Journal of Materials Science and Engineering B 3 (9) (2013) 597-604 Ways of Increasing Synergy in Automated Factory Design and Commissioning Teamwork Rommi Källo, Martin Eerme and Vello Reedik Department of Machinery, Tallinn University of Technology, EhitajateTtee 5, Tallinn 19086, Estonia Received: August 25, 2013 / Accepted: September 10, 2013 / Published: September 25, 2013. Abstract: The present paper is focused on theproblems of reducing losses of resources at thestart-up of new automated factories caused by human shortcomings in teamwork activities. The research is based ona unique database of empirical studies of human faults and mistakes at thedesign and commissioning of factory automation systems.This database covers over 25 automated factories on three continents, containing pulp and paper mills, chemical and petrochemical plants and power stations. It is shown that themost suitable tool for teamwork analysis is thedesign structure matrix (DSM)method, which allows visualisation of thefullcomplexity of synergy relations between all team members on thebasis of the frequency and amount of information interchange. The mathematical treatment of DSM matrixes enables us to form the most capable teams, to schedule and evaluate their activities. It is shown that as a result of logical analysis it is possible to create an optimal communication and cooperation system, where the competences and capabilities of the teams and their members can be more fully exploited. Key words: Factory automation, engineering design, teamwork management, synergy deployment, quality assurance. 1. Introduction The losses of resources at thestart-up of new automated factories causedby human shortcomings reachup to 5%-10% of whole investment costs and tendto increase with thegrowing complexity of control systems. The real key to reducing these losses is a profound analysis of human shortcomings in the automation systems design and commissioning teamwork. Nowadays production processes are changing towards higher degrees of automation and new effective solutions in control systems technology. Modern automation systems have been developed to be more universal, being capable of controlling different types of equipment. These requirements also include reconfigureability, responsiveness and flexibility [1]. In addition to that, advanced functions such as Corresponding author: Rommi Källo, Ph.D. student, research fields: factory automation, engineering design, synergy and product development. E-mail: rommi.kallo@mail.ee. optimization, scheduling and planning are becoming an important part of process control systems [2]. The traditional barriers between information, communication and automation technologies are, in the operational context, gradually disappearing. The latest technologies, including wireless networks, fieldbus systems and asset management systems, boost the efficiency of automation systems. On the other hand, a specific factory needs a peculiar automation system configured from universal systems [3]. A system can become more complex not only from the engineering side but also due to an increase in the amount of data and variables or the number of disciplines that are involved in the design. Therefore, the need for systems engineering is growing owing to a steady increase in systems complexity. Despite everything, the key figures in this overall change process are still human beings with their cultural, educational and technical backgrounds and working habits. There search in the field of socio-technical teamwork inefficiency due to human DAVID PUBLISHING D