A Presentation to the A Presentation to the IEEE Jamaica Conference, 2000IEEE Jamaica Conference, 2000::

““Mechatronics, Sociotechnical Mechatronics, Sociotechnical Work Systems and the Work Systems and the

Development of Sustainable Development of Sustainable Competitive Advantages for Competitive Advantages for Manufacturing Industries in Manufacturing Industries in

Jamaica”Jamaica”

Gordon Mullings, MSc Physics (UWI)Gordon Mullings, MSc Physics (UWI)

UWI Centre for Environment and DevelopmentUWI Centre for Environment and Development““The Caribbean’s Sustainable Development Gateway”The Caribbean’s Sustainable Development Gateway”

ICIC22Ts, Mechatronics & Ts, Mechatronics & Industrial Renewal in Industrial Renewal in

JamaicaJamaica

Echoing Nicholas Negroponte, we Echoing Nicholas Negroponte, we can see that engineered systems can see that engineered systems are now made from . . .are now made from . . .

BITS, plus ATOMS, in INTELLIGENT BITS, plus ATOMS, in INTELLIGENT STRUCTURESSTRUCTURES

Thus, digital information is now as Thus, digital information is now as much a part of products or much a part of products or processes as hardwareprocesses as hardware

From IT to ICFrom IT to IC22T’sT’s

While our Colleagues in Computing While our Colleagues in Computing often tend to think in terms of often tend to think in terms of “Information Technologies,” a broader “Information Technologies,” a broader perspective is more useful for perspective is more useful for engineering in a world of bits plus engineering in a world of bits plus atoms . . . ICatoms . . . IC22T’sT’s– That is, That is, Information, Communication Information, Communication

and Control Technologiesand Control Technologies– This highlights the role of This highlights the role of MechatronicsMechatronics

Mechatronic SystemsMechatronic Systems

Increasingly, engineered products and Increasingly, engineered products and systems integrate mechanical, electrical, systems integrate mechanical, electrical, electronic, instrument and other electronic, instrument and other components under computer control.components under computer control.

The term “Mechatronics” relates to this The term “Mechatronics” relates to this fusion, such as in a robot, a page printer, fusion, such as in a robot, a page printer, an automobile engine management an automobile engine management system, or an industrial sewing machine. system, or an industrial sewing machine.

Exemplar: Robotic Work Exemplar: Robotic Work Cell With NC LatheCell With NC Lathe

SOURCE: Rhino Rohotics, http://www.rhinorobotics.com/workcell.html

Mechatronics As a Design Mechatronics As a Design PhilosophyPhilosophy

““Mechatronics” also refers to a design Mechatronics” also refers to a design philosophy/strategy that stresses the philosophy/strategy that stresses the synergistic performance of systems that synergistic performance of systems that integrate precision mechanisms and integrate precision mechanisms and electronics, under robust computer electronics, under robust computer control. (Such designs, as a rule, will control. (Such designs, as a rule, will require team-based engineering.)require team-based engineering.)

This design strategy is set to dominate This design strategy is set to dominate the future; thus it is critical to the the future; thus it is critical to the renewal of Jamaica’s industrial base.renewal of Jamaica’s industrial base.

Mechatronic System Mechatronic System ArchitectureArchitecture

DYNAMIC SYSTEMDYNAMIC SYSTEM

SENSORSSENSORS& INSTRUMENTS& INSTRUMENTS

INTELLIGENTINTELLIGENTCONTROLLERCONTROLLERACTUATORSACTUATORS

I/P’sI/P’s O/P’sO/P’s

REFERENCE I/P’sREFERENCE I/P’s

DISTURBANCESDISTURBANCES

Control StrategyControl Strategy

The underlying The underlying control strategycontrol strategy is: is:– Sense the dynamic system’s behavior.Sense the dynamic system’s behavior.– Compare it with the desired behaviour Compare it with the desired behaviour

(which may vary across time) as set by (which may vary across time) as set by reference i/p’s (which may be stored in reference i/p’s (which may be stored in the controller or externally impressed).the controller or externally impressed).

