Designing an online and real time simulation, control and monitoring of disturbances in an intelligent manufacturing system

M. N. Yuniarto, A. W. Labib*

*Corresponding author for this work

Research output: Chapter in Book/Report/Conference proceedingConference contributionpeer-review

12 Citations (Scopus)


In this paper, the principles and methodologies for developing an online and real-time simulation system for controlling and monitoring an intelligent manufacturing system are proposed. An online and real-time system is a system that always been dynamically connected to another system so if there is a changing in state within one system, the other system will be affected directly. The research focuses on the application of these principles and methodologies into a manufacturing system model that is developed. The combination of the two features (online and real time) and the possibility to add an intelligent feature (by using knowledge-based approach) into the online and real time system will lead to an improvement of manufacturing system performance, which will be more reactive, responsive, flexible and also saving time for making decisions if there are any changing or disturbances in the manufacturing system. In short this paper is mainly concerned with controlling and monitoring disturbance that is caused by deterioration in state, for example machine/resource breakdown. This paper aims at addressing two fundamental issues. The first issue is related to the existence of a gap between shop floor level systems in the form of Programmable Logic Controllers (PLCs) and sensor at one level and scheduling databases such as Material Requisition Planning (MRPII), Enterprise Resource Planning (ERP) and simulation at the supervisory/managerial level. The second issue is related to the parallel interface of maintenance data collection and decision support with the production system. In this paper, the development of hardware and software will be presented to address the two issues. The hardware is a miniaturised/model of a manufacturing system that is controlled by a PLC, a Supervisory Control and Data Acquisition (SCADA) systems and a PC in real-time manner. The software is developed and used to monitor and control the miniaturised system in online and real-time condition.

Original languageEnglish
Title of host publicationProceedings - IEEE International Conference on Industrial Informatics, INDIN 2003
EditorsRainer Unland, Alfred C. Weaver, Mihaela Ulieru
PublisherInstitute of Electrical and Electronics Engineers Inc.
Number of pages6
ISBN (Electronic)0780382005
Publication statusPublished - 2003
Externally publishedYes
EventIEEE International Conference on Industrial Informatics, INDIN 2003 - Banff, Canada
Duration: 21 Aug 200324 Aug 2003

Publication series

NameIEEE International Conference on Industrial Informatics (INDIN)
ISSN (Print)1935-4576


ConferenceIEEE International Conference on Industrial Informatics, INDIN 2003


  • Intelligent and integrated manufacturing systems
  • Real time knowledge-based simulation and control
  • Supervisory control and data acquisition systems


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