The Global Manufacturing Revolution: Product-Process-Business Integration and Reconfigurable Systems / Edition 1

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For a manufacturing enterprise to succeed in this current volatile economic environment, a revolution is needed in restructuring its three main components: product design, manufacturing, and business model. The Global Manufacturing Revolution is the first book to focus on these issues. Based on the author's long-standing course work at the University of Michigan, this unique volume proposes new technologies and new business strategies that can increase an enterprise's speed of responsiveness to volatile markets, as well as enhance the integration of its own engineering and business.

Introduced here are innovations to the entire manufacturing culture:

An original approach to the analysis of manufacturing paradigms

Suggested methods for developing creativity in product design

A quantitative analysis of manufacturing system configurations

A new manufacturing "reconfigurable" paradigm, in which the speed of responsiveness is the prime business goal

An original approach to using information technology for workforce empowerment

The book also offers analysis and original models of previous manufacturing paradigms' technical and business dimensions-including mass production and mass customization-in order to fully explain the current revolution in global manufacturing enterprises. In addition, 200 original illustrations and pictures help to clarify the topics.

Globalization is creating both opportunities and challenges for companies that manufacture durable goods. The tools, theories, and case studies in the volume will be invaluable to engineers pursuing leadership careers in the manufacturing industry, as well as to leaders of global enterprises and business students who are motivated to lead manufacturing enterprises and ensure their growth.

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Editorial Reviews

From the Publisher
"This edition contains new data and examples, plus b&w drawings. The book can be used as a text for a class in global manufacturing for graduate engineering and business students; it will also be helpful for engineers pursuing managerial careers in manufacturing, and for leaders of global enterprises." (Book News Inc, November 2010)
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Product Details

Meet the Author

Yoram Koren is a member of the National Academy of Engineering and the Paul G. Goebel Professor of Engineering in the Department of Mechanical Engineering at the University of Michigan, as well as the Director of the NSF Engineering Research Center for Reconfigurable Manufacturing Systems. He has won many awards, including, most recently, the Stephen S. Attwood Award from the University of Michigan College of Engineering, 2008, and the Gold Medal from the Society of Manufacturing Engineers, 2007.

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Table of Contents

Preface xiii

Acknowledgments xvii

1 Globalization and Manufacturing Paradigms 1

1.1 The Importance of Manufacturing to Society 2

1.2 The Basics of Manufacturing in Large Quantities 5

1.3 The 1990s: A Decade of Intensified Globalization 9

1.4 The Global Manufacturing Revolution 12

1.5 The Manufacturing Paradigm Model 22

1.6 Four Major Manufacturing Paradigms 24

1.7 Paradigm Transitions Over Time 32

Problems 39

References 39

2 Product Invention Strategy 41

2.1 Technology-Driven Products 42

2.2 Customer-Driven Products 51

2.3 Competition-Driven Products 55

2.4 Classification of Product Inventions 57

2.5 Product Development for Globalization 59

2.6 The Product Development Process 62

2.7 Head in the Sky, Feet on the Ground-Be a Dreamer on a Solid Foundation 68

Problems 69

References 71

3 Customized, Personalized and Reconfigurable Products 72

3.1 Introduction to Customization 72

3.2 Design for Mass Customization 75

3.3 Personalized Products 77

3.4 Product Modularity 88

3.5 Reconfigurable Products 96

3.6 Design of Customized and Reconfigurable Products 98

Problems 101

References 102

4 Mass Production and Lean Manufacturing 103

4.1 The Principles of Mass Production 104

4.2 Supply and Demand 108

4.3 The Mathematical Model of Mass Production 110

4.4 Lean Production-Goals and Benefits 114

4.5 The Principles of Lean Production 117

Problems 124

References 125

5 Analysis of Mass Customization 126

5.1 Introduction to Mass Customization 126

5.2 Business Strategies of Mass Customization 129

5.3 Manufacturing System Characteristics 134

5.4 Economics of Product Variation 136

5.5 Mathematical Analysis of Mass Customization 142

5.6 Summary 145

Problems 146

6 Traditional Manufacturing Systems 148

6.1 Manufacturing Systems 148

6.2 Production of Complex Products 150

6.3 The State of Art at the End of the Twentieth Century 154

6.4 Assembly Systems 167

6.5 Industry Experience with FMS-A Survey 170

Problems 173

References 174

7 Economics of System Design 175

7.1 Life-Cycle Economics 176

7.2 Capacity Planning Strategies 178

7.3 Economics of System Configurations 186

7.4 The Economics of Buffers 188

7.5 Batch Production 192

7.6 Optimal Cutting Speeds 199

Problems 201

References 203

8 Reconfigurable Machines 205

8.1 The Rationale for Reconfigurable Machines 206

8.2 Characteristics and Principles of Reconfigurable Machines 210

8.3 Reconfigurable Machine Tools 211

8.4 Reconfigurable Fixtures 218

8.5 Reconfigurable Inspection Machines 220

8.6 Open-Architecture Controllers 224

Problems 225

References 226

9 Reconfigurable Manufacturing Systems 227

9.1 The Challenges of Globalization 227

9.2 RMS-A New Class of Systems 232

9.3 Characteristics and Principles of Reconfiguration 235

9.4 Integrated RMS Configurations 240

9.5 System Rapid Ramp-Up 243

9.6 Hexagonal RMS Configurations 246

Problems 250

References 252

10 System Configuration Analysis 253

10.1 Classification of Configurations 253

10.2 Comparing RMS with Cell Configurations 257

10.3 Calculating the Number of RMS Configurations 260

10.4 Example of System Design 261

10.5 Impact of Configuration on Performance 266

Problems 278

References 280

11 Business Models for Global Manufacturing Enterprises 281

11.1 Examples of Business Models 281

11.2 Business Model of Manufacturing Companies 285

11.3 Competitive Advantage 289

11.4 Strategic Resources 293

11.5 Supply Chains 297

11.6 Responsive Business Models for Global Opportunities 304

11.7 Product Life cycle Business Model 307

Problems 309

Case Study I-The Rise and Fail of FriendlyRobotics 310

Case Study II-He Bet on Botox and Won 312

References 313

12 IT-Based Enterprise Organizational Structure 315

12.1 Twentieth-Century Organizational Structure 316

12.2 Twenty-First Century IT-Based Organizational Structure 318

12.3 Information Transfer in Manufacturing Systems 323

12.4 IT-Based Maintenance of Large Systems 327

Problems 330

References 330

13 Enterprise Globalization Strategies 331

13.1 Why Enterprises Become Global 332

13.2 Countries of Potential New Markets 336

13.3 Product Design for Globalization 338

13.4 Location of Manufacturing Plants 340

13.5 Global Business Strategies 343

13.6 Global Strategic Alliances 349

Problems 357

References 358

14 The Twenty-first Century Global Manufacturing Enterprise 360

14.1 P-Productivity 361

14.2 R-Responsiveness and Reconfiguration 363

14.3 I-Integration of Product, Process, and Business 364

14.4 D-Design for the Global Manufacturing Paradigm 368

14.5 E-Empowerment of the Workforce 369

14.6 The Dilemma of Globalization 370

14.7 Where are Manufacturing Enterprises Headed? 375

References 380


Appendix A Computer Controlled Milling Machine in 1973 381

Appendix B Three Types of Manufacturing Systems 383

Appendix C Business Cycles 384

Appendix D Term Project: Project Description and Requirements 386

Author Biography 391

Author Index 393

Subject Index 395

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