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With the growing instability of the global business arena and increasingly aggressive
competition, there is a corresponding increase in the complexity of engineering systems and
challenges faced by manufacturing enterprises. Although current developments in the area of
distributed (manufacturing) engineering systems bring a significant contribution, the results
achieved so far are not a sufficient approach to the needs of modern manufacturing enterprises.
This drives the need to take a broader and more holistic view on distributed manufacturing
engineering systems (e.g., considering engineering-management aspects [1], economic and
technical issues, environmental drivers, social implications).
This article pertains to address challenges of distributed manufacturing engineering systems,
with a holistic approach. The aim of this article is to present preliminary results of an interdisciplinary (on-going) research and development project focusing on the design, specification,
economic performance modeling, and implementation of a wise manufacturing system. Main
manufacturing paradigms are briefly presented, emphasizing their main strengths and
weaknesses. The proposed system architecture towards a wise manufacturing engineering system
is introduced, emphasizing main challenges and open issues. A cost model is also presented. The
article concludes with a section addressing the needs for further research.
2. Manufacturing Systems
This section presents a brief overview of the main requirements of a manufacturing engineering
system, followed by main paradigms on manufacturing. Main challenges and trends are
introduced.
2.A. Main Requirements
Main requirements to be satisfied by manufacturing systems have been summarized in [2] and
[3], and they include: full integration of heterogeneous software and hardware within an
enterprise and across a supply chain; open system architecture to accommodate new (hardware
or software) sub-systems; communication within an enterprise and across enterprises;
embodiment of human factors into manufacturing systems; quick response to external changes
and unexpected disturbances from internal and external manufacturing environments; fault
tolerance at the system and sub-system level (e.g., so as to detect and gracefully recover from
system failures and minimize their implications on the working environment); agility; reconfigurability; scalability. Additionally, todays manufacturing enterprises face several
challenges (e.g., determined by changing clients demands, high diversity of standards for ecommunication, increasing competition) with which they have to deal with and remain
competitive.
Although current developments in the areas of manufacturing and (distributed) engineering
systems bring a significant contribution, the results achieved so far are not a sufficient approach
to the needs of modern manufacturing enterprises and several issues are still unsolved, such as:
seamless interoperability in networks of enterprises (e.g., [4], [5]), scalability, optimal decision
making, self-adaptability, self-improvement).
Manufacturing
System/
Paradigm
Focus
Main Strengths
Main Limitations
Technology/
Approach
1.
Mass production
Reduction of product
cost; Full utilization
of plant capacity.
Inflexibility; Do not
cope with todays
requirements.
2.
CIM
Integration of
computers and
computer-based
tools.
Use of computers to
support different
activities (e.g., design).
3.
Flexible
Manufacturing a
variety of products on
the same system.
High diversity of
manufactured
products.
Expensive;
(Usually) include
unnecessary
functions/ software;
Subject to
obsolescence.
4.
Reconfigurable
Rapid adjustment of
production capacity
and functionality.
Modularity;
Integrability;
Convertibility;
Diagnosability;
Customization.
Include unnecessary
functions/ software;
Subject to
obsolescence.
5.
Intelligent
Systems enhanced
with human
intelligence (e.g.,
concerning decision
making).
Acceptance.
Missing access to a
body to interact
with, and learn
from environment
[25], [26].
Agents.
6.
Holonic
Holons [15].
Centralized control.
Agents, Petri-Nets.
7.
Balanced
automation
Optimal mix of
machines and
humans.
Balance of automated
and human-based
activities.
8.
Bio-inspired
Based on bio-inspired
approaches.
High adaptability,
Flexibility; Often work
well even when a
desired task is poorly
defined,
Agents, bio-inspired
computing, evolutionnary computing
and related algorithms, bio-robotics,
swarm intelligence.
9.
Wise
Wisdom-enhanced
manufacturing
systems.
Wise information
and communication
technologies (wICT);
evolvable hardware;
cloud computing.
Agents.
