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Cover image for Next generation manufacturing : methods and techniques
Title:
Next generation manufacturing : methods and techniques
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Publication Information:
New York : John Wiley, 2000
ISBN:
9780471360063
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30000004467456 HD9720.5 J67 2000 Open Access Book Book
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30000005170364 HD9720.5 J67 2000 Open Access Book Book
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Summary

Summary

During the 1990s, an ambitious three-year research program identified the steps manufacturing companies must take to become globally competitive. The prestigious Next Generation Manufacturing (NGM) Project combined the insights and perspectives of business and academia's most astute thinkers. It featured the cumulative experience of over thirty top global manufacturing firms, the Agility Forum, the engineering and management schools of the Massachusetts Institute of Technology, and the Oak Ridge Centers for Manufacturing Technology, as well as many other highly regarded organizations. The Project resulted in a vision for the future of manufacturing and a framework for action.

Next Generation Manufacturing is the first book to cover the NGM Project and its recommendations for creating and maintaining a successful manufacturing enterprise. It describes how manufacturing is continuing to evolve and the significant changes companies must make to remain competitive in the next decade.

Addressing the dilemmas faced by today's corporate management, the authors walk the reader through strategies for meeting corporate goals and the expectations of customers; the techniques and tools available to achieve them; and how to define success through measurements. They offer a comprehensive program for applying the product development techniques, metrics, and knowledge management approaches for stellar manufacturing.

Vital to next generation manufacturing is understanding the roles of innovation, knowledge, and people in ensuring the competitive readiness of a company. The book identifies the strategies to achieve this, including:
* Build a strong workforce
* Develop and implement advanced knowledge processes
* Use advanced manufacturing systems, processes, equipment, and technology
* Integrate competitive strengths

Included are real-world examples from participating firms in the NGM Project that have achieved NGM attributes, such as Chrysler and Boeing, as well as a full-length hypothetical case. Also provided are the methodologies for making a high-quality product at the lowest possible cost and getting it to market in the shortest possible time.

The authors have extended the work of the NGM Project by developing ways to link NGM with corporate strategic goals for achieving and sustaining profitability. They expand the concepts of NGM by covering management and financial issues that, until now, have not been fully addressed. The authors also provide a glimpse into the future, examining where manufacturing may be headed beyond the next decade.

For any manager or owner concerned about the long-term survival of their manufacturing enterprise, Next Generation Manufacturing provides the knowledge, strategies, and tools necessary for achieving success in the twenty-first century.

Praise for
NEXT GENERATION MANUFACTURING

"Jordan and Michel capture the diverse and often conflicting concerns of manufacturing business leaders worldwide. . . . The lessons [in this book] have widespread application in companies of almost any size."-Professor Peter Sackett, Head of Department, Cranfield University

"Throughout history, manufacturing of flint arrowheads to sophisticated computer chips has been a mainstay of societal growth. Indeed, technology epochs have been named for significant occurrences; e.g., the Industrial Revolution, manufacturing productivity fueled by mass production technology. We are now witnessing the start of one of these rare epochs, the Knowledge Age, manufacturing productivity fueled by information and knowledge technology. Next Generation Manufacturing provides an exciting insight into this emerging epoch; an easily read, accurate, and insightful book on manufacturing history in the making."-Gene Meieran, Intel Fellow, Intel Corporation


Author Notes

JAMES A. JORDAN Jr. is cofounder and President of NGM Knowledge Systems, an educational and management consulting firm for manufacturing companies. Before founding the company, Jordan participated in the NGM Project and in other advanced manufacturing R&D projects. Jordan is the author of numerous papers and patents.

FREDERICK J. MICHEL is cofounder and Executive Vice President of NGM Knowledge Systems. With more than forty years of experience in program management, product design, manufacturing, and product support, he also participated in the NGM Project. Michel is a board member of the Society of Manufacturing Engineers.


