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Published by the Manufacturing Technology Information Analysis Center (MTlAC)10 West 35th Street. Chicago, Illinois 60616
CONTENTS
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Center for Manufacturing Sciences •••• 1Automation Initiative •••••••••••••••• 2Flexible Repair Center •••••••••••••••• 2Navy Report Automation Factories •••••• 3Advanced Processing in the u.S •••••••• 3
Manufacturing Cost Estimates •••••••••• 4Data & Analysis Center for Software ••• 4
Page
Automated Brush Deburring•••••••••••••••• 4Material Handling Video.................. 4000 IAC Meeting•••••••••••••••••••••••••• 5Learning Curves.......................... 5Books. . . . • . • . . . . . . . . . • • • . . . . • • . . . . . • • • . . . 5Meeting Calendar••••••••••••••••••••••••• 6End-of-Contract Demonstration Calendar ••• 7
National Center for Manufacturing Sciences
The National Center for ManufacturingSciences (NCMS) is fast hecoming a reality. The choice of the final site for theCenter was narrowed to four states inJune Texas, Michigan, Connecticut andOhio. Michigan was subsequently selectedas the fifth potential site.
At its last meeting the Board of Directorsset September 1, 1987 as the target datefor the NCMS becoming operational. By thattime, the NCMS had membership commitmentsfrom 80 companies, and $10 million incommitted funds.
The National Manufacturing Research Agendafor the first three years is being formulated. The Summer Study Panels, chargedwi th helping to develop this "launchagenda", have begun work in earnest. Allseven panels have held meetings. Thefirst meetings generally succeeded inidentifying industry problems at the program level, and there was nearly unanimousdesire for broader representation beforerecommending specific proj ects for funding.
A Department of Defense Information Analysis Center
MTIAC is a full-service information analysis center managed by Cresap, McCormick and Paget Division of TPF&C, Inc.,a firm which provides technical services to government and industry. The principal subcontractor is the lIT ResearchInstitute, one of the largest not-for-profit organizations in the United States.
For additional informationtelephone 312-567-4730
Cresap, McCormick and Paget Division ofTPF&C, Inc. and lIT Research Institute1fllAT.oc" "1£;''')." c.....oo.. rh; ..... ""t"I'l"\ Tll; __;,ro t:.flL1L
•
The MT!AC Cur~ent Awareness ~ulletin is pu~1is~ed at regular intervals and distributed free-of-charge by MTIAC. Forfurther mformation on the servIces and publIcations of the Center, contact Robert Walk, Director or Fred Seaman,Technology Coo.rdinator. A pamphlet on the mission, scope and functions of the Center is available on request. MTIAChas been establIshed under Contract DLA900-84-C-1508.
The Center concern~ it~elf with areas of manufacturing technology that are applicable to defense systems. These areasmclude but are not lImIted to: Metals, Nonmetals, Electronics, CAD/CAM, Inspection and Test, and Munitions. In thecontext of the contract, the term "manufacturing" covers the entire life-cycle of a product - i.e., design, productionand operational support.
Each of the above six subject areas includes but is not limited to the defense-related fields of: machine tools and manufacturing equipment, robots and special machines, material handling equipment, controls, software and data bases, communication lines and networks, sensors and inspection or checkout procedures, signal processing, materials and materials treatment, production processes, the specific defense products being produced and management aspects of manufacturing technology.
The Automation Initiative Flexible Repair Center
The flexible repair center will standardize many repair procedures for enginecases, thus reducing the cost and cuttingby half the time now required to makerepairs. Reduced repair time is expectedto lead to an improved surge capability,i.e., accelerated production duringperiods of mobilization.
The cell management system will schedule,monitor and track parts and resourceswithin the flexible repair center. Therepair operations planning system willprovide detailed operational informationto the center. It will create a detailedrepair process plan for each part and willgenerate numerical control instructions tooperate the machining equipment needed tofix the part.