Manufacturing systems built on the concept of lean manufacturing were focused on continuous
improvement in product quality while decreasing product costs. Flexible manufacturing systems
4
place emphasis on manufacturing a high variety of products using the same system. Agile
manufacturing systems have as main concern quick response to changes (e.g., [11]). A review of
agile manufacturing systems is available in [12]. Main drivers for agile manufacturing are
analyzed in [13].
Although lean and agile manufacturing concepts sound similar, they have different approaches to
manufacturing engineering systems. While lean manufacturing is a response to competitive
pressure with limited resources, agile manufacturing represents the response to complexity
brought about by constant change. As emphasized in [12], lean is a collection of operational
techniques focused on a productive use of resources, while agility is an overall strategy focusing
on thriving in an unpredictable business environment.
Reconfigurable manufacturing systems are manufacturing systems designed to rapidly adjust
their production capacity and functionality, in response to new circumstances (e.g., changes on
product demand, production of a new product on an existing system, integration of new process
technology into existing manufacturing systems), by rearranging or changing its components
(e.g., [14]; [7]). A historical summary of key events related to reconfigurable manufacturing
systems is available in [7]. Unlike dedicated machine systems and flexible manufacturing
systems, reconfigurable manufacturing systems do not have a fixed capacity and functionality,
and they are designed through the use of reconfigurable hardware (e.g., modular machines) and
software (e.g., open-architecture control).
Flexible, agile and reconfigurable manufacturing systems concern the adaptation of the
manufacturing system to new market conditions. While flexible manufacturing systems address
expected changes, agile manufacturing systems concern adjustment to unexpected changes or
events. It is a partial overlapping between agile and reconfigurable manufacturing systems;
however, while agility concerns changes for the entire enterprise, re-configurability refers to the
responsiveness of the production system to change.
Intelligent manufacturing systems are manufacturing systems enhanced with human-like
capabilities (e.g., human-like decision making capabilities). A review of Internet-based
manufacturing system, with emphasis on distributed intelligent manufacturing is available in [8],
and a review of the application of agent systems in intelligent manufacturing is available in [3].
Holonic manufacturing systems rely on the concept of holonic systems introduced in [15].
Accordingly, a holon is an identifiable part of a system with a unique identity, and consists in
sub-ordinate parts belonging to a larger whole. In a holonic manufacturing system, a holon is an
autonomous and cooperative manufacturing block for transforming, transporting, storing/
validating information and physical objects (e.g., [16], [17]). Despite the great promise of
holonic (and multi-agent) systems, they did not make significant inroads in manufacturing plants
in use today (e.g., [18]) mainly due to: lack of widely accepted standards; their implementations
cover partially the manufacturing landscape; the use proprietary standards and mechanisms; the
concept of centralized decision is difficult to accept.
take optimal wise decisions (e.g., concerning resource utilization, incorporating scheduling
algorithms, planning and control execution techniques), having a goal-driven and cooperative
behave; performance assessment.
Concerning future trends: it is rather difficult to forecast long term trends for manufacturing
engineering systems. However, it is possible to indicate future trends for relatively short term,
and directions for further research. Among research and development areas which will have an
increasing attention are: scalability, seamless interoperability, algorithmic engineering systems
biology (e.g., [29]), and manufacturing systems enhanced with human capabilities, such as
wisdom-enhanced manufacturing systems.
3. Wise Manufacturing Systems
3.A. Main Characteristics
A wise manufacturing engineering system represent a wisdom-enhanced3 intelligent
manufacturing system, which has the ability to solve problems (e.g., related to control,
collaboration) and make decisions taking into consideration human values and humans
subjectivity. In this research work (which reflects results of an on-going research and
development project), a wise manufacturing system is an intelligent manufacturing engineering
system (that is a system which has the ability to solve problems and make decisions taking into
consideration human values and humans subjectivity), which tends to be self-improving (e.g.,
able to monitor and assess the economic performance of a manufacturing process, unit or subunit, diagnose the causes of lower performance and take appropriate decisions for the overall
unit/ systems performance improvement), self-adaptable (e.g., by detecting abnormalities and
taking decisions to recover from them), and self-healing (e.g., being able to monitor itself,
diagnose causes of failure and recover from them, and may concern a single service or
manufacturing unit, or address a more global level, such as manufacturing network).
