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Robert C. Byrd Institute for Advanced Flexible Manufacturing Systems

Robert C. Byrd Institute for Advanced Flexible Manufacturing Systems
Research and Economic Development Center
Marshall University
David M. Porreca, Director
Greg Shrewsberry, Marketing Director
Susan Hahn, 304-696-6273
1050 Fourth Avenue
Huntington, W. Va. 25755
(304) 696-6275
(304) 696-6277 fax

America faces hard but simple choices in the world economy of the 21st Century, says Byrd Institute Director Dave Porreca, citing the arguments of the best-selling economist and author Lester Thurow: "If our work force has only low skills, we will compete with all the other countries that have low skills to offer, and we can only win if we are the cheapest producers of low-skill products."

The alternative? A trained work force that's trained and able to compete in a high-technology economy, using "flexible manufacturing" techniques that take advantage of computer and robotics technology to respond instantly to changing needs.

That's what the Byrd Institute is all about. Similar in some ways to Detroit's model program, Focus: HOPE, the institute's centerpiece is a small but well-equipped "teaching factory," where small and medium-size West Virginia businesses can come to try out high-tech, computerized manufacturing equipment and have their employees trained to use it. This is critical for smaller companies, as most West Virginia firms are, because there's a direct link between a firm's ability to upgrade technology and its efficiency and productivity. The institute makes it practical for small companies to try technologies, like the $350,000 Cincinnati Milacron T-10 computerized milling machine, that only major corporations otherwise could afford.

Financed by military grants, initially a $2.9 million grant from the Air Force three years ago, and a $4 million current award from the Defense Department, the institute is on the leading edge of a hot new development that President Bill Clinton has vowed to see replicated. Clinton wants to develop 170 similar programs across the U.S. (apparently choosing that number because Japan has 170, Porreca says), and the Defense Reinvestment Program has more than $471 million set aside to finance them.

The Byrd Institute, named in honor of the senator who helped establish it, operates in a two-story former bank building in downtown Huntington. It operates several programs, all of them aimed at helping the state's small and medium-size businesses remain competitive by mastering technology. It currently deals primarily through businesses and trains their employees, although Porreca says he would like to establish an apprenticeship-type program soon for unemployed high-school students and graduates.

Among highlights, the two highest-profile activities are:

  • The COMPUTER INTEGRATED MANUFACTURING "CELL," a miniaturized but working model of a state-of-the-art manufacturing line, on which students can operate actual computer control consoles to shape products from metal (or even wood or wax) to master the operation of these high-tech processes.

  • The OPERATIONS & TECHNICAL SERVICES CENTER, a working "factory" including the Cincinnati Milatron and other computer-operated machines that local firms can use to test procedures and train personnel. For instance, Mountaineer Archery, a small but respected Huntington manufacturer of hunting bows, is using the Institute's equipment to "reverse engineer" its handmade bows, allowing them to substitute efficient computerized processes to make key parts rather than time-consuming hand techniques.

    In addition, the institute's telecommunications program is working on establishing ultramodern communications linkages, ranging from training videos and conferences downloaded via satellite to electronic mail connections among home workers such as the knitters in the Charleston-based Center for Economic Options' Knitwear project. Its systems intern project offers technical assistance to small businesses, and it provides training in computer-assisted design and computer-assisted manufacturing through Marshall's local community college.

    With a staff of 18 and a commitment to make a difference in the West Virginia economy, the Byrd Institute is an excellent, replicable model.

    "We've always been very good in the United States about inventing things," Porreca said. "But this is no longer as important. More important now is how you MAKE things, and the Japanese and Germans have made this into a real science."


    All the feature stories on @GRASS-ROOTS.ORG's pages are reported and written by Robin Garr, a prize-winning journalist who has visited more than 500 innovative grassroots programs in all 50 states since 1990.
  • Browse his book, Reinvesting In America, at Amazon.com.
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