– Drive the resulting error towards zero, or Drive the resulting error towards zero, or at least an acceptable level, in the face at least an acceptable level, in the face of noise, drift, disturbances, etc.of noise, drift, disturbances, etc.

Typical Controller ModesTypical Controller Modes

Controllers in such mechatronic Controllers in such mechatronic products, units or systems may use products, units or systems may use several modes, such as:several modes, such as:

Digital PID (servo and/or regulator)Digital PID (servo and/or regulator) Discrete state control (a sequence of Discrete state control (a sequence of

states/phases executes a process)states/phases executes a process) Fuzzy control (using weighted sums of partial Fuzzy control (using weighted sums of partial

fuzzy setfuzzy set memberships to give memberships to give crispcrisp control control actions)actions)

Neural Network (emulate the behaviour of Neural Network (emulate the behaviour of neurons and synapses, in hardware or neurons and synapses, in hardware or software)software)

E.g. A Fuzzy-PID LoopE.g. A Fuzzy-PID Loop

PIDPID ACTUATORACTUATOR PLANTPLANT

MEASURINGMEASURINGTRANSMITTERTRANSMITTERFLCFLC

++

--

•A Fuzzy Logic Contoller has three stages:A Fuzzy Logic Contoller has three stages:•A fuzzification stage that assigns degrees of membership in fuzzy setsA fuzzification stage that assigns degrees of membership in fuzzy sets•A fuzzy rules stage that applies IF-THEN rules to the membershipsA fuzzy rules stage that applies IF-THEN rules to the memberships•A defuzzification stage that uses weighted sums to give crisp o/psA defuzzification stage that uses weighted sums to give crisp o/ps

SET-SET-POINTPOINT

O/PO/P

Computer Integrated Computer Integrated ManufacturingManufacturing

When such mechatronic process units are When such mechatronic process units are integrated in a plant-wide information integrated in a plant-wide information system, through say the manufacturing system, through say the manufacturing automation protocol (MAP) bus, it leads to automation protocol (MAP) bus, it leads to computer integrated manufacturing, CIM.computer integrated manufacturing, CIM.

This creates an opportunity for extremely This creates an opportunity for extremely flexible manufacturing systems that can flexible manufacturing systems that can reap the advantages of reap the advantages of bothboth mass and mass and custom manufacturing.custom manufacturing.

Typical CIM ArchitectureTypical CIM Architecture

FACTORY-WIDE BACKBONE LANFACTORY-WIDE BACKBONE LAN

MFG CELLMFG CELL

GG

MFG CELLMFG CELL

INTERNETINTERNET

Each Cell has anEach Cell has anIntra-Cell LAN,Intra-Cell LAN,with a Cell with a Cell ControllerController

MKTGMKTG

SALESSALES

ENG’GENG’G

ADAPTED: Halshall, 1992ADAPTED: Halshall, 1992

The Heart of a CIM: The Heart of a CIM: Manufacturing Planning & Manufacturing Planning &

Control SystemsControl Systems

MPC SYSTEMMPC SYSTEM•Mat’s req’ts planningMat’s req’ts planning•PurchasingPurchasing•Master prod schedMaster prod sched•Shop floor controlShop floor control

FinancialFinancialControlControl

EngineeringEngineering& Manufacturing& Manufacturing

Quality AssuranceQuality Assurance

Sales &Sales &Marketing Marketing

ADAPTED: Miller & Vollman, 1985ADAPTED: Miller & Vollman, 1985

The Internet:The Internet:E-Commerce E-Commerce Links: Links: B2C, B2B, B2GB2C, B2B, B2G

Mass CustomisationMass Customisation

““Mass Customisation” results when Mass Customisation” results when CIM is integrated into e-commerce:CIM is integrated into e-commerce:– Customers order what they want, Customers order what they want,

when and where they want it.when and where they want it.– Through plant communication Through plant communication

networks and CIM, the networks and CIM, the custom productcustom product is manufactured with is manufactured with mass efficiencymass efficiency..

– Rapid delivery exploits modern Rapid delivery exploits modern transportation networks. transportation networks.