The USAF Materials Laboratory has awardeda contract to Dravo Automation Sciences,Pittsburgh, for construction of a flexiblerepair center. The center will beinstalled at Air Force Logistics Command'sOklahoma City Air Logistics Center (ALC),Tinker AFB, Oklahoma. The flexible repairfacili ty will automate complex machiningand inspection operations for the J57,J79, TF30, TF33 and TF41 family of enginecases. It will integrate machining andinspection operations.
The "Automation Initiative", a filmdesigned for industrial users andinvestment-level decision makers ofAmerican industry, provides an opportunityto see first-hand some of the many, oftenoverlooked benefits of flexible factoryautomation. It presents experts in thefields of science and technology as wellas case studies which demonstrate howautomation has been put to work.
The film raises key issues about thecompetitiveness of U.S. manufacturingcapability. Underlying all is the messagethat executives need to be aware of theforces of change operating in a worldmarket. One of the most critical of theseforces is automation.
Automation is a large part of the complexsolution to surviving foreign competition,changing consuroer attitudes, demands forquality, responding to governmentregulations and obsolescence. It alsoyields a wide range of benefits fromenergy savings to long-term productivityimprovements. For automation to achieveall it might, top executives must bewilling to make commitments in people,time and resources.
Consider the rate of change in U.S.industry in the last 25 years. Themomentum has, if anything, increased.Imagine U.S. industry 25 years hence;one of the safest and most reasonableassumptions is that automation will beplaying a major role. Now is the time tobegin preparing.
This film is available on U-matic and VHSvideocassettes and 16mrn film from NEMA.Electrical Manufacturers Association, 2101L Street, NW, Washington DC 20037.
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ProgramVeronicaOklahoma
managers for the centerCline and Pat Harris of
City Air Logistics Center.
arethe
Navy Report Details MethodsFor Automating Factories
Advanced Processing of ElectronicsMaterials in the United States
and Japan
This state of the art review considerssurface processing which is the drivingtechnology for semiconductor electronics. This 42-page report is worth obtaining and reading for those interestedin electronic manufacturing.
Surface modification is at the heart ofthe semiconductor processing industry.The trend for future devices is towardsmaller structures embodying di fferentcombinations of electronic and opticalmaterials. Such structures can only befabricated with techniques that have theprecision to tailor materials on thesubmicrometer level. This again is theregime of surface processing.
The report, entitled Best Practices: Howto Avoid Surprises in the World's MostComplicated Technical Process, presentsinsider's tips for implementing advancedautomation technologies while avoidingpitfalls of conventional Department ofDefense (000) policies. The 316-pagereport was produced by the Government'sDefense Science Board Task Force on theTransition from Development to Productionheaded by W. J. Willoughby Jr.
This report includes a checklist at theend of each section to aid both theproject manager who wants to takeadvantage of best practices and thereviewing authority who wants to ask theappropriate questions. Below is thechecklist that follows sections onCAD/CAM. All questions should be answered"yes" according to authors of the report:
o Is CAD use dictated by corporate policy?
o Are individual alphanumeric terminalsavailable for each design engineer?
It appears that the United Statesholds the technological edge inestablished areas:
o Ion implantation
stillthree
o Are interactive graphics terminals provided for groups of engineers?
o Does a formalized training program existfor introducing engineers to CAD?
o Is a command and up-to-date base available containing parts and materials information as well as design engineeringinformation?
o Is CAD oriented to support all productlines?
o Is CAD included in overall corporatemodernization strategy?
o Does a corporate policy exist on thephase of CAM and other factory modernization initiatives.
o Does an integrated implementation planensure a top-down strategy for introducing CAM.
o Does a common data base exist that includes the entire plant operation?
o Is reduction of manual operationsemphasized?
