Structured methodology for the selection and effective implementation of manufacturing control systems

All manufacturing companies, irrespective of their size, make use of appropriate manufacturing planning and control systems. Very often such systems are computer-based, involving considerable effort and the expenditure of large amounts of money. Yet the whole process of selecting the type of manufacturing control system which should be implemented in a given environment remains unstructured. The paper describes a structured and industrially validated methodology for the selection and implementation of manufacturing control systems. A reference model, based on complexity, uncertainty, flexibility and company culture characteristics, is used to assess the need for and the difficulties associated with the implementation of particular types of manufacturing control systems in a given environment. A gap analysis approach is used to assess the disparities between the prerequisites for the effective implementation of a given type of manufacturing control system and what actually exists in a given environment. The structured-help system shows how to overcome the problems identified at the gap analysis stage. The complete methodology and the associated knowledge bases have been implemented in a computer-based system