The Management of Additive Manufacturing: Enhancing Business Value

250 Pages·2018·7.75 MB·English

by  Mojtaba Khorram Niaki

Springer Series in Advanced Manufacturing
Mojtaba Khorram Niaki
Fabio Nonino
The
Management
of Additive
Manufacturing
Enhancing Business Value
Springer Series in Advanced Manufacturing
Series editor
Duc Truong Pham, University of Birmingham, Birmingham, UK
The Springer Series in Advanced Manufacturing includes advanced textbooks,
researchmonographs,editedworksandconferenceproceedingscoveringallmajor
subjects in the field of advanced manufacturing.
The following is a non-exclusive list of subjects relevant to the series:
1. Manufacturing processes and operations (material processing; assembly; test
and inspection; packaging and shipping).
2. Manufacturing product and process design (product design; product data man-
agement; product development; manufacturing system planning).
3. Enterprise management (product life cycle management; production planning
and control; quality management).
Emphasiswillbeplacedonnovelmaterialoftopicalinterest(forexample,books
on nanomanufacturing) as well as new treatments of more traditional areas.
As advanced manufacturing usually involves extensive use of information and
communication technology (ICT), books dealing with advanced ICT tools for
advanced manufacturing are also of interest to the Series.
Springer and Professor Pham welcome book ideas from authors. Potential
authors who wish to submit a book proposal should contact Anthony Doyle,
ExecutiveEditor,Springer,e-mail:[email protected].
More information about this series at http://www.springer.com/series/7113
Mojtaba Khorram Niaki Fabio Nonino
(cid:129)
The Management of Additive
Manufacturing
Enhancing Business Value
123
Mojtaba Khorram Niaki FabioNonino
Sapienza University of Rome Sapienza University of Rome
Rome Rome
Italy Italy
ISSN 1860-5168 ISSN 2196-1735 (electronic)
SpringerSeries inAdvancedManufacturing
ISBN978-3-319-56308-4 ISBN978-3-319-56309-1 (eBook)
https://doi.org/10.1007/978-3-319-56309-1
LibraryofCongressControlNumber:2017947021
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Contents
1 What Is Additive Manufacturing? Additive Systems, Processes
and Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Definition. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.2.1 Earlier Research and Development . . . . . . . . . . . . . . . . . . 3
1.2.2 Technology Background . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.2.3 Evolution Phases in the Scope of AM. . . . . . . . . . . . . . . . 7
1.3 AM Technologies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.3.1 Liquid-Based. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.3.2 Powder-Based . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.3.3 Solid-Based. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
1.4 Methods offabrication and Materials. . . . . . . . . . . . . . . . . . . . . . 24
1.4.1 Vat Photopolymerization . . . . . . . . . . . . . . . . . . . . . . . . . 24
1.4.2 Powder Bed Fusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
1.4.3 Extrusion-Based . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
1.4.4 Material Jetting and Binder Jetting . . . . . . . . . . . . . . . . . . 26
1.4.5 Sheet Lamination Process. . . . . . . . . . . . . . . . . . . . . . . . . 27
1.5 Low-Cost Desktop 3D Printing . . . . . . . . . . . . . . . . . . . . . . . . . . 28
1.6 Top Ten Commercial AM Systems . . . . . . . . . . . . . . . . . . . . . . . 31
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
2 Industries and Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
2.1 The Role of Additive Manufacturing in the Industry of the
Future . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
2.2 Industrial Diffusion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
2.3 Main Application Sectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
2.3.1 Healthcare Industry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
2.3.2 Automotive Industry . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
2.3.3 Aerospace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
v
vi Contents
2.3.4 Consumer Goods. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
2.3.5 Other Industries. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