This report (NAVSO P-0671) can be orderedfrom: Superintendent of Documents, U.S.Government Printing Office, Washington, DC20402
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o Thin film expitaxy (chemical vapordeposition, molecular beam epitaxy andmetallo-organic chemical vapor deposition)
o Film deposition and etching
The panel concluded that Japan leads on:
o Optical lithography
o Microwave plasma processing
o Lithographic sources
o Electron and ion microbeams
o Laser-assisted processing
o Compound semiconductor processing
o Optoelectronic integrated circuits
o Three-dimensional device structures
Copies of this report are available fromThe National Materials Advisory Board,2101 Constitution Avenue, N.W., WashingtonDC 20418.
Manufacturing Cost Estimates
•
Automated Brush Deburring
The project produced two automated deburrsystems. One is a long, linear part-feed"carwash" system and the other is a floormounted, single-arm robotic system for thesmaller parts the robot arm can reach.Optimized manufacturing process parametershave also been established. Specifications to guide others in the acquisitionof similar deburr systems are available.
Use of the carwash style deburr system cansave up to 33% in labor hours. Eliminating the tumble deburr process broughtmonthly savings of $2,500 in deburringmedia and approximately $30,000 in laborcost. Improved parts quali ty, increasedfatigue life, and improved throughput arereported. Implementation costs of thesystem were $125,000 with a 3.6 monthpayback.
The obj ecti ve of this Air Force MANTECHfunded project was to implement an automated brush for deburring machined aircraftparts. Traditional methods are inconsistent, labor-intensive, time consuming andlong recognized as a costly aircraftproduction requirement. AVCO Corporationof Nashville, Tennessee completed thisproject successfully by reducing cost,improving quality and eliminating a dirty,tiring job.
The Society of Manufacturing Engineers(SME) is offering a computerized costestimating system called MiCAPP. Thesoftware contains a series of 18 computerprograms tied together with filingsystems.
Cost estimating is one of the latestaspects of manufacturing to be computerized, and procedures are available for 80machines. Operations include turning,drilling, milling, boring, honing, broaching, and grinding. The cost estimatingconsiders:
o Speeds and Feeds: calculated and adjusted as necessary for materialhardness
o Material Selection: the menu selectsfrom 14 major material groups
o High Speed Steel and Carbide: eithercan be selected
o Plus: error checking routines; learning curves; up to nine different lotsizes for each part, and much more!
To learn more about MiCAPP contact JillBova, SME Educational Services, P.o. Box930, Dearborn MI 48121; 313/271-1500.
Data & Analysis Center forSoftware (DACS)
The DACS is chartered to serve governmentand industry as a center for exchangingand disseminating technical data and information concerning software technology.
Contact Proj ect Engineer: Lee R.AFWAL/MLTM (F33615-82-C-5117),3612.
Material Handling Video
Gulley,513/255-
The products and services provided by theDACS are varied. Typical products includesubsets of the Software Life Cycle Empirical Database (SLED), data compendiums,analysis reports, bibliographies, newsletters, and technical monographs. DACSservices include accumulating, maintaining, and tailoring data subsets for software engineering and software technology;and special technical studies whichinclude technology assessments, criticalreviews, and state of the art surveys:
For further information contact: Data &
Analysis Center for Software, RADC/COED,Griffiss AFB, New York NY 13441-5700;315/336-0937.
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Material Handling, a videotape in theSociety of Manufacturing Engineer'sManufacturing Insights series is nowavailable. Trends in technology, materials handling operation, an anticipatedadvancements that will keep manufacturingon the move are studied. Actual in-plantscenes featuring advanced applications areshown.
Tapes can be purchased individually or ina yearly, four-tape subscription. Societyof Manufacturing Engineers, Video Communications Department, One SME Drive, P.O.Box 930, Dearborn MI 48121.
the role forbeen tradethe workingCenters.
DoD lAC Meeting
On 21 July 1987 the annual 000 InformationAnalysis Center's Business Meeting washeld at the Applied Physics Lab of JohnsHopkins University. Approximately 50 people representing the lACs and variousgovernment agencies participated. MTIAC,one of 25 000 lACS was represented by TomTurner, retiring director, Bob Walk, newMTIAC Director, and Michal Stevens, MTIACInformation Specialist.