The idea of self-adaptation is to not new; e.g., the concept of self-adaptive software is related to
the field of evolutionary computation (e.g., [27]). Accordingly, self-adaptation enables the
algorithm to dynamically adapt to the characteristics of a problem and cope with changing
environmental conditions. The novelty of this approach described in this article is related to selfimprovement (especially from an economic perspective) and wisdom-enhancement.
Additional requirements (besides the ones identified in Section 2) of such systems include:
- Constant data integration, to assure real-time capturing and loading from different
operational sources;
- Highly available analytical methods and tools based on an analysis engine that can
consistently generate and provide access to current business analyses at any time. Such
analytical tools and applications are aimed at supporting real-time operational and tactical
decisions, and they should be completely connected to the operational/ manufacturing
units of the manufacturing system and information and communication technology
platform;
3
This characteristic may be related with Penroses explanation of consciousness [28], or elan vital concept, as
introduced by Chalmers [29].
The Analyzer (10) unifies the information received from the Monitoring Unit (9) before the
actual data processing begins. The received data is interpreted (e.g., what indicates the captured
data). The Analyzer executes a software program which selects the metrics/ indicators which
may be calculated with the received information (e.g., based on a set of predefined metrics stored
in the local repository). It analyzes which is the significance of the captured data for the current
situation of the manufacturing company (e.g., concerning the execution of the manufacturing
processes), based on the values obtained for the performance assessment indicators/ metrics, by
comparing the attained values with threshold values of key indicators. Based on the results
attained for the key indicators, the Analyzer identifies which improvement decisions (for the
overall manufacturing enterprise, and/ or for specific units) could be made, what risks may arise.
The Analyzer determines whether the manufacturing system and all its units operate within a
range of acceptable values for a set of parameters (e.g., related to economic performance, noise,
optimal use of resources). Based on this information, a prediction of the performance and
assessment of the risks for changes in the environment are made. The Analyzer indentifies the
areas of improvement (e.g., manufacturing processes that can be improved), and makes (selfimproving) decisions (e.g., assignment of resources) aiming at attained the desired values for the
selected parameters. Thus, the Analyzers software capabilities should include decision support,
on-line analytical processing, statistical analysis, forecasting and data mining.
The Analyzer takes the appropriate wisdom-enhanced decisions (e.g., based on the expected
values of the parameters and the actual quality degradation of these parameters) and transmits
them to the Architecture Model Unit (12) and Repair Handler (11),
Violations of constraints are handled by a repair mechanism: the Repair Handler (9). Based on
the information received from the Analyzer, the architecture of the system may be adapted by the
Architecture Model Unit (12) (e.g., when the values obtained for certain parameters fall outside
well established limits), and the changes are propagated to the (operating) manufacturing unit. In
this way, the Architecture Model Unit and Repair Handler support reasoning of the production
system.
3.C. Cost Model
A predictive cost model is proposed in this sub-section, which is derived from the cost model
proposed by Chituc and Nof [30]. This proposed cost model is aimed at studying a wise
manufacturing system.
The costs incurred in manufacturing a product are the costs associated with all activities
performed by the enterprise during the manufacturing process. Costs represent a useful
parameter in assessing a systems performance. The next paragraphs refer to costs incurred by
making use of a wise manufacturing system to manufacture a product. Thus, other costs
associated to manufacturing (e.g., raw material and components acquisition; e-communication
costs; outsourcing costs; overheads; warehousing costs) are not addressed in this study.
To develop a cost model for a wise manufacturing system the cost model proposed by Chituc and
Nof [30] has been extended, as follows. The recovery cost from [30] corresponds to (self-)
healing costs in a wise manufacturing system. Other costs (besides the costs identified in [30])
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have been considered here: costs associated with self-adaptation, Cadapt, and cost associated with
self-improvement, Cimpr.
