1 Copyright © 2008 by ASME Proceedings of IMECE2008 2008 ASME International Mechanical Engineering Congress and Exposition October 31-November 6, 2008, Boston, Massachusetts, USA IMECE2008-66374 A PROPOSED ROADMAP FROM THE CURRENT TO AGILE MANUFACTURING Dr. Mohamed A. Gadalla Assistant Professor, Engineering Department Central Connecticut State University 1615 Stanley Street, New Britain, CT 06050 ABSTRACT With growing tendency towards globalization and the number of free trade agreements, we are approaching not only a global market but also a manufacturing era that has no boundaries. This is accomplished through off-shoring and outsourcing. Manufacturing companions and particularly Small to Medium size Enterprise (SME’s) are facing a very tough and fierce competition. This article is intended to provide a roadmap for manufacturing companies to help them survive and excel. INTRODUCTION A great deal of research has been done in many areas related to design, implementation, and managing of manufacturing systems [2, 5]. Common characteristics of the future manufacturing systems found are: the capability to handle rapid changes in market demand, process and operation flexibility, decreased product realization time-line including the manufacturing lead times, and other ever-changing economical factors. The main focus of this research is to study, evaluate and recommend strategic and structural development components necessary for the existing manufacturing systems. Some of these components are: Lean Manufacturing, Six Sigma, TQM, FMS, RMS, CIM, and Manufacturing Cell. Very little has been done to recognize and reorganize the underlying relationships among these different components. This research is intended to draw a road map to help industry particularly decision makers and technical-management executives to realize the relationships among these different components and thus may provide a tool to justify their future investments. DEFENSE MECHANISM In a battle ground when attached by out-numbered army there are two main counter attack strategies: - Increasing the firing power by using more advanced weapon system. - Hide, and if found hide again. In a manufacturing environment the first strategy is to use more automation and system integration tools to increase productivity while the second is to transform (hide) the whole manufacturing system to either suit new product innovations or to change the manufacturing system to avoid the attack. It is worth saying that in a battle field the first choice is an honorable choice, while in the manufacturing environment the second choice is a smarter choice, because this transformation is the drive for continuous improvement and innovation. Figure 1 shows a simple drawing to explain the idea. In the past, such transformation was overlooked as a tool to excel in what the company did. The work in this paper stresses the fact that the manufacturing system in the western world is under sever attack from low cost labor market from China, India, eastern Europe south east Asia and the anticipated growth in the African market, thus the excel trip becomes the survival trip. Figure 2 shows the road map to implement the second the strategy, it also stresses that these steps have to be taken in series (this is explained by climbing up the stairs, it becomes difficult to skip some steps). IMECE2008-66374 Proceedings of IMECE2008 2008 ASME International Mechanical Engineering Congress and Exposition October 31-November 6, 2008, Boston, Massachusetts, USA