This meeting provided an opportunity tohear from Defense Technology InformationCenter (OTIC) about the lACS role andplans for the future. One of the maj orbenefits of this meeting is the opportunity for the lAC monitors and interestedstaff to interact. A directory of the DoDlACs is available from OTIC, CameronStation, Alexandria, VA 22304-6145.
Learning Curves
Everyone talks about learning curves butlimi ted attention is paid to them. Theconcept is simple--for every doubling inproduction quantities cost can be reducedby a given percent. For many products 20%has been found to be applicable, i.e., forevery doubling of production, labor costsare reduced by 20%.
The Air Launched Cruise Missile (ALCM)Program Office and the contractor Boeinghave been striving to reduce costs. "Theseefforts resulted in a lowering of factorylabor from 8000 person hours for the firstpilot production vehicle to about 880hours by the one thousandth missile--areduction of 89%. If one accepts a 20%learninq curve, the labor reduction ingoing through 10 doublings of quantityfrom 1 to 1024 would be 89. 3%--the 89%reported is right on the money.
Boeing and the ALCM Program Office havedemonstrated that learning curves stillwork, and ,provide excellent documentationon which to base use of 20% for missiles.With these data, similar targets should beset for other missiles. The learningcurve cost savings require work but theyare realistic targets.
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BOOKS
ASQC PUBLlCATlalS CATALffiThe American Society for Quality Control
This annual catalog covers 375 books andother publications. For those interestedin quality this signi ficant resource isavailable from ASQC, 310 West WisconsinAve, Milwaukee WI 53202.
ZERO QUALITY CONTROLShigeo Shingo
Productivity Press, 1986ISBN-0-915288-07~0
Zero Quality Control: Source Inspectionand the Poka-yoke Systems; a 305-page bookdescribing techniques for producing 100percent good parts.
THE ROLE OF MANUFACTURING TECHNOLffiYIN TRADE ADJUSTMENT STRATEGIES
Manufacturing Studies BoardNational Academy Press, 1986
This 52-page report evaluatesthose companies that haveimpacted. It also considersof Trade Adjustment Assistance
JUST IN TIME MANUFACTUREIntI Trends in Mfg Technology
C. A. Voss, editorIFS (Publications) Ltd, 1987
ISBN 0-948507-49-7
This 398-page collection of 31 articles isan excellent introduction to JIT.
SENSORS AND ACTUATORSState of the Art of Sensor R&D
S. Middelhoek and J. Van der Speigel,Elsevier Sequioia S.A. Lausanne, 1987
ISBN 0-444-75065-7
Twenty-two invited papers by internationalauthorities. A 42S-page ready referenceto sensors R&D. Includes technical introductions and reference lists for furtherstudies.
MANUFACTURING TECHNOLffiYManufacturing Studies Board
National Academy Press, 1987
This relatively general and philosophical36-page report is for those interested inmanufacturing of DoD products.