3 The Value for Sustainability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
3.1 Economic Sustainability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
3.1.1 Operational and Manufacturing Costs Savings. . . . . . . . . . 68
3.1.2 Logistics’ Costs Saving . . . . . . . . . . . . . . . . . . . . . . . . . . 72
3.1.3 Implications for Corporate Taxation . . . . . . . . . . . . . . . . . 72
3.2 Environmental Sustainability. . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
3.2.1 Impacts on Energy Consumption . . . . . . . . . . . . . . . . . . . 73
3.2.2 Impacts on Resources and Pollutions . . . . . . . . . . . . . . . . 78
3.3 Societal Sustainability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
4 The Value for Business and Operations Strategy . . . . . . . . . . . . . . . 91
4.1 The Value for Business Strategy . . . . . . . . . . . . . . . . . . . . . . . . . 91
4.1.1 AM as a Driver for Business Competitiveness. . . . . . . . . . 91
4.1.2 AM as a Driver for Creativity and Innovation. . . . . . . . . . 94
4.1.3 AM as a Driver for New Services: The Online 3D
Printing Platforms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
4.2 The Value for Operations Strategy. . . . . . . . . . . . . . . . . . . . . . . . 101
4.2.1 Impact on Manufacturing Paradigms. . . . . . . . . . . . . . . . . 103
4.2.2 Impact on Product Lifecycle and Operational Costs. . . . . . 107
4.2.3 Impact on Supply Chain Management. . . . . . . . . . . . . . . . 110
4.3 TheValueforCustomers:FromMassCustomizationtotheNew
Entrepreneurial Role of Prosumers. . . . . . . . . . . . . . . . . . . . . . . . 113
4.3.1 Prosumers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
4.3.2 User Entrepreneurship Opportunities. . . . . . . . . . . . . . . . . 116
4.4 Strategic Challenges and Barriers Ahead of AM Technology
Diffusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
4.4.1 Challenges Ahead of AM Technology Suppliers . . . . . . . . 121
4.4.2 Challenges Facing the AM Community. . . . . . . . . . . . . . . 125
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
5 The Value for Operations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
5.1 The Value for New Product Development . . . . . . . . . . . . . . . . . . 131
5.1.1 Impact of AM on the Product Development Process . . . . . 131
5.1.2 Driving an Evolution in Design Methodologies . . . . . . . . . 134
5.1.3 Design Freedom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
5.2 The Value for Manufacturing . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
5.2.1 Impact on Production Process. . . . . . . . . . . . . . . . . . . . . . 140
5.2.2 Impact on Product Quality . . . . . . . . . . . . . . . . . . . . . . . . 142
5.2.3 Impact on Manufacturing Costs . . . . . . . . . . . . . . . . . . . . 145
5.2.4 Impact on Material Waste . . . . . . . . . . . . . . . . . . . . . . . . 148
Contents vii
5.3 The Value for Logistics and Supply Chain Management. . . . . . . . 149
5.3.1 The Impact on Inventory Turnover . . . . . . . . . . . . . . . . . . 150
5.3.2 The Impact on the Spare Part Supply Chain . . . . . . . . . . . 152
5.3.3 3DP Online Platforms Supply Chain. . . . . . . . . . . . . . . . . 157
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
6 Strategic Alignment of Additive Manufacturing . . . . . . . . . . . . . . . . 163
6.1 Framework for Strategic Alignment. . . . . . . . . . . . . . . . . . . . . . . 163
6.2 Contingency Factors Driving AM Performance . . . . . . . . . . . . . . 168
6.2.1 Organizational Factors . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
6.2.2 Operational Factors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
6.2.3 Product Characteristics. . . . . . . . . . . . . . . . . . . . . . . . . . . 177
6.3 Economic Analysis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
7 Selection and Implementation of Additive Manufacturing . . . . . . . . 193
7.1 Technology Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
7.2 Selecting AM Technology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
7.2.1 Selection Criteria. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
7.2.2 Selection Process. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
7.3 Implementing Additive Manufacturing. . . . . . . . . . . . . . . . . . . . . 205
