Affordability and SustainabilityPaul Collopy, ChairJanuary 11, 2011Topic 2:Extremely Efficient & Effective Manufacturing
Overview

• Definition/scope of topic area• Importance and key issues• Highlights from the issue papers
Definitions and Scope

• Affordability - Ability to survive in the current econo• Sustainability - Capacity to endure (survival in a differ

Mass Customization Innovation Networks 

Complexity at low cost• casting and lithography• additive manufacturing• configurable materialsOrganization• Electro-mechanical fabs• Bit-programmable floor• Command & Control

• sensors• intelligent control 

Robust Design Infrastructure• Rules and Tools• accepted limitationsOrganization• Separation: Design // Mfg• Small / Medium Design 

organizations are Gorillas

• Ultra small design teams 

breaking oligopolies

• Desktop manufacturing 

Materials, Technologies, and Enabling 
Why is this important?

• “A manufacturing plant that develops and applies man

intelligence will be able to dramatically reduce costs an

exports. The widespread application of virtual plant enproduce at least a 10x improvement in time to commer

• “Sophisticated tools that have traditionally been availa

in industrial settings are now becoming accessible to in

formal training in engineering.” 

• “If (high performance computing is) shared throughou

manufacturing base, America’s global competitiveness enhanced, particularly in desirable areas such as high-tmanufacturing and modeling/simulation tools developm
Issues and Concerns

•

“Data needs to be more easily obtained via low cost se

collected, consistently defined, managed as an operatin

within companies, and selectively shared among comp

•

“Producibility issues can have significant long term immanufacturing enterprise operating costs due to the ‘hirework, process inefficiencies, and overhead they introday production operations.” 

• “Some of the most pressing challenges in manufacturin

need to cost-effectively produce low-cost, high-performlong-life energy technologies at high throughput rates.
Highlights of the Issue Pap

• “Recently, a new materials platform has been discover

mass customization to the extreme. This new approach of unique open-cellular materials with micro-scale trus

ranging from tens to hundreds of microns. ” 

• Knowledge Infrastructure for Innovation and Efficienc

– “...creating an infrastructure that can give...teams of citizen-des

means...for designing, prototyping, testing, financing, manufacmarketing their inventions is extreme.” 

– “...establishment of a new community source data analytics, m

platform that will function as a clearinghouse and gateway for tools and practices which small, medium and large enterprises 

contribute.” 

– “...define a roadmap for the development of advanced simulatio

supply chain analysis capabilities and frameworks that will enaengineering and virtual prototyping of both product, manufactudesign concepts...” 

Breakout 2

Efficient & Effective

Affordable & Sustainable

• What does this topic area mean to you and how w• What aspects of this topic area might be especiall

why?

• What is the current state of the art and what extre

foresee in the future, and when?

• What are some of the compelling technology que

about these particular extreme realms in manufac