MEETING CALENDAR
NOVEMBER
5TH INTERNATIONAL STRUCTURAL ADHESIVEBONDING SYMPOSIUMMilitary/Government-Industry, Nov 3-5,Dover NJ ••• Contact 703/522-1820
TOOL AND MANUFACTURING ENGINEERINGCONFERENCE AND EXPOSITIONSME, Nov 3-5, St Paul MNContact: 313/271-0023
INTEGRATED COMPOSITES CENTER EXECUTIVEBRIEFINGU.S. Air Force & McDonnell Douglas,Nov 5-6, Tempe AZ ••• Contact: 602/965-1740
INTEGRATED SYSTEMS CONFERENCElIE, Nov 5-7, Nashville TNContact: 404/449-0460
AUTOFACT '87SME and CASA/SME, Nov 9-12, Detroit MIContact: 313/271-1080 or 0023
TOOL AND MANUFACTURING ENGINEERINGCONFERENCE AND EXPOSITIONSME, Nov 10-12, Chicago ILContact: 1-800/535-8005
MACHINE VISION FOR PROCESS CONTROL ANDMONITORING CLINICSME and AMTDA, Nov 17-19, Cincinnati OHContact: 313/271-1500 or 301/654-1200
DECEMBER
19TH ANNUAL MANUFACTURING TECHNOLOGYCONFERENCE (MTAG '87)DOD, Dec 1-4, San Diego CAContact: D. Fabry 215/897-6684
COMPOSITES IN MANUFACTURING 7CoGSME,Dec 7-10, Long Beach CAContact: 313/271-0777
STATISTICAL PROCESS CONTROL COURSERADC/RAC, Dec 7-10, Orlando FLContact: 315/330-4151
DESIGN RELIABILITY TRAINING COURSERADC/RAC, Dec 7-10, Orlando FLContact: 315/330-4151
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MACHINE VISION IN ELECTRONICSMANUFACTURI NGEM/SME, Dec 8-10, San Jose CAContact: 313/271-1500 (ext 393)
ADVANCED MANUFACTURING SYSTEMS EXPOSITIONAND CON FERENCECahners Exposition Group, Dec 15-17,Anaheim CA ••• Contact: 312/299-9311
JANUARY
REPTECH '88Wright Patterson AFBJan 25-27, Salt Lake City, UTContact: 513/426-8530
TOOL AND MANUFACTURING ENGINEERINGCONFERENCE AND EXPOSITIONSME, Jan 26-28, Charlotte NCContact: 313/271-0023
LOGISTEX '88MHI, Jan 26-28, Anaheim CAMar 15-17, Baltimore MDContact: 704/522-8644
FEBRUARY
ADVANCED MACHINING TECHNOLOGY (AMT II)SME, Feb 16-18, Phoenix AZContact: 313/271-1500 (ext 356)
MARCH
9TH ANNUAL CONFERENCE AND EXPOSITION ONCOMPUTER GRAPHICS APPLICATIONSNCGA, Mar 20-24, Anaheim CAContact: 703/698-9600
WESTERN METAL AND TOOL EXPOSITION ANDCONFERENCESME, Mar 21-24, Los Angeles CAContact: 313/271-0023
APRIL
LASER SURFACE MODIFICATION: WELDING SHOWAWS, Apr 14-15, New Orleans LAContact: 305/443-9353
ADVANCED MANUFACTURING SYSTEMS EXPOSITIONAND CONFERENCECahners Exposition Group, Apr 19-21,Chicago IL ••• Contact: 312/299-9311
End-of-Contract Demonstration Calendar
One of the important steps in a 000 Manufacturing Technology proj ect is the End-ofContract Demonstration. On this occasion, the contractor or agency which has developedand/or applied the technology puts on a demonstration of the equipment and processesinvolved.
The following calendar of events has been compiled by the staff at MTIAC. It is alsoavailable on-line to MTIAC users through the MTIAC Manufacturing Technology ProjectsData Base (MTPDB). The data base is updated at intervals.
