science & Engineering (ICMSE) – An integrated process for design, certification, and manufacture of materials and components – Concurrent design of materials and components – Designing to novel / flexible mfg processes – Eliminating barriers to introduction of materials – Being pursued by AFRL Nonmetallic Materials Division and industry Injection Molding Compression MoldingRotational Molding Extrusion Thermoforming "Delivering Value through Defense Manufacturing Technology"
  • Closing Thoughts . . .“The best way to predict the future is to invent it.” - Alan Kay “Good Leadership Is Knowing How Much of the Future to Implement in the Present.” - Anonymous “Even if you are on the right track, youll get run over if you just sit there.” - Will Rogers"We must hang together, gentlemen...else, we shall most assuredly hang separately.” - Benjamin Franklin "Delivering Value through Defense Manufacturing Technology"