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The Economic Impact of Technology Infrastructure for Smart Manufacturing

 

Smart Manufacturing Gary Anderson (gary.anderson@nist.gov)
Technology Partnerships Office, Innovation & Industry Services

October 2016

 

Key Findings

  • Novel smart manufacturing technology infrastructure would save manufacturers $57.4 billion annually.
  • Barriers to innovation increase the cost of smart manufacturing R&D, weaken private investment incentives, and magnify the role of public institutions.
  • Overcoming critical technical barriers may require investments in public-private manufacturing consortia.
  • Small enterprises face significant barriers to adoption of smart manufacturing technology.

The full report may be found here:

http://nvlpubs.nist.gov/nistpubs/eab/NIST.EAB.4.pdf

The IMS Fall newsletter is available for download below. In this issue: “IMS PROJECT CLUSTERS LAUNCHED”, a report on the “INDUSTRIALLY ROBUST AM CHAIN”, and manufacturing news and commentary of global interest.

Download

ims-fall-newsletter-2016

 

Currently in the planning stages, IMS-USA will conduct a workshop to form new project clusters under Industry 4.0 topics. We are in the process of selecting topics and searching for relevant research. If you have any interest under this topic, please contact your local IMS office or write to Dan Nagy, Managing Director, at dnagy@ims.org. The event will be held in the United States.

More information will be posted as it becomes available.

The Korean Ministry Industry, and Energy (MOCIE) through KAIT, “Korea Association for ICT” will be sponsoring the “2016 Korea Research and Development Exhibition in Seoul, Republic of Korea, on 17 November 2016. IMS will send a delegation and speak about global cooperation through its project clustering program at the event. More information will be posted when available.

Currently in the planning stages, IMS will hold a follow-up workshop for it’s Additive Manufacturing project clusters and will launch new clusters under Industry 4.0 topics. We are in the process of selecting topics and searching for relevant research. The workshop is planned to be held in South Africa in conjunction with a major manufacturing conference. If you have any interest under this topic, please contact your local IMS office or write to Dan Nagy, Managing Director, at dnagy@ims.org.

More information will be posted as it becomes available.

IMS Additive Manufacturing Cluster Report

Industrially Robust AM Chain

Prabir Chaudhury, Global Metals Technology Director Designate

Exova

The objective of the cluster is to develop an industrially robust Metal Additive Manufacturing (MAM) supply chain in order to establish MAM as a global mainstream manufacturing technology. Work will include development of cost effective and performance specific raw materials, testing and qualification protocols, generation of design properties database, enhancement of machine capabilities, and identification of NDT techniques and in-situ quality testing. This cluster will also examine (a) the opportunities in use of low cost powder via machine enhancement or by using novel processing techniques and (b) enhancement of MAM surfaces for net shape manufacturing. This cluster will involve users of the MAM technology and its supply chain from raw material to finished and qualified metal parts. This report is a short synopsis of the discussion in Barcelona on May 2nd and a tentative plan arising from the discussions. The intention of this report is to inform the members about the opportunities and scope of the Cluster to put together a comprehensive plan for future collaboration.

Cluster Formation: At the IMS meeting in Barcelona on May 2nd, the Industrially Robust AM Chain cluster was formed based on the review of exploitable results (ERs) from the AM enthusiasts around the globe and interests shown by participants at the workshop.  A total of 54 participants from US, EU, MX, and SA attended the workshop, 39 ERs were reviewed from three disciplines (Metal Parts, Polymer-Ceramic-Biomaterial Parts, and General Technologies), and 6 Clusters were established for further by the attendees. Industrially Robust AM Chain was one of the three in metals AM area. Interested participants from US, EU, SA, and MX joined together to form this cluster. Table below shows all the clusters formed and respective regional leads.

 

Cluster Name Champion Leads
USA EU SA MX
Industrially Robust AM Chain Prabir Chaudhury (EXOVA) Jeff Grabowski (QuesTek) Paolo Calefati (BOREALIS) Hardus Greyling (CSIR) Cortez Dante (FRISA)
Metals for AM David Wimpenny (AMAZE) Luis Portoles (NANOTUND3D) Dimitri Dimitrov (S. UNIV) Villarreal Gilberto (SISAMEX)
Titanium Aero Structures AM Daniel Safranchik (AATID) Federico Sciammarella (NIU) David Gonzalez Fernández (FOFAM) Willie du Preez (CENT. UNIV)
BioAMplant/IAMI Dirk W. Grijpma (RAPIDOS) Dirk W. Grijpma (RAPIDOS) Gerrie Booysen (CENT. UNIV) Leopold Ruiz (UNAM-MADIT)
Assistive Tools for Extending AM Paula Queipo Rodríguez (FOFAM) Paula Queipo Rodríguez (FOFAM) Deon De Beer (NW UNIV) Hugo Medellin (UASLP)
AM Knowledge Based Decision Support for Industry Jens Pottebann Hans Van Toor (MANSYS)

 

 

Cluster Members: Seven teams from all regions of IMS made commitments to join this cluster and discuss the scope and immediate actions for the cluster. The seven teams are: Questek, Exova, AMAZE, Borealis, NDTLBM, FOFAM, and MANSYS. The following Table shows the names of the representatives from each team and their contact information:

 

 

Region Last Name First Name email Organization Role
EU Wimpenny David David.Wimpenny@the-mtc.org MTC Chief Technologist
EU Calefati Paolo paolo.calefati@primapower.com Prima Industries Innovation Manager
EU Buining Henk Henk.Buining@tno.nl TNO
EU Valente Anna Anna.valente@supsi.ch SUPSI Head of Industrial Robotics Systems for Adv. Manufacturing
US Grabowski Jeff jgrabowski@questek.com QuesTek Innovations, LLC Applications Manager
US Chaudhury Prabir prabir.chaudhury@exova.com Exova Technical Director
MX Cortez Dante dcortez@frisa.com FRISA Manager
MX Tijerina Abraham abraham.tijerina@metalsa.com METALSA Manager
SA Greyling Hardus hgreyling@csir.co.za CSIR National Laser Centre Manager: Com & Nat Programs

 

Cluster Discussion: The team of seven committed cluster members discussed the scope of this cluster and came up with the cluster name as Industrially Robust AM Chain. Then a cluster champion was selected and regional cluster leads were identified as shown above. The members decided to incorporate related ERs from the present members and discuss the scope of the cluster. The team also discussed focus on large structures versus small pars limited by the current mahines. It was decided to focus on both large strauctural and small parts in this cluster. Based on these discussions, the goals and objectives were identified as shown below in the order of AM chain from raw material to finished products:

  • Develop new AM alloys for specific performance requirements in various industries
  • Explore machine modifications to use low cost, such as non-spherical powder in powder-based AM processes
  • Develop AM materials property database for design engineers
  • Explore in-process and post processing surface finish enhancement opportunities
  • Develop testing and qualification protocols for process, machine, and product for various industries
  • Investigate in situ quality assurance opportunities
  • Explore Non-Destructive Testing (NDT) techniques for product acceptance.

Action Plan: Although the team discussed technical action plans at the cluster meeting, it is felt that first and foremost we need to focus on organistional action plan. Therefore, the action plans are divided into organizational and technical actions in the order of priority and execution.

Organizational Actions:

  • Develop the Memorandum of Agreement (MOA) for all partners to sign. This will be done by the regional leads by August, 15 2016.
  • Sign the MOA – All current patners by August 31
  • Recruit additional partners for the cluster from the AM supply chain including: AM alloy developers, powder and rod producers, AM machine developers, AM prototype and part manufacturers, AM product designers and users (OEMs), AM database developers, process and product analysis software developers, destructive and non-destructive testing laboratories, standards agencies, accreditation agencies, and others service providers. This work will be on-going and will be reported regularly at cluster meetings.
  • Coordinate technical actions with other cluster programs to avoid duplication and enhance complementary work.

Technical Actions:

  • Research current machine capabilities for use of low cost, non-spherical powders
  • Research current AM methods for production of large structures
  • Foster collaboration with international standards bodies.
  • Devlop a comprehensive technical program for funding from international sources covering the following issues globally:
    1. Develop new alloys for Aerospace, Energy, Gas and Oil, Automotive, and Medical sectors based on AM process characteristics
    2. Collaborate raw material suppliers for new AM alloys
    3. Develop AM material standards and specifications with international standards bodies
    4. Develop material properties database for engineering design and material and process selection
    5. Develop qualification protocols and standards for AM processes and mchines
    6. Develop protocols and standards for product testing and qualification
    7. Develop NDT methods for in-process and post processing quality assurance
    8. Develop in-process and post processing methods for surface enhancement
    9. Develop AM machines to use low cost raw materials.

Conclusion: Industrially Robust AM Chain cluster is established for international collaboration to rapidly develop AM industry supply chain and assist in global acceptance of AM as a mainsteam manufacturing process.

Following the success of the 2015 event, the 3rd annual Manufacturing Indaba will be held on the 28 – 29 June 2016 at Emperors Palace in Ekurhuleni, South Africa. David Romero, IMS Project Coach, will give a speech regarding international cooperation at the event and the benefits to South Africa to expand beyond their borders.

South Africa’s economy is under pressure and as a result business confidence is in a decline.

The aim of the Manufacturing Indaba is to bring together business owners, industry leaders, government officials, capital providers and professional experts to discuss challenges and to brainstorm solutions. The success of South Africa depends on a strong and innovative manufacturing base working together to promote prosperity through manufacturing, science and innovation.

For more information, please visit http://manufacturingindaba.co.za .

IMS International Steering Committee: Adolfo Gonzales (MX), Garth Williams (SA), Abraham Tijerina (Chair), Robert Kiggans (Chair Emeritus), Dan Nagy (IRS), Clara de la Torre (EU), Kevin Carpentier (US)

Mr. Robert Kiggans, outgoing IMS Chair, was honored by the IMS International Steering Committee, key stakeholders,  and distinguished guests at a celebration event held in Mexico City at Piso 51 Club on 22 July, 2015. Bob, as he is known to his colleagues, was always pushing for more research and higher visibility of the organization. He quickly and strongly supported the concept of the World Manufacturing Forum. He also is known for his desire to promote the IMS concept of international collaboration and was always a tireless ambassador for the organization. We hope he will continue to do so on our behalf.

Mr. Dan Nagy, Managing Director, gave a review of accomplishments under the US Chairmanship including the addition of a new member, South Africa, the development of a highly successful program for the World Manufacturing Forum held in Milan, and the many meetings and conferences that IMS held and/or presented the organization to expand our mission. Mr. Kiggans dedicated many hours of his personal time to IMS, and in recognition, the International Steering Committee recognized him with an award.

Mr. Kiggans has a very long list of accomplishments including the following:

  • IMS Chair, 2012-2015
  • IMS US head of Delegation, 2004-2012
  • International Leadership Award by the American Society of Mechanical Engineers (ASME)
  • Chief Operating Officer of SCRA and President of its Federal Sector
  • President and CEO of ATI and General Manager of PDES, Inc., an international standards collaboration.
  • Vice President of SCRA and Director of the Advanced Technology Group.
  • Director for C3I Advanced Systems at Cincinnati Electronics.
  • Deputy Director, Information Science and Technology Office at the Defense Advanced Research Projects Agency (DARPA) where he supported the development of a multi-billion dollar computer/communications upgrade program. And while with the Air Force Strategic Air Command, he directed advanced computer technology initiatives, including development of a multi-million dollar automated executive information system.
  • He completed the Electronic Data Systems (EDS) System Engineering Development Program and became a software systems engineer for EDS.
  • Kiggans received a B.S. degree from The Citadel and an M.S. degree from the Air Force Institute of Technology.
  • He was a Research Fellow with the National Institute of Standards and Technology, a former senior member of the Society of Manufacturing Engineers, and a Tau Beta Pi Eminent Engineer.
  • He serves on the Board of Directors of the Association for Enterprise Integration; International TechneGroup, Inc., PDES, Inc.; the National Council for Advanced Manufacturing and the Silver Crescent Foundation.
  • Kiggans has been with SCRA for more than 25 years and his contributions to their Applied Research and Commercialization Programs, Innovation Centers and Research Parks helped SCRA generate a cumulative economic contribution of more than $13.7B to South Carolina since its inception in 1983.

 

Organized by the National Academy of Sciences “Defense Materials Manufacturing and Infrastructure (DMMI) Standing Committee”, the Mar 25-26 workshop on “Globalization of Defense Materials and Manufacturing” was opened by Dr. Mike McGrath in the prestigious Members Rooms at the National Academy of Sciences building in Washington DC. Screen Shot 2015-03-27 at 8.07.21 AM At the opening keynote speech Ruth David, CEO of ANSER, said that “We need to leverage what others are doing” setting the tone of the meeting for global collaboration.

Throughout the day some of the challenges heard from the IMS perspective included intellectual property protection when working in a collaborative environment, limited funding for research, and the difficulty in forming consortiums. Dan Nagy (International Office), Steve Ray (US), and David Romero (MX) explained how these concerns can be addressed and how sustainable manufacturing and cross-platform technologies can and should be developed collaboratively through the IMS program. They also presented some project success and opportunities that drew interest from both government and industry representativeIMG_3311_2s spurring off-line discussions for future collaboration. The full agenda and speaker bios are below.

The international event heard perspectives from industry, institutional, and government representatives from Australia, Mexico, Germany, United States, and United Kingdom. The companies and institutions that were represented included ANSER, ATI Metals, CSIRO, Fraunhofer, McKinsey, Pfahl Consulting, Rochester Institure of Technology, Rolls Royce, Office of Naval Research, United Kingdom Attache for Defense R&T, and Universal Technology Corporation. Although IMS is not a defense-related organization, many large manufacturers in the United States manufacture for the defense industry.

Downloads

Agenda for Globalization of Defese Materials and Manufacturing Final A rapporteur recorded and publish the event. The link will be shared when available.

Screen Shot 2015-05-05 at 12.56.55 PM

IMS has accepted an invitation to speak and meet with government officials at the annual South African Manufacturing Indaba that will take place 29-30 June 2015 in Johannesburg. Over 300 leaders from government and industry are expected to attend this two day event.

The organizers have assembled a website for review and registration. The event brochure is below.

IMS also plans to meet separately with business leaders and relevant government Ministers from the region to discuss international collaboration through IMS. South Africa is a member of IMS.

 

Download

MI Brochure 2015 (v3)

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