7.3.1 Organizational Changes . . . . . . . . . . . . . . . . . . . . . . . . . . 206
7.3.2 Operational Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
7.3.3 Supply Chain Changes. . . . . . . . . . . . . . . . . . . . . . . . . . . 217
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
Appendix A—Methodological Note . .... .... .... .... .... ..... .... 221
Glossary.. .... .... .... .... ..... .... .... .... .... .... ..... .... 233
Uncited References . .... .... ..... .... .... .... .... .... ..... .... 239
Index .... .... .... .... .... ..... .... .... .... .... .... ..... .... 241
List of Exhibits
Exhibit 1 Environmental Impact—AM Technology as a Driver for
Sustainability .. .... ..... .... .... .... .... .... ..... .. 83
Exhibit 2 Impact on Business Competitiveness—Catching New
Opportunities .. .... ..... .... .... .... .... .... ..... .. 92
Exhibit 3 Impact on Business Competitiveness—Accessing New
Markets and Acquiring New Customers... .... .... ..... .. 93
Exhibit 4 Impact on the New Product Development Process—AM
Support Innovation and Creativity ... .... .... .... ..... .. 98
Exhibit 5 Impact on a New Product Development Process—AM
as a Driver For Customization .. .... .... .... .... ..... .. 105
Exhibit 6 Current Barriers to the Adoption of AM Technologies—Is
AM Technology Accessible or Is It Still Too Expensive? .. .. 126
Exhibit 7 Impact on the New Product Development
Process—Reducing the Time to Market... .... .... ..... .. 134
Exhibit 8 Impact on the New Product Development
Process—Complexity for Free .. .... .... .... .... ..... .. 138
Exhibit 9 Impact on Manufacturing Process—Reducing the
Manufacturing Time?..... .... .... .... .... .... ..... .. 141
Exhibit 10 Impact on the Manufacturing Process—Improving Product
Quality? .. .... .... ..... .... .... .... .... .... ..... .. 145
Exhibit 11 Impact on Manufacturing Process—Reducing the Labor
Cost . .... .... .... ..... .... .... .... .... .... ..... .. 147
Exhibit 12 Impact on Manufacturing Process—Reducing the Material
Waste.... .... .... ..... .... .... .... .... .... ..... .. 148
Exhibit 13 Impact on Supply Chain Management and
Logistics—Reducing the Inventory Turnover... .... ..... .. 150
Exhibit 14 Economical Analysis—Return On Investment .. .... ..... .. 189
ix
Introduction
The book resulted from a growing awareness of the ongoing mutations in many
oftheindustrialsectorsdrivenbyAdditiveManufacturing.AdditiveManufacturing
(AM) is the official and universal term for all applications of the technology as
defined by ASTM Standard F2792: a process of joining materials to make objects
from 3D model data, usually layer upon layer, as opposed to subtractive manu-
facturing technologies, such as traditional machining. However, AM is something
more: it is a disruptive technology, and a technological shift that can lead com-
panies into a new area of manufacturing characterized by phenomenal changes to
industries and the development of new business models.
Withtherapidmanufactureofcustomized,low-costproducts,AMtechnologies
have considerable and far-reaching effects on the industrial world. They affect
nearly all managerial and organizational thinking that was previously adapted to
conventional manufacturing. Currently, the technology is well suited to manufac-
turingareasthatinvolvehigh-valueproductswithcomplexgeometriesinsmalland
medium production volumes. It boosts the productivity of the new product devel-
opment process by slashing costs, saving time and increasing creativity and inno-
vativeness. It shrinks the supply chain by bringing firms closer to their customers.
Objective of the Book
Thebookaimstomeettheneedsofprofessionalsandscholars;itoffersthereadera
view of the world of AM technologies and proposes an analysis of this theme in
order to examine its attractiveness and effectiveness from a managerial point of
view. The underlying questions to which the book responds are as follows:
(cid:129) How do AM technologies affect manufacturing, business strategy and business
performance?
(cid:129) HowdostrategicandorganizationalcontingentfactorsdriveAMperformance?
(cid:129) How can companies gain a competitive advantage from AM?
(cid:129) How should companies select and implement AM technologies?
xi