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 Advances in
Manufacturing
Technology - XX

Proceedings of the 4th International Conference on Manufacturing Research

(ICMR2006)

Liverpool John Moores University, UK

5th - 7th September 2006

Edited by
M. N. Morgan and I. D. Jenkinson

Liverpool John Moores University

iii
Knowledge Based Systems Support in Micro-Manufacturing

N.D. Mekras 1' a, N. A. Karbadakis 2' b' P. V. Kontovazenitis 3• C, N. M. Vaxevanidis4 • d

1• 2• 3• 4 ANTER Ltd.-Technology Development and Research Co, Feidippidou 22 Str., 11527 Athens, Greece
aanter@anter.gr, ankmekras@otenet.gr, bnkarba@anter-net1.com, "pkonto@anter-net1.com,
dvaxev@ath. forthnet.gr

Abstract. The scope of this paper is to indicate how Knowledge Based Systems (KBS) can be
applied to support manufacturing systems and especially activities concerning decision support on
micro-manufacturing. Also an approach will be presented concerning the integration of the KBS
with the rest IT applications of a manufacturing enterprise. Such an approach is already being
implemented within the EU FP6 project MASMICRO, where a Knowledge Based Decision Support
System is being developed to support micro-manufacturing. The paper includes: a) an introduction
to Knowledge Based Systems, with a short presentation of the three main Knowledge
Representation Structures (KRS) used in KBS and their relevant knowledge processing methods for
reasoning and knowledge update, b) a list of possible Knowledge Bases (KB) examples to support
applications within a manufacturing system, concerning processes, products, materials, machines
and tools, and c) a presentation of an approach for the integration of the KBS support with the rest
IT applications of a manufacturing enterprise.

Keywords: Artificial Intelligence, Knowledge Based Systems, Micro-manufacturing.

Introduction
In this paper a short presentation is given on how Knowledge Based Systems (KBS) technology can
support manufacturing systems, and also a presentation of a methodological approach for the
integration of the KBS with the rest IT applications in a manufacturing company. KBS have
emerged as an Artificial Intelligence (AI) research field more than 20 years ago and provided useful
methods and techniques for knowledge representation and processing, mainly for two basic
categories of Knowledge Representation Structures (KRS) which are based on Rules and Object-
Oriented structures. In the next sections of this paper, besides a short introduction on these
knowledge representation and processing methods, a presentation will be included concerning
possible KBS application examples, which can be used to support activities in manufacturing,
together with a proposed approach for the integration of these applications with the rest Information
System of an enterprise. The goal of this integration approach is to help the KBS developer, to
develop KBS applications, which are part of the rest IT system of the enterprise, use common IT
resources (like common production databases) and work as a supplement to the rest production
software modules. Through this approach manufacturing knowledge and experience that can not be
expressed algorithmically, can be represented, stored and processed through the KBS methods and
techniques, and cooperate with the rest IT software in an integrated manner, increasing by this way
the utilization, use and efficiency of the KBS in manufacturing. The software implementation of
this approach is under development within the EU FP6 project MASMICRO, focusing on the
development of KBS applications for micro-manufacturing systems.

Introduction to KBS. Since the 70's Artificial Intelligence (AI) researchers focused on efforts
to represent knowledge and process it by computers trying to develop methods that resemble the
way that the human mind stores and processes knowledge, besides algorithmic knowledge and
mathematical procedures. From these efforts several methods have appeared for the representation

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and processing of Knowledge Bases of both rule-based type and object-oriented type (Semantic
networks, Frames/Objects) [1,2,3], aiming mainly at the representation and processing of symbolic
knowledge, that can also cooperate and work supplementary with algorithms and mathematical
models. A short introduction on the three main Knowledge Representation Structures (Rules,
Semantic Networks and Frames/Objects) used in KBS follows next:
One of the most common Knowledge Representation Structures used for the creation of
knowledge bases are the Rules in the form of Hom clauses. Rules may also use and be supported by
data, stored in simple predicates or in records in a conventional database. Creating and combining
rules, knowledge bases can be created and processed with formalized techniques, like the
techniques of forward and backward rule chaining. Processing the rules, inferences can be made
and results can be obtained, that are based on the rules and data of the knowledge base.
Another form of Knowledge Representation Structures is the representation through the
Semantic Networks. In this model entities are represented as the nodes of a graph structure, in which
the links represent the relationships between entities. The links can represent functional
relationships, class membership relationships, hierarchical relationships, etc. The semantic network
reasoning process is based on the processing of the network aiming to establish whether two
concepts can be related within a network. The most common processing method within a semantic
net is the method of intersection search.
A third structure for representing knowledge are the Frames or Objects, which were developed
originally by Minsky in 1968 at MIT. The main idea in frames/objects is that knowledge is
organized in classes of entities (frames), which are related and classified in the knowledge base.
Each frame contains information that is stored in specific infonnation slots, which identify its basic
structural properties and may include values, restrictions and methods. We may say that the
frame/object structure resembles to the structure of complex networks, where on each node much
more information is stored than the infonnation stored on the nodes of a semantic net. Processing a
frame system for reasoning purposes gives the possibility for obtaining inferences about existence
of frames/entities, generic and default properties and methods' results. Also results of reasoning by
analogy and checking for abnormal situations are possible. Object-oriented programming that is
used widely nowadays originates from the frame systems and uses the basic principles of
classification, inheritance, slot-filler knowledge representation and message passing between
objects/frames.