Table of Contents

Chapter 1 Manufacturing Excitement!p. 1
Challenges and Rewards for Leaders of Manufacturingp. 7
The Major Themesp. 8
Into the Weekp. 16
Notep. 16
Chapter 2 The New Competitionp. 17
Monday, 8:00 AM: Today's Challenges and Dilemmasp. 17
Monday, 9:00 AM: The Market Forecastp. 18
Global Drivers of the Futurep. 19
Exercisep. 26
Notep. 26
Chapter 3 Meeting Balanced Corporate Goalsp. 27
Monday, 10:00 AM: Building a Visionp. 27
Goals and Strategies for Next Generation Manufacturingp. 28
The Roadmap: Four Operational Strategiesp. 36
Exercisep. 40
Notesp. 42
Chapter 4 From Operational Strategies to Implementation Substrategiesp. 43
Monday, 11:00 AM: Building a Structure for Choicep. 43
The NGM Framework for Actionp. 43
Summaryp. 59
Exercisep. 59
Notesp. 60
Chapter 5 Organizing the Company for Next Generation Manufacturingp. 61
Complexity Theory and NGM Company Organizationp. 65
Leadership and Managementp. 67
The NGM Company within the Communityp. 71
Globalization of Communityp. 73
Exercisep. 73
Notesp. 74
Chapter 6 The Voice of the Customer--Againp. 75
11:30 AM: Lunch with Hawkp. 75
Exercisep. 78
Chapter 7 Product Realizationp. 80
Monday, 1:05 PM: Facing a Changing Marketp. 80
Characteristics of Rapid Product and Process Realization (RPPR)p. 82
Exercisep. 86
Chapter 8 Integrated Product and Process Development (IPPD)p. 88
IPPD--A Structured Processp. 89
Using QFD to Structure Communication in IPPDp. 90
Essential Elements of IPPDp. 94
Better, Faster, Cheaperp. 113
Exercisep. 114
Notesp. 114
Chapter 9 Modeling and Simulationp. 116
Tuesday, 1:30 PM: Seeing the Futurep. 116
Introducing Modeling and Simulationp. 117
The Evolving State of the Art of Modeling and Simulationp. 120
Modeling and Simulation in the Manufacturing Enterprisep. 126
Summaryp. 138
Exercisep. 138
Notesp. 138
Chapter 10 Next Generation Processes and Equipmentp. 139
Monday, 2:30 PM: Turning to Physical Realityp. 139
Connected Factory Systemsp. 139
Sensors and Actuatorsp. 142
Quality, Maintenance, and Safetyp. 145
Development of Processes and Equipmentp. 149
Understanding Manufacturing Processesp. 151
Controllersp. 157
Advanced Processes and Equipmentp. 160
Exercisep. 168
Notesp. 169
Chapter 11 Extended Enterprise Collaborationp. 170
Monday, 3:15 PM: 2[superscript 2] = 9p. 170
Product Realization in Extended Enterprisesp. 172
The Evolution to Networked Extended Enterprisesp. 174
Collaboration and Core Competenciesp. 182
Legal and Financial Facilitatorsp. 188
Ethics and Trustp. 192
A Process Model for Networked Extended Enterprisesp. 196
Monday, 5:00 PM: To the Supplier Council Dinnerp. 204
Exercisep. 205
Notesp. 206
Chapter 12 Systems Support for Extended RPPRp. 208
Product Datap. 209
Product Developmentp. 210
Advanced Planning and Schedulingp. 213
Manufacturing Execution Systems (MES)p. 216
Enterprise Resource Planning (ERP)p. 218
Summaryp. 221
Notesp. 221
Chapter 13 The Innovative NGM Companyp. 223
Tuesday, 9:00 AM: Facing the New Worldp. 223
Innovationp. 225
Building an Innovation Culturep. 229
The Language of Innovationp. 232
Managing for Innovationp. 236
Enabling Innovationp. 238
Innovation Investment Strategiesp. 245
Innovation in an Extended Enterprisep. 247
Tools for Innovationp. 247
Summaryp. 250
Exercisep. 250
Notesp. 253
Chapter 14 Managing and Measuring Changep. 254
Creating the Environment for Changep. 256
The Ups and Downs of a Changep. 259
The Characteristics of Changep. 261
Change Considerationsp. 264
The Steps of Changep. 268
Exercisep. 277
Notesp. 278
Chapter 15 The Knowledge Enterprisep. 279
Tuesday, 10:30 AM: Knowledge--The Competitive Edgep. 279
The Knowledge Enterprisep. 279
Knowledge Sourcesp. 287
Knowledge Supply Chainsp. 291
The Knowledge-Ready Workforcep. 298
Concurrent Educationp. 299
Knowledge Repositories and Delivery Technologyp. 300
Exercisep. 302
Notesp. 303
Chapter 16 Working in the NGM Companyp. 304
Tuesday, 1:30 PM: A Different Workforcep. 304
Pressures on the NGM Workplacep. 304
Impacts on Peoplep. 305
Key Concerns for Human Resource Managementp. 309
Risk and Rewardp. 319
Life-Long Learning: A Culture of Inquiryp. 323
New Social Contractsp. 333
Summaryp. 338
Exercisep. 338
Notesp. 339
Chapter 17 Information Systems Integrationp. 341
Wednesday, 9:00 AM: The Electronic Interstatep. 341
Evolution of Information Systemsp. 342
Global Manufacturing Networksp. 346
User Interfaces and Toolsp. 373
Exercisep. 378
Notesp. 378
Chapter 18 Measuring the NGM Companyp. 380
Wednesday, 1:30 PM: How Good Are We?p. 380
Strategic Goals and Metricsp. 380
Achieving Strategic Goalsp. 390
Exercisep. 393
Notesp. 393
Chapter 19 Integrating the Enterprise for Next Generation Manufacturingp. 394
Wednesday, 4:00 PM: The Bottom Linep. 394
Integrating the Workforcep. 394
Key Enablers of Enterprise Integrationp. 399
Summaryp. 405
Exercisep. 406
Notep. 407
Chapter 20 Into the Futurep. 408
Manufacturing 2010p. 408
Beyond NGM: Competing in a Tightly-Coupled Worldp. 410
Transforming Technologies for Manufacturingp. 412
The Environmental Imperativep. 414
Modeling the Extended Enterprisep. 419
The Neighborhood Factoryp. 420
The End of the Week at BAIp. 422
Notesp. 422
Indexp. 423
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