Like in [30], let pj be the probability of an unexpected event u to occur, which prevents the
manufacturing of product g. Let Cp be the cost associated in case pj is positive (e.g., disturbances
occur). Let rj be the probability that the consequences of the event u can be healed, so that the
product g is manufactured, and let Cheal be the corresponding additional (self-)healing cost.
With these assumptions, the total cost of manufacturing a unit of a product (considering costs
which are incurred by using of a wise manufacturing system) (Cwms) can be modeled as
illustrated in Eq. (1), where Cm represents the total manufacturing cost to produce a unit of a
product4.
Cwms = Cm + pj Cpj + pj rj (Cheal + Cadapt ) + Cimpr
(1)
TCwms =
qi Cwms
(2)
i =1
A restriction could be set here: qmin " qi " qmax, where qmin and qmax are the minimum and
maximum quantities of an ordered product (e.g., an order is accepted only if qi # qmin).
This approach has to be interpreted with care. Firstly, this is a simplified cost model (and the
reality is more complex). Secondly, this predictive cost model has been elaborated considering
the received orders refer to a single product. Thirdly, in order to assess the performance of a wise
manufacturing system, the prospective costs have to be analyzed in correlation with the expected
payoffs.
Cm includes costs related to the acquisition of raw materials and components, labor costs, e-communication costs,
and other costs related with the manufacturing process, which have not been detailed here because the aim of this
sub-section is to model specific costs related to the use of a wise manufacturing system.
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inspired manufacturing systems, attempts to hybridize engineering systems by combining bioinspired computing with formal methods) hold a great promise through the next generation of
engineering systems. Although such approaches have been applied only to simple problems,
there is hope that they may be scalable to large/ complex problems. However, as emphasized by
[26] the field of artificial intelligence has been labeled as failure, since the produced artefacts
cannot actually be confused with a living organism (e.g., models helped modeling biological
engineering systems better, but the produced models never worked as well as biology).
Maybe wise information and communication technologies (wICT) can be regarded as the new
generation of information and communication technologies, encompassing the theories and
applications of artificial intelligence, pattern recognition, learning theory, data warehousing, data
mining, knowledge discovery, swarm intelligence, adaptive management, bio-inspired methods,
cloud computing.
wICT may be regarded as an inter-disciplinary field, involving techniques developed not only in
computers science/ engineering, but in other related communities, e.g., economics, mathematics,
cognitive science, neuroscience, operations research. A promising step towards wICT is the
World Wide Wisdom Web (W4) (e.g., [33], [34]).
4. Conclusions and Future Work
Despite the developments in the area of engineering systems and advancements of information
and communication technologies, current (manufacturing) engineering systems fail to address all
the needs of todays manufacturing enterprises.
Current trends of manufacturing engineering system are towards enhancing machines with bioinspired and human abilities (e.g., intelligence, wisdom, cognitive functions), and in hiring
(fewer) highly skilled employees. However, this trend has to be closely accompanied with
(positive and negative) human, social and environmental consequences.
This article reflects results of an on-going inter-disciplinary research and development project
towards a wise manufacturing engineering system. A proposed system architecture has been
described, which support self-adaptability, self-healing, self-improving and wisdom-enhanced
capabilities. Main challenges concerning monitoring, interpretation, resolution, self-adaptation,
system wisdom-enhancement, economic performance assessment, and implementation issues are
discussed. A cost model is also presented.
Wise information and communication technologies (wICT) are envisioned (through the prism of
current technologies and approaches) as supporting technologies for the implementation of a
wise manufacturing system. wICT may represent a paradigm shift, driven from artificial
intelligence techniques, the Wisdom Web (W4), autonomy-oriented computing, service-oriented
computing, cloud computing, swarm intelligence. It will yield the new tools and infrastructures
necessary to support wise manufacturing systems. As technologies evolve, and simulation,
modeling and prototyping techniques mature, the hope is that manufacturing such a wise
engineering system will become relatively straightforward. However, this requires research and
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