CASE: Dell ComputersCASE: Dell Computers““The Internet allows Dell to find out what each customer The Internet allows Dell to find out what each customer wants, instantly and cheaply. Continuous-flow manufacturing wants, instantly and cheaply. Continuous-flow manufacturing cuts the cost of customizing: 35 cargo doors line both ends of cuts the cost of customizing: 35 cargo doors line both ends of Dell’s . . . facility. On one side, suppliers deliver Dell’s . . . facility. On one side, suppliers deliver components . . . on the other, workers load finished products components . . . on the other, workers load finished products onto trucks. Actual assembly takes five minutes. Even adding onto trucks. Actual assembly takes five minutes. Even adding time for loading software and testing for quality, the whole time for loading software and testing for quality, the whole process takes just four hours. By economizing on spare parts, process takes just four hours. By economizing on spare parts, product inventory, delivery and every other step of the product inventory, delivery and every other step of the process, the company provides a customized product at a process, the company provides a customized product at a competitive price. No wonder Michael Dell has been lauded as competitive price. No wonder Michael Dell has been lauded as the Henry Ford of mass customization.” [NCPA, June 1999.]the Henry Ford of mass customization.” [NCPA, June 1999.]

As a direct result, “factories incorporating such technologies As a direct result, “factories incorporating such technologies are no longer ‘factories of the future’ but ‘factories with a are no longer ‘factories of the future’ but ‘factories with a future’.” [future’.” [Bogazici University, 1999]Bogazici University, 1999]

Sociotechnical Work Sociotechnical Work SystemsSystems

Technology innovation is not the whole Technology innovation is not the whole story; organisations are as much social as story; organisations are as much social as they are technical.they are technical.

Thus, the Thus, the sociotechnical perspectivesociotechnical perspective holds holds that optimum performance comes from a that optimum performance comes from a balanced structure.balanced structure.

So, “Sociotechnically designed So, “Sociotechnically designed organisations seek . . . A ‘best fit’ among organisations seek . . . A ‘best fit’ among workers, jobs, [work teams,] technology and workers, jobs, [work teams,] technology and the environment.” the environment.” [Newstrom & Davis, 1993; p. 358.][Newstrom & Davis, 1993; p. 358.]

Sociotechnically-Aware Sociotechnically-Aware Organisational Organisational DevelopmentDevelopment

1. EMPLOYEE - natural work modules1. EMPLOYEE - natural work modules that produce a whole product or subunit;that produce a whole product or subunit; start-finish work flow gives skill variety, task start-finish work flow gives skill variety, task identity and task significance.identity and task significance.

2. GROUP - natural work teams,2. GROUP - natural work teams, perform an entire unit of work (withperform an entire unit of work (with significant autonomy); promotes teamwork/significant autonomy); promotes teamwork/ synergy – thus, enhanced performance.synergy – thus, enhanced performance.

3. ORGANISATION - 3. ORGANISATION - develop balanced develop balanced sociotechnicalsociotechnical work systems.work systems.

[ADAPTED: N& D]

The EvidenceThe Evidence Volvo’s Udevalla and Kalmar factories of the Volvo’s Udevalla and Kalmar factories of the

‘70’s and ‘80’s, and the Fremont, CA GM-‘70’s and ‘80’s, and the Fremont, CA GM-Toyota NUMMI show increased job satisfaction Toyota NUMMI show increased job satisfaction and productivity, with lower costs; and productivity, with lower costs; absenteeism is down as well.absenteeism is down as well.

The Udevalla factories (and other cases) also The Udevalla factories (and other cases) also show that smaller scale industrial concerns show that smaller scale industrial concerns can be competitive with standard mass can be competitive with standard mass production.production.

Thus, sociotechnically aware plants can play a Thus, sociotechnically aware plants can play a significant role in industrial renewal in significant role in industrial renewal in Jamaica. Jamaica.