KBS applications in micro-manufacturing

As it is already mentioned in previous paragraphs, KBS methods and tools are applied by the
authors of this paper within the FP6 EU project MASMICRO, for the development of a KBS
decision support tool for mass-micro-manufacturing. The aim of this tool is to support the
representation, storage and processing of both symbolic and algorithmic knowledge concerning
processes, products, materials, machines and tools. In the next paragraphs of this section a short
introduction on KBS implementation and a listing of possible KBS examples for micro-
manufacturing is presented for the above 5 main categories of production entities. The listing of the
KBS examples is given in Table 1, which includes the Knowledge Representation Structures (KRS)
for the Knowledge Bases (KB) content and examples of results that the knowledge processing
mechanisms (inference engines) can provide for the several applications.
Note, that micro-manufacturing in the context of the present paper is considered to be the
production of parts and components with at least two dimensions in the sub-millimeter range; see
also [4,5].

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 Processes. Software applications for the representation, storage and processing of both symbolic
and algorithmic manufacturing processes' knowledge, are of vital importance for a manufacturing
enterprise since processes are considered the core elements of a manufacturing system. From the
time that the industrial revolution started, until today, several approaches for the design and
improvement of production systems are based on the concept of a well designed and efficient
process that can be represented and re-engineered using methods for process mapping, calculations
and measurements [6]. KBS methods, both rule-based and object-oriented (semantic networks,
frames/objects) can be useful for the representation and the processing of processes' knowledge, to
support their management and improvement [3,7,8]. A presentation of the available processes for
the production of micro-components is beyond the scope of the paper; see [5,9] for an overview.
However, it should be noted that three main production routes are followed: (a) the down-scaling of
existing precision manufacturing processes, (b) the up-scaling of MEMS processes from the micro-
electronics sector and (c) the development of entirely new technologies. Both up-scaling and down-
scaling suffers, in most cases, from process stability and worsening of materials properties whilst on
the other hand, entirely new processes have not yet reached the level of industrial use [4,9].

Products. The types of knowledge for describing and classifying micro-products and micro-
components concern mainly symbolic knowledge structures of the object-oriented form for the
representation of the product/component entities, their attributes and their relations [3, 10]. On the
other hand rule-based knowledge and algorithmic knowledge can be attached to these entities to
express products' manufacturability, dimension limits and tolerances, conformance with quality
standards, etc. Note, that in case of micro-products the geometry (dimensions and tolerances)
affects significantly not only the possible manufacturing sequence but also the associated
production support in terms of handling, assembly and metrology. Micro-products should possess a
high degree of integration of functionalities and components and require an innovative product
design methodology; see [9].

Materials. The structure of materials' knowledge needed for manufacturing usually describes
certain attributes and specifications of the materials needed in a process for the production of a
specific type of product. Usually the knowledge concerning materials information for
manufacturing purposes is rather of a simple structure and can be stored in data tables of relational
databases that can be used by both symbolic and algorithmic knowledge bases of processes and
products. Also, apart from materials information in the form of data records, additional knowledge
is often necessary, mainly for the relation of the materials attributes and properties to the processes
and the products that need these materials. Since the origin of micro-manufacturing is the micro-
electronics sector the use of semi-conducting materials (mainly silicon) is quite established. The
specific properties of the more traditional materials (metals, ceramics, polymers) and the observed
size effect, limit for the time being, their direct use in micro-products [4,9]. However, these
"traditional" materials together with the corresponding manufacturing methods are well suited for
mass production.

Machines and tools. Both object-oriented and rule-based knowledge structures can be used for
the representation of machines' and tools' attributes & functionalities [3,7,10]. The object-oriented
structures can be used for the classification of the machines and tools according to their general and
more specific attributes, while the rules can express manufacturing size limits, sequence of tasks,
tools' usage etc.

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 Examples ofKBS content Examples oflnference Engines' Results
a) PROCESSES (Forming I Machining I Thermal processes (micro-EDM, LBM), Assembly,
Handling, Quality Control, Metrology, Operations Management)_
al) Rules for selecting type of micro-fabrication a1) Micro-fabrication process to be applied
process and material according to product type. and material selection.
a2) Rules for relating the sequence of micro- a2) The sequence of micro-fabrication steps.
fabrication tasks with product geometrical features.
a3) Rules for relating the fabrication process a3) Operational parameters of micro-
parameters with material attributes. fabrication processing steps (e.g. punch force
and speed, type of lubrication)
a4) Rules for selecting assembly method and the a4) Assembly method (e.g. miniature nut and
sequence of assembly steps according to material type, bolt fasteners, glue, snap fit, built-in
shape of components and product attributes. approach) and sequence of assembly steps.
a5) Rules for selecting the type of micro-handling a5) Micro-handling method to be applied
method and micro-handling parameters according to (e.g. using friction, electrostatic, cryogenic)
product attributes (e.g. product dimensions, fragility, and handling parameters (e.g. movement
etc.). range, velocity, gripper dimensions, force).
a6) Object-Oriented structures (Semantic Networks or a6) Grouping of micro-production processes
Frames I Objects) to classify and relate micro- according to common attributes.
_Qroduction processes.
a7) Rules for relating values of quality variables with a7) Causes for non-conformities.
machinery status, raw material and other factors &
parameters that influence quality.
a8) Rules for recognizing product features indicative a8) Product features with quality problems.
to quality problems.
a9) Semantic networks to represent and process cause I a9) Causes for non-conformities.
effect models to investigate quality problems
(Ishikawa method).
a 10) Rules for expressing availability constraints and a 10) Scheduling of processes.
precedence conditions for processes or for tasks within
a process.
b) PRODUCTS (Micro-pins, micro-gears, micro-cups, micro-valves, MEMS, implants, etc.)
b 1) Object-Oriented structures (Semantic Networks or b 1) Grouping of products according to
Frames I Objects) to represent, classify hierarchically generic and more specific attributes.
and relate product entities and their attributes.
b2) Rules for modifying existing products according to b2) New product specifications.
new specifications I needs.
c) MATERIALS (Metallic Alloys, Silicon, Ceramics, Polymers, etc.)
c 1) Rules for selecting the material according to c 1) Selection of appropriate material.
product type and process needs & conditions.
c2) Rules for controlling material properties during c2) Process parameters that do not affect the
process implementation. material quality.
d) MACHINES I TOOLS (Forming, Machining, Micro-EDM, Micro-Assembly, Handling,
Metrology & Inspection)
d 1) Rules for selecting machine set-up parameters and d 1) Machine set-up parameters.
tools according to product specifications and process
needs (e.g. product geometry, material).

Table 1. KBS application examples in micro-manufacturing

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Integrating the KBS applications
The level of integration of the KBS methods and tools in the factory is an important factor for
improved performance and better utilization of the KBS applications, which should work in a
cooperative manner and as a supplement to the rest IT applications of a manufacturing enterprise.
Considering the KBS applications as part of an integrated IT system, among others, the following
main benefits appear:
• Use of common databases for both the KBS and the rest IT applications. Often such
databases already exist and both rule-based and object-oriented knowledge bases
can utilize the already existing information.
• KBS can solve problems that concern mainly symbolic processing of knowledge
and can work in parallel and cooperatively with algorithmic applications, in cases
that together with the implementation of mathematical formulas and procedures,
human decision making takes place that needs symbolic processing of expert
knowledge.
• KBS applications, as part of an integrated IT system, can be used by several people
in the company, and will not be implemented as isolated applications on a personal
computer of a specific staff member or for a single work center.

Anyway, the achievement of full integration of the KBS applications within a manufacturing
company is a quite difficult task and almost in all cases the KBS applications that have appeared,
were developed to support knowledge processing for a specific manufacturing activity (e.g. design).
By this way, the later integration of the KBS with the rest IT applications (e.g. Bill of Materials,
MRP, Process Planning, etc.) is difficult, if not impossible in most cases.
Within the EU FP6 project MASMICRO, in which the authors of this paper are working for the
development of a KBDS (Knowledge Based Decision Support System), which in fact consists of a
set of KBS applications to support micro-manufacturing processes, an approach is being followed,
by which the core components of the whole production system are considered to be the processes,
as these are described by the IDEFO and ASME international standards for processes representation
[6]. The several MASMICRO KBS applications are considered as part of these processes, by
including rules and object-oriented structures to represent and process knowledge both of rule-
based type and object-oriented type that are applicable and are needed for decision making during
the process implementation. By this way the systemic approach for production systems
representation is followed, considering that the whole production system consists of chains of
processes, which are linked, interrelated and use common production databases, and on the other
hand the KBS applications are developed as attached to and as part of these processes, by
representing and processing knowledge that the processes need and can not be expressed through
mathematical formulas or algorithms. KBS applications, that are supporting decision making for the
other four main categories of production entities, which are: the products, the materials, the
machines and the tools, are also considered tightly linked and are attached to the processes,
considering that the products are the outputs of the manufacturing processes, the materials are the
inputs and the machines and the tools are the means for the processes to be implemented.

The basic structure of the MASMICRO KBDS is given in the next Fig. 1.

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 J
L
User Interface ]
/ •
Knowledge Processing Mechanisms
(Inference engines) for:
- Processes (Fanning, Machining, Non-conventional processes,
.. Inspection, Assembly, Operations Management)
- Products
- Materials
- Machines/tools
'-
Knowledge I Data
Acquisition
t ...;;;;

Micro-manufacturing
Knowledge Bases
... - Rule-based
..._
-Object-Oriented (Semantic Nets, Frames/Objects)
-
...
•
Micro-manufucturing
Databases

Fig. 1. Basic structure ofthe MASMICRO KBDS

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