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The product development process, within a typical manufacturing company, utilises huge amounts of knowledge related to manufacturing and design activities. Knowledge based systems are increasingly being used to support manufacturing and design decisions. These systems are important tools for obtaining a competitive advantage and leverage using company "know-how". However, it is important to define suitable knowledge structures in the creation of these decision support systems. Due to the significant volume of knowledge generated in the manufacturing and design stage, there is a need to create structures and methods that readily manage and maintain the knowledge in order to a) assure the long-term use of these systems b) improve the company's competitiveness. The research reported in this thesis explores and defines a Manufacturing Facility Information and Knowledge Model (MFIKM) allowing a) the ability to store and manage various types of knowledge, b) the capturing of valuable new knowledge using a knowledge maintenance method. The understanding of an information and knowledge infrastructure using different types of knowledge categorisation has been explored. The major emphasis has been placed on understanding the facility knowledge structure related to processes and resources supporting process planning decisions. Using a knowledge maintenance life cycle as a method to maintain knowledge, it was possible to capture new and valuable machining knowledge using different types of representations. Knowledge models and methods are essential in the definition of structures to support manufacturing decisions allowing knowledge management and maintenance. It has been shown that the knowledge structures defined for the new model can serve as a source and repository for different types of knowledge allowing the support of manufacturing decisions with up-to-date knowledge. The framework defined enables the structuring of facility knowledge, processes, and resources, as super classes; improving the understanding of the relationships and dependencies among them, and allowing accessibility depending on the characteristics of each. A UML tool helped in the creation of new structures detailing attributes for the classes defined. An experimental system has been implemented using the object-oriented database ObjectStore© and the Visual C++ programming environment. The MFIKM has been explored using scenarios from machining knowledge to successfully demonstrate the feasibility of knowledge maintenance supporting process planning decisions using the knowledge structures defined.

Trends towards reduced life-time of products and globalised competition has increased pressure on manufacturing industries to be more responsive to changing needs of product markets. Consequently, the use of simulation to describe short term future performance of manufacturing system has become more significant than ever. An application of simulation that has attracted attention is for testing of control logic before commissioning on site by using a detailed simulation model called emulation model. However, though the success of using emulation particularly in improving cost-effectiveness of automated material handling system delivery has been acknowledged by industries and simulation model developers, the uptake for this technology is still low. The major inhibitors are the high costs of its model building as well as simulation and emulation models are perceived to be non convertible. The main objective, of this research is to establish a methodology to develop simulation model that can be converted into emulation model with ease, thus making emulation technology more affordable. The product of this research called the methodology to build Hybrid Simulation Emulation Model (HSEM) is a new approach of building emulation model comprising of three phases namely (1) development of base simulation model, (2) development of detail emulation model, and (3) integration of controller with the emulation model. Important requirements for HSEM are flexibility of adding details to the simulation model and inter process communication between model and real control system. To facilitate implementation of the methodology, it is essential that the simulation software package provide functionalities for modular model development, access and adding of codes, integration with other application and real time (RT) modelling. The methodology developed offers a more affordable emulation modelling and an opening for further research into the comprehensive support for the implementation of real time control system testing using emulation.

The search for automatic manufacture of components has been and continues to be a major goal of researchers since NC machines appeared in 1952. The ability to generate a NC tool path is now commonplace from CAD/CAM systems, but the technology used to program NC machines is still based on the original standards. Today under the IMS project named STEP-NC in Europe and Asia, and Super Model in the USA, industrialists and academics are collaborating to deliver a new data model for CNC machines entitled the ISO 14649 standard, informally known as STEP-NC. The author believes that the STEP-NC standard will provide software vendors with the basis to achieve this goal of automatic CNC manufacture.

In recent decades there has been a major shift in the Design and Technology curriculum in secondary schools away from manual techniques and towards digital processes and products. CAD/CAM (computer-aided design/computer-aided manufacturing) is not only commonplace it is also embedded into the English National Curriculum. There is much evidence to suggest that this shift of emphasis has not been without problems. The equipment used to design and quickly modify products mirrors the technological advancement in everyday life. This rapid change can be a source of uncertainty especially when one considers that software taught to Year 7 (11-12 years old) students today will often be outdated by the time they finish compulsory secondary education in Year 11 (16 years old). Perhaps more significantly, because of these issues teachers struggle to encourage creativity when teaching CAD/CAM within design and technology education. 3D solid modelling software is particularly difficult to use and be creative with in the early stages of learning the software. Furthermore Design and Technology teachers often struggle to keep up to date with rapidly changing software and frequently lack the confidence to teach it, which, in turn, affects their students' progress. This research investigates the effects of teaching and learning CAD/CAM software and the impact this has on encouraging creativity in the classroom with Key Stage 3 students and their teachers. It suggests we require some rethinking concerning what we want students to know and be able to do and considers an alternative pedagogy which may help students to achieve more creative outcomes when using CAD. The research is undertaken through an intervention study within an action research framework. It outlines new methods and strategies to improve the confidence and creativity of students when using 3D modelling software and addresses the reality of day-to-day teaching pressures.