The Result: Creating The Result: Creating Competitive AdvantageCompetitive Advantage

RESOURCESRESOURCES

COMPETENCIESCOMPETENCIES

SKILLS &SKILLS &SYNERGIESSYNERGIES

EFFICIENCYEFFICIENCY

QUALITYQUALITY

INNOVATIONINNOVATION

CUSTOMER NEEDCUSTOMER NEEDRESPONSIVENESSRESPONSIVENESS

LOW UNIT COSTLOW UNIT COST

DIFFERENTIATIONDIFFERENTIATIONOF PRODUCTSOF PRODUCTS

VALUEVALUE

COSTCOST

PRICEPRICE

ADAPTED: Hill & Jones, 1998ADAPTED: Hill & Jones, 1998

The Impact of High The Impact of High Differentiation & Low Differentiation & Low

CostsCosts

LOWLOW HIGHHIGH

HIGHHIGH

DDIIFFFFEERREENNTTIIAATTIIOONN

RELATIVE PRICERELATIVE PRICE

FAILUREFAILURELIKELYLIKELY

SUCCESS SUCCESS HIGHLYHIGHLYUNCERTAINUNCERTAIN

SUCCESSSUCCESSLIKELYLIKELY

A*A*

CC

BB

ADAPTED: Scott, 1998ADAPTED: Scott, 1998

DD COMMODITIESCOMMODITIES

LUXURY/LUXURY/CUSTOM CUSTOM PRODUCTSPRODUCTS

* Highly differentiated, low unit cost products* Highly differentiated, low unit cost products

Durability of Competitive Durability of Competitive AdvantagesAdvantages

RESOURCE-BASED: tend to be short-term.RESOURCE-BASED: tend to be short-term. SKILLS & SYNERGIES: harder to imitate, SKILLS & SYNERGIES: harder to imitate,

especially if based on teamwork and especially if based on teamwork and culture (corporate and community).culture (corporate and community).

COMPETITION'S INERTIA: if competitors are COMPETITION'S INERTIA: if competitors are locked into a dead past, this may block locked into a dead past, this may block their ability to adapt and/or require a their ability to adapt and/or require a survival-threatening crisis for them to survival-threatening crisis for them to change.change.

DYNAMIC INDUSTRIES: Competitive edges DYNAMIC INDUSTRIES: Competitive edges are short-lived.are short-lived.

The Key Challenge: The Key Challenge: SustainabilitySustainability

Competitive advantages must be sustainable, in a Competitive advantages must be sustainable, in a global era, or they will at length fail. (So, they global era, or they will at length fail. (So, they must be must be globallyglobally unique and hard to duplicate.) unique and hard to duplicate.)

Further, given the global environmental challenge, Further, given the global environmental challenge, Industrial Renewal for Jamaica must factor in the Industrial Renewal for Jamaica must factor in the biophysical environment [e.g. ISO 14000] and biophysical environment [e.g. ISO 14000] and related socio-cultural issues including poverty, related socio-cultural issues including poverty, inequity and the welfare of future generations.inequity and the welfare of future generations.

In short, echoing Leakim Semaj, “We had better In short, echoing Leakim Semaj, “We had better think globally before acting locally!”think globally before acting locally!”

Thus, INNOVATION becomes the critical concern.Thus, INNOVATION becomes the critical concern.

Innovation - the Process of Innovation - the Process of Creative DestructionCreative Destruction

In the 1940’s, Schumpeter argued that market In the 1940’s, Schumpeter argued that market economies are subject to “a perpetual gale of economies are subject to “a perpetual gale of creative destruction,” as innovations (NOT creative destruction,” as innovations (NOT mere inventions) create new mere inventions) create new productsproducts and and reallocate productive resources to new, more reallocate productive resources to new, more productive uses.productive uses.

As this happens, the value of assets locked As this happens, the value of assets locked into the old industrial order is destroyed, as into the old industrial order is destroyed, as income expectations dry up.income expectations dry up.

Thus, constant innovation is the key to Thus, constant innovation is the key to sustainable competitive edges, survival and sustainable competitive edges, survival and prosperity in a global market economy.prosperity in a global market economy.

