International Conference on Competitive Manufacturing International Conference on Competitive Manufacturing Creation of Synergy in Manufacturing by using Intelligence, Integration and Remote Monitoring Cornelius J. Fourie Centre for Advanced Manufacturing, Department of Industrial Engineering, University of Stellenbosch, Stellenbosch, South Africa Abstract Some concepts of manufacturing on their own play a decisive role in manufacturing like Integration, Intelligence and Remote Monitoring. They have been tried and tested with great success in various applications in manufacturing. However, very little has been written on the synergy that is created when all three is deployed in one system. It is the aim of this paper to report on the attributes of each of these key concepts, to compare them on the grounds of applicability and to study the effects when combined into one system. Final conclusions are made after the hypotheses have been validated with the aid of an experimental model. Keywords Intelligent manufacturing, Integration, Remote monitoring. 1 IMPORTANCE OF THE RESEARCH WORK While considering the importance of the synergy between the key concepts of integration, intelligence and remote monitoring, the individual contribution made by each of these concepts is discussed in this paper. The extent of how they will enhance and support each other when teamed together in the same system is evaluated. An original validation procedure is also suggested. The individual aspect and influence of each area is discussed in terms of their respective contribution. 1.1 Intelligence and Intelligent systems In an attempt to evaluate and validate the contribution of intelligence in a manufacturing system, the first objective is to fully discuss and debate the origin, characteristics and role of intelligence. The important contribution made in this section is the similarities drawn between human and artificial intelligence and how these similarities can be implemented to validate the concept of intelligence. In the past, two of the critical fields in manufacturing were organisational theory and information technology [1]. The prevailing paradigm was the command and control paradigm with major characteristics of economy of scale, deep hierarchical structures, clear lines of command/reporting, limited span of control, division of labour (including the division between thinking and doing), functional organisational units and a competitive relationship with suppliers. These however, along with many other previously accepted norms in manufacturing, have been experiencing some very fundamental changes. The new paradigm consists of very different principles like flexibility, responsiveness, shallow hierarchies, devolution of decision-making, multidisciplinary teams, process-oriented organisational units and global partnerships. In the manufacturing system, conventional or fixed automation is presently considered to be too rigid. Aspects like precision and repeatability (i.e. a robotic system) are now considered to be insufficient because of the inability to cope with unexpected events. Under the new paradigm, sensors and artificial intelligence enable the development of intelligent systems capable of making decisions under conditions of uncertainty. 1.2 System Integration A further objective of this work is to show how integration adds the element of synergy to a system. This is done by showing several ways of achieving integration firstly by non-technological means like departmental consolidation, plant consolidation, product rationalisation, more flexible working practices, etc. There are as many options for integration by technical means as well, ranging from group technology to process or transfer lines, and from flexible automation such as robots through to hard automation using special-purpose machinery and transfer lines. The following are some of the advantages of integrated systems that may be expected in the manufacturing environment: - A complete flow of production and management information throughout the entire organisation at all levels. - Universal communication links with interfacing between all hardware and software. - The standardisation of software packages, achieving the transferability of information from engineering applications to commercial modules and vice versa.