1987 PROJECT
OCT ARMY17471
OCT NAVY - SEA 06S0806
OCT NAVY - SEA 05S0901
NOV ARMY50926
NOV ARMY54633
TITLE & LOCATION
Process Control System tor NC and CNC Machine
Laser Articulating Robotic System (LARS)MrS Systems, Minneapolis MN
Numer Ic Contro II ed Structura I ShapesProcess CenterBath Iron Works, Bath ME
MMT for XM22 Chemical Agent Alarm System
Auto Sensor Systems Test F/MMW and IR Sensor
PO INT OF CONTACT
J. Wong617-923-5340
W. L. ChrIstensen215-897-6684/AV 443-6684
W. L. Christensen215-897-6684/AV 443-6684
R. Leblanc301-671-4424
R. HII I
201-724-5525
NOV
NOV
NOV
DEC
DEC
DEC
DEC
DEC
DEC
DEC
AI R FORCEF33615-84-C-5015
NAVY - AIR
NAVY - ASN MoL
ARMY58518
ARMY68511
ARMY68633
AIR FORCEF33615-84-C-5012
AIR FORCEF33615-84-C-5137
NAVY - ASN S&LM0516
NAVY - AIR
Improved Ultrasonic Eaulpment Rei labl I Ityand ProduclbilityNortec, Kennewick WA
Solid State Data Annotation Write HeadsOptotek, Ottawa, Canada
FabrIcatIon of FIber Reinforced Metalsby Ion PlatingCordec Corporation, Washington DC
Thin Film CoatIngs for Laser Eye Protection
Ole Casting of Antlfrlctlon Metal Components
A Three-Dimensional Noncontact Measuring System
ManUfacturing Technology for AdvancedDispenser CathodesSemlcon Associates, Lexington KY
Flexible Assembly Subsystem IntegrationRohr Indus, Riverside CA and Grumman, Bethpage NY
Promote the BCL Standard In the DoDNaval Weapons Center, ChIna Lake CA
Ion Beam LithographyHughes Research Labs, Mal lbu, CA
7
Edward Wheel er513-255-5037/AV 785-5037
W. L. ChrIstensen215-897-6684/AV 443-6684
W. L. Christensen215-897-6684/AV 443-6684
E. Mlchonskl201-724-6276
C. Cardenas309-782-1488
W. Garber518-266-4231/AV 974-4231
BII I Schul z513-255-2232/AV 785-2232
Ted Brandewle513-255-7371/AV 785-7371
W. L. Christensen215-897-6684/AV 443-6684
W. L. Christensen215-897-6684/AV 443-6684
Copies of the summaries of papers referenced in this and future Bulletins are not available from MTIAC. For copies ofthe source articles, you may refer, depending on the nature of the material to:
National Technical Information Service (NTIS) Defense Technical Information Center (OTIC)U. S. Department of Commerce Cameron StationorSpringfield, VA 22151 Alexandria, VA 22314
(800) 336-4700 (202) 274-7633
or
The publisher of the journal in which the document appeared.
MTIAC Products and Services
MTIAC's objective is to collect, analyze and disseminate timely information on the characteristics and utilization ofmanufacturing technology for the production of defense materiel. Its services are available to all sectors of governmentand industry within the limitations of the contract. The Center's principal services include:
Technical advice and assistanceAccess to bibliographic data, data bases and reference sources
Written reports in the form of technology assessments, state of the art reviews and handbooks
MTIAC is a full-service information analysis center managed by Cresap, McCormick and Paget Division of TPF&C, Inc.,a firm which provides technical services to government and industry. The principal sub-contractor is the lIT ResearchInstitute, one of the largest not-for-profit research organizations in the United States.
MTIAC is able to draw on the expertise of both organizations to
• conduct searches for manufacturing technology information
• answer technical inquiries
• conduct studies within its established scope
An initial inquiry and quick response to determine available data can be accommodated at no charge. For furtherinformation call MTIAC at 312-567-4730 and request an informational brochure.
Robert A. WalkDirector
All data and information herein reported are believed to be reliable; however no warrant, expressed or implied, is to beconstrued as to the accuracy on the completeness of the information presented.
The MTIAC Current Awareness Bulletins are prepared under the sponsorship of the Department of Defense, underContract DLA-900-84-C-1508 and are available only to qualified U. S. users. Some of the reports referred to in this andsubsequent issues may be subject to current U. S. export control laws and regulations.
Manufacturing Technology
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Distribution Clarification
AMMTIAC REVIEW
Reviewer’s Explanation: The rights and the Distribution Authority to all IAC publications reside with the Defense Technical Information Center (DTIC) and the appropriate IAC. As the proprietor of these publications, AMMTIAC reviewed the past Current Awareness Bulletins for distribution limitations and found them to contain open/unlimited information consistent with a public release newsletter (Distribution Statement A). In the absence of a clearly recognized distribution statement and conforming to the IAC intent to disseminate unlimited information through a newsletter, AMMTIAC has marked this publication with the distribution statement:
“Approved for Public Release; Distribution is Unlimited”.