Creative Destruction, Economic Creative Destruction, Economic Profit and Economic Profit and Economic

DevelopmentDevelopment

Drucker summarises Schumpeter: “In the economy of change andDrucker summarises Schumpeter: “In the economy of change and innovation, profit . . . is the only source of jobs for workers and of innovation, profit . . . is the only source of jobs for workers and of labour income . . . No one except the innovator makes a genuine labour income . . . No one except the innovator makes a genuine [economic] profit; and the innovator’s profit is always short-lived. [economic] profit; and the innovator’s profit is always short-lived. But innovation is also ‘creative destruction.’ It makes obsoleteBut innovation is also ‘creative destruction.’ It makes obsolete yesterday’s capital equipment and capital investment. The moreyesterday’s capital equipment and capital investment. The more an economy progresses, the more capital formation will it need . . .an economy progresses, the more capital formation will it need . . .To maintain the wealth-producing capacity of the economy and, aboveTo maintain the wealth-producing capacity of the economy and, above all, to maintain today’s jobs and to create tomorrow’s jobs. . . . all, to maintain today’s jobs and to create tomorrow’s jobs. . . . The question . . . is always, Is there sufficient profit? Is thereThe question . . . is always, Is there sufficient profit? Is there adequate capital formation to provide for the costs of the future,adequate capital formation to provide for the costs of the future, the costs of staying in business, the costs of ‘creative destruction’?” the costs of staying in business, the costs of ‘creative destruction’?”

Creative Destruction and Creative Destruction and Jamaica’s EconomyJamaica’s Economy

While we may challenge Schumpeter on the While we may challenge Schumpeter on the deleterious effects of Monopolies and their profits, it deleterious effects of Monopolies and their profits, it seems clear that we have repeatedly been caught seems clear that we have repeatedly been caught napping by creative destruction:napping by creative destruction:

Sugar, Bananas & Agriculture generally Sugar, Bananas & Agriculture generally Bauxite, import substitution and light Bauxite, import substitution and light

manufacturesmanufactures Tourism . . . ??? Tourism . . . ???

The basic lesson: only in innovation is there hope for The basic lesson: only in innovation is there hope for survival - the very super-normal profits that we enjoy survival - the very super-normal profits that we enjoy today are the magnet that attracts the competition today are the magnet that attracts the competition that will erode those profits tomorrow!that will erode those profits tomorrow!

Therefore, let us take the Therefore, let us take the Product Life CycleProduct Life Cycle to heart. to heart.

The Product Life CycleThe Product Life Cycle

1

2

34 5

1. Emergence1. Emergence2. Growth2. Growth3. Shakeout3. Shakeout4. Maturity4. Maturity5. Decline/Renewal5. Decline/Renewal

Time

Index Index ofofSuccessSuccess

Fostering Innovation: The Fostering Innovation: The Business IncubatorBusiness Incubator

New businesses are often risky, given the New businesses are often risky, given the inexperience of those who start and staff them.inexperience of those who start and staff them.

Thus, over the past several decades - and worldwide Thus, over the past several decades - and worldwide - Business Incubators, often tied to Universities, - Business Incubators, often tied to Universities, have been developed to supply mentoring, training, have been developed to supply mentoring, training, financing, office services and space to promising financing, office services and space to promising start-ups.start-ups.

In many cases, they have moved the five-year In many cases, they have moved the five-year survival rate for such start-ups from about 20% to survival rate for such start-ups from about 20% to sometimes in excess of 80% - a major success story.sometimes in excess of 80% - a major success story.

Such incubators should also be backed up with Such incubators should also be backed up with adequate adequate venture capitalventure capital capacity. (Say, a joint capacity. (Say, a joint GOJ-CDB-Universities- Financial Industry initiative?)GOJ-CDB-Universities- Financial Industry initiative?)

Implications for Industrial Implications for Industrial RenewalRenewal

Mechatronics, CIM, mass customisation and Mechatronics, CIM, mass customisation and sociotechnical plant design offer possibilities for sociotechnical plant design offer possibilities for a new, innovative and competitive industrial a new, innovative and competitive industrial architecture for Jamaica.architecture for Jamaica.

Innovation and entrepreneurship are obviously Innovation and entrepreneurship are obviously survival imperatives for Jamaican industry, in a survival imperatives for Jamaican industry, in a global ICglobal IC22T world.T world.

A A Business IncubationBusiness Incubation strategy offers the strategy offers the potential to jump-start and sustain this process.potential to jump-start and sustain this process.

A national A national venture capital capacityventure capital capacity will be a will be a critical support for such an initiative.critical support for such an initiative.

