Lean Manufacturing and the Environment: Research on Advanced Manufacturing Systems and the Environment and Recommendations for Leveraging Better Environmental Performance doc

... Manufacturing and the Environment: Research on Advanced Manufacturing Systems and the Environment and Recommendations for Leveraging Better Environmental Performance Lean Manufacturing and the Environment ... between lean implementation and organizational environmental performance. Establishing the Link Between Lean and Environmental Improvement Research for this report indicates that environmental performance ... Section IIprovides background information on lean manufacturing, section III documents four keyobservations on the relationship between lean manufacturing and environmental management, and section...

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DRAFTWorkingPapersVersion040510a systems approachthatinvolvesfundingofmultipleactivitiesfrombasic research toprototypedevelopment,inanintegratedfashionisbest.DOE’sARPA‐Eprogramisonesuchprogramthathas the flexibilitytosponsorR&Dthatspansmultiplestages,frombasic research tocommercialization, and inareasthatareotherwisetoocross‐cuttingormulti‐disciplinarytofitinto the currentS&Tfundingsystem.123456789101112131415161718192021222324252627282930313233343536373839404142Createregulations and standardsettingin the areaof advanced manufacturing isanotherappropriaterole for S&Torientedagencies.ExpertsatNISTstatethatwhilehundredsofstandardsexist for ICs,almostnonedone for MEMs and othertechnologiesrelevant for advanced manufacturing. MEMS and evolvingnanotechnologyproductstendtobespecialized,customproducts; and lackofstandardscankeepcosts for newapplicationshigh, and hurtU.S.competitivenessbothindomestic and internationalmarkets(NISTMEL).16Depending on howtheyarestructured,regulations and standardsmayaddtocostofproduction,butcanalsospurinnovation.Thereareseveralexamplesin the environment domainwhereregulationstriggered the discovery and introductionofcleanertechnologies and environmental improvements.Build the physicalinfrastructure.AsGregTasseynotes,“whileproductscommercializedbased on newtechnologiesareprivategoods, the underlyingtechnologyplatforms(“generictechnologies”) and supporting“infratechnologies”arederivedfromacombinationofpublic and privateassets.”17Thisobservationisimportant for tworeasons.First,thatinfrastructureis the foundationthatcommercializedtechnologiesarebuiltupon and enablestheirdesign,development, and production, and, second,that the governmentcan and shouldplayaroleinfosteringearlyinvestmentinunder‐supported manufacturing infrastructureR&D,supplychainintegration, manufacturing systems integration, and technologymaturitylifecyclemanagement.Emergingfirmsthatlackdesignsupport,tools,matureprocesses, and technical and businessknow‐howmustdemonstratesomeplanorabilitytodeveloptheseinordertoattract the requisiteinvestmentcapitaltogetoff the ground.Existingfirmsmustconstantlyrefine and renew the technologyplatform and manufacturing processesthattheyemployinordertokeepupwithcompetitors,letalonecapturecompetitiveadvantage.Therefore, manufacturing infrastructureinnovationisseenasessentialtobothnew and existingfirms and wouldbenefitfromagovernmentcommitmenttoprovidingaccesstoworld‐bestR&D,processes, and technologies.Skill‐Building for Advanced Manufacturing Akeyfactorinrespondingquicklytocustomerneeds and developingnewprocesses and productsmorerapidly(twoimportantattributesof advanced manufacturing) isaworkforcethatisready for thesechallenges.Severalexperts,especiallyfrom the manufacturing industry,lamented the lackofappropriatelytrainedworkersfromU.S.institutions.Thisdearth(amongotherreasonstobesure)leadsthemtomanufactureelsewhere,especiallyAsia.Whenaskedifhiscompanywasbeingheldbackbyweakscience and matheducationinAmerica’sK‐12schools,PaulOtellini, the CEOofIntelcommented,“Asacitizen,Ihateit.Asaglobalemployer,Ihave the luxuryofhiring the bestengineersanywhere on earth.IfIcan’tgetthemoutofMIT,I’llgetthemoutofTsinghua.”Expertswithwhomwespokeindicatedthattoaid the UnitedStatesingrowingits advanced manufacturing economy and toovercometechnologicalchallenges,workersneedtobe better and moredifferentlyeducated. For example,inarecentreport,JamesDuderstadtof the UniversityofMichiganproposedthatundergraduateengineeringshouldbereconfiguredasanacademicdiscipline,similartootherliberalartsdisciplinesin the sciences,arts, and humanities,allowingstudentstobenefitfrom the broadereducationalopportunities for alifetimeoffurtherlearningratherthanprofessionalpractice.Simultaneously,engineering(or,perhapsmorebroadly,technology)shouldbeincludedin the liberalartscanonundergirdingatwenty‐first–centuryundergraduateeducation for allstudents.18 The governmentmayneedtoconsiderarangeofnewideassuchasthistorevampeducation for manufacturing relatedjobs.16NISTMELhomepagehttp://www.nist.gov/mel/,accessedJanuary29,2010.17GregTassey,“Rationales and mechanisms for revitalizingUS manufacturing R&Dstrategies,”op.cit.18JamesDuderstadt,“Engineering for aChangingWorld:ARoadmapto the FutureofEngineeringPractice, Research and Education,” The MillenniumProject,UniversityofMichigan,2008. ... DRAFTWorkingPapersVersion040510123456789101112131415161718192021222324252627282930313233343536373839404142434445464748 The industrysees the waytoovercomethiscost and complexityhurdleisthroughphotonicintegration.Assuch,threeclassesofdevicesrepresent the integrationin the photonicsworld. The planarlightwavecircuit(PLC)consistsonlyofpassivedevicesfabricatedfromtransparentmaterialsusingplanartechnology.Itisessentiallyopticalwiring and canperformsomesignalprocessingbutdoesnotalter the signal.TypicallyPLCmaterialsaresilica on silicon,polymers, and silicon on isolator(SOI). The industryhasusedthistechnologywidely for the last10years. The photonicintegratedcircuit(PIC)is the sameasaPLCbutalsoincludes on chipgeneration,modulation,alteration, and detection.Ithasbothpassive and activephotonicdevices(InPorGaAs‐based) and transparent and opaquesemiconductormaterialswithdifferentbandstructures and doping.Semiconductorwaferprocessingtechnologiesfabricate the opticalwaveguidedevices.PICscanbemonolithic,whereallof the devicesresideinonedie,orhybrid,wherecertaindevicesarephysicallyattachedtogetherontoacommonplatformtofunctionasoneunit.Thistechnologyrepresents the currentstate‐of the art, and whereindustryR&Disfocused. The optoelectronicintegratedcircuit(OEIC)is the sameasaPICbutincludes on chipelectronicstodrive the activeelements and provideelectricaloutputs.Itconsistsofphotonic and electronicdevicescombinedontoonechip and fabricatedusingsemiconductorprocessingtechnologies.Thisfuturetechnologyisone the industryhopestoachieve.Becauseof the largeexistinginfrastructure,siliconwouldbe the idealcandidate for photonicintegration.Althoughresearchershavefabricatedmostof the requiredactive and passiveopticalfunctionsinsilicon(Si), the fundamentalchallengehasbeenthatsilicondoesnotsupportalaser,anessentialcomponentin the opticalworld.Academic and industrialresearchershavedevisedcleverapproachestomitigatethisshortcomingofsilicon. For the mostpart,theyhaverelied on the indiumphosphide(InP)materialssystem for the laser. The problemwithInPistwofold—immatureproduction environment and concomitantly the lackofasharedcommonproductionapproach.First, the material and fabricationinfrastructureisimmature.TypicalwafersizesofInPare3inches,withleadingedgeat6inches.Siliconfabrication, on the otherhand,typicallyuses8‐or12‐inchwafers.Six‐inchtechnology for Siismanygenerationsold.Because the market for InPdevicesisrelativelysmall, the toolinfrastructurehasnotbenefitedfromahighlevelofinvestment.Second,InPdeviceshaveevolvedina manufacturing environment where the intellectualpropertyisembeddedin the process,ratherthan the design.Asaresult,onecannottakeadevicefabricatedinonefacility and replicateitusing the processesofanotherfabricationfacility(fab).Again,inthisrespectphotonicintegrationisat the levelofmaturityofsiliconin the 1960s,beforeCMOSbecame the technologyofchoice.Notwithstanding the difficultiesofmonolithicintegration on the InPplatform,somecompanies,suchasJDSU and Infinera,havesuccessfullybroughtproductsbased on monolithicInPintegrationtomarket.Oclerobelievesitiswell‐positioned for thismarketsegmentbecauseofitsInPfabinCaswellUK. The secondapproachtoPICsistointegrateasmanypassive and activecomponents on asiliconsubstrateaspossible, and thenattach and couplecriticalnon‐Sicomponentsto the platform.Oneof the advantagesofSiasaplatformisthatSiO2makes for anexcellentwaveguidematerial, and the processescanbefullycompatiblewith the existingCMOSinfrastructure. The challengeisin the mismatchof the thermalconductivitiesofInP and Si.Astemperaturechanges, the componentsmayshiftslightly,impacting the alignmentof the opticalpath.CompaniesthatfollowthisapproachincludeKotura,Luxtera, and NeoPhotonics.Potentialroadblocksaheadincludedensitylimits,both on and offchip.With the massiveamountofwirebondingrequired for theseintegratedphotonicdevices, and withall the wiresrunning10or40GHzsignalsthoughthem,theyactlikeaphaseantenna,bringingupseriousissuesofelectromagneticinterference.AnotherkeyimpedimenttoPICdevelopmentis the lackofaneconomicallyviablefoundrybase. The economicrealityisthatmanyIII‐Vfoundriesarestrugglingwithexcesscapacity and no“killerapplication”insightthatwoulddrivevolume.Companiestrytolockinwhatlittlecustomerbasetheyhavethroughproprietaryprocessesthatarenotportablefromfoundrytofoundry. On the technicalside, the lackofarobustmarket,haslimited the developmentofcomprehensivemodelingsoftware and otherinfrastructureelements.Researchersinterestedinbuildingphotonicintegratedcircuitshaveto ... DRAFTWorkingPapersVersion040510MassCustomization12345678910111213141516171819202122232425262728293031323334Oneof the definitionsof advanced manufacturing references the need for new manufacturing platformstobeflexibletorespondtocustomerdemands.Anemerging advanced manufacturing conceptsuggestedindiscussionswithexpertsis the abilitytoachievecost‐effective“masscustomization”ofaproduct.Throughadvancesincomplexproductrealization and single‐unit manufacturing, asdescribedpreviously,masscustomizationisbecomingamoreplausiblereality. Advanced manufacturing techniques,suchassolidfree‐formfabrication(oftencalled“additive manufacturing ) and laserprocessing,cancreatecomplex,customproducts and replacementpartsthatarerequiredtobeproducedquicklyinlowvolumes.5Suchadvancesin manufacturing couldleadtonewwaysofapproachingpersonalizedmedicine and biomanufacturingofpharmaceuticals.Somedefinepersonalizedmedicineas“aformofmedicinethatusesinformationaboutaperson’sgenes,proteins, and environment toprevent,diagnose, and treatdisease.”6Givenlimitations and reducedefficacyofconventionalmedicinesacrossbroadpatientpopulations,manyresearchersarelookingtowardspersonalizedhealthcarestrategies and cell‐basedtherapiesto better targetdiseases.However, manufacturing technologies for targetedtherapiesthatmeet the regulatory and economicrequirements for successfulcommercializationarestillinembryonicstages.Anotherexampleofmasscustomizationthatemergedfromdiscussionswithindustryexpertsis the manufacturing ofcustomizableprescriptioneyelenseswithuniquefeatures. The technology,developedbyLuxottica,allows for specialfeaturessuchascoatings and progressivelensestobemademorepreciselythroughnewlayeringtechnologies.Advancesin manufacturing processestocreatedesktopmachineshaveenabled the companytoautomatelens manufacturing for improvedqualityatalowercost.OpenInnovation Manufacturing Anotheremergingconceptleverages the powerofcollectiveintelligence and informationtechnologytocollectnewdesign and manufacturing strategies for productdevelopment.ArecentarticledescribesaBoston‐basedCompany,LocalMotorsInc.,as the firstopen‐sourceautomotivecompany.7LocalMotorsaimstobuildanoff‐road,butstreet‐legal,vehicletobereleasedinJune2010.ThroughaCreativeCommonslicense,8notonlydesignideasbutalsodevelopment and manufacturing solutions(mostofwhichwereoff the shelfcomponents)weresolicitedfrom the public.Throughwell‐managedcommunityinputaswellastechnologiessuchas3‐Ddesignsoftware and photorealisticrenderingtechnology,enthusiasts and LocalMotorsemployeesworkedtogethertodesign and buildacarthat,accordingto the article,“putsDetroittoshame.”Network‐Centric Manufacturing Arecentreport,Rationales and Mechanisms for RevitalizingU.S.R&D Manufacturing Strategies,arguesthatamajorrequirement for competitivenessin manufacturing isagreateruseofinformationtechnologytomoreeffectivelyintegrateallbusinessoperationsin manufacturing supplychains.Onemethodofachievingthisgoalisthroughnetwork‐Centric manufacturing (NCM),definedas:95GregTassey,“Rationales and mechanisms for revitalizingUS manufacturing R&Dstrategies,”JournalofTechnologyTransfer,publishedonline29Jan2010,availableathttp://www.springerlink.com/content/e70574777627wmg4/fulltext.pdf.6SeeNationalCancerInstitute,“DefinitionofTerms,”availableathttp://www.cancer.gov/templates/db_alpha.aspx?CdrID=561717.7ChrisAnderson,“In the NextIndustrialRevolution,AtomsAre the NewBits,”WiredMagazine,January25,2010.8CreativeCommonsisanonprofitorganizationthatworkstoincrease the amountofcreativity(cultural,educational, and scientificcontent)in“the...

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... agencies—NIST, the Centers for Disease Control and Prevention, FDA, the Pacific Northwest National Laboratories of the Department of Energy and the National Aeronautics and Space Administration (NASA) ... for Cancer Screening, Diagnosis and Therapy: The State of the Science, Evaluation, Implementation and Economics (Margie Patlak and Sharyl Nass, 2006) and Cancer Biomarkers: The Promises and ... translational paradigm for the discovery and validation of biomarkers for cancer early detection and risk assessment. As noted, early performance was uneven. CEVCs, in collaboration with others...

... targeted to research in energy, the environment, and information and communications technologies, and $37 million to the Canadian Institutes of Health Research (CIHR) for research in the health ... and design, the assembly and guidance of the research team, oversight of the conduct of the research, and the dissemination of the results to academics, practitioners, and organizations. 2 Chapter ... the use of the journal classication system developed for the U.S. National • Science Foundationa comparison against the Scopus and Web of Science classication systems the identication...