Possible Target IndustriesPossible Target Industries PRESENT INDUSTRIES: renewal consultancies and initiatives, in PRESENT INDUSTRIES: renewal consultancies and initiatives, in

light of CIM and Mass Customisationlight of CIM and Mass Customisation POSSIBLE INCUBATOR INITIATIVES:POSSIBLE INCUBATOR INITIATIVES:

– ““Mass Custom” clothing, shoes and textiles: Cf. Levi’s Mass Custom” clothing, shoes and textiles: Cf. Levi’s Personal PairPersonal Pair Jeans Jeans

– Robotics (including industrial robots and robotic vehicles Robotics (including industrial robots and robotic vehicles such as courier, agriculture & security aircraft)such as courier, agriculture & security aircraft)

– Agro-industry Machinery & Transportation (CIM-based, Agro-industry Machinery & Transportation (CIM-based, sociotechnical production systems, cf. Volvo)sociotechnical production systems, cf. Volvo)

– Factory-built custom housingFactory-built custom housing– Biomedical Electronics & Instrumentation, smart prostheticsBiomedical Electronics & Instrumentation, smart prosthetics– Biotechnology-based industriesBiotechnology-based industries– CD manufacture and publishing (music, multimedia, CD manufacture and publishing (music, multimedia,

education)education)

Implications for Implications for Engineering & Technology Engineering & Technology

EducationEducation Curricula should not only emphasise ICCurricula should not only emphasise IC22Ts & Ts &

Mechatronics (“from day one”), but also Mechatronics (“from day one”), but also entrepreneurial management and general entrepreneurial management and general analytical and strategic thinking - towards world-analytical and strategic thinking - towards world-class competitive advantages.class competitive advantages.

These schools should have attached enterprise These schools should have attached enterprise incubation and venture capital capacity; and also incubation and venture capital capacity; and also consultancy capacity to support renewal of existing consultancy capacity to support renewal of existing industries in Jamaica.industries in Jamaica.

U.Tech’s SOE (and other schools of engineering, U.Tech’s SOE (and other schools of engineering, technology and applied science) must provide the technology and applied science) must provide the critical manpower through a world-class education critical manpower through a world-class education at professional, technologist and technician levels.at professional, technologist and technician levels.

A Possible Timetable for A Possible Timetable for RenewalRenewal

YEARS 1 - 5: Develop Basic Capacity: YEARS 1 - 5: Develop Basic Capacity: – Technology & Applied Science EducationTechnology & Applied Science Education– Technology Enterprise IncubationTechnology Enterprise Incubation– Industry Renewal ConsultancyIndustry Renewal Consultancy– Venture Capital Institutions & finaningVenture Capital Institutions & finaning

YEARS 6 - 10: Further develop New/Renewed YEARS 6 - 10: Further develop New/Renewed IndustriesIndustries– Support further growth of incubator/renewal successesSupport further growth of incubator/renewal successes– Develop Targetted Research Capacity & a follow-on Develop Targetted Research Capacity & a follow-on

generation of industriesgeneration of industries– Multiply the number of support institutionsMultiply the number of support institutions

YEARS 11 - : Accelerate the process YEARS 11 - : Accelerate the process

Towards Industrial Towards Industrial Renewal in JamaicaRenewal in Jamaica

Given the fact of creative destruction, if Jamaican Given the fact of creative destruction, if Jamaican industry is to survive, much less thrive, in the industry is to survive, much less thrive, in the century ahead, we must build sustainable century ahead, we must build sustainable competitive advantages on the foundation of competitive advantages on the foundation of innovation.innovation.

Such innovation will have to stress ICSuch innovation will have to stress IC22Ts, Ts, mechatronics, mass customisation, sociotechnical mechatronics, mass customisation, sociotechnical insights and entrepreneurial management.insights and entrepreneurial management.

It will also have to be backed up by world-class It will also have to be backed up by world-class education, enterprise incubation and venture education, enterprise incubation and venture capital capacity. There is no alternative, if we are capital capacity. There is no alternative, if we are to survive and prosper in the emerging global age. to survive and prosper in the emerging global age.

The Bottom-line:The Bottom-line: