The present dynamic manufacturing environment has been characterized by a greater variety of products, shorter life-cycles of products and rapid introduction of new technologies, etc. Recently, a new manufacturing paradigm, i.e. Reconfigurable Manufacturing Systems (RMS), has emerged to address such challenging issues.

RMSs are able to adapt themselves to new business conditions timely and economically with a modular design of hardware/software system. Although a lot of research has been conducted in areas related to RMS, very few studies on system-level control for RMS have been reported in literature. However, the rigidity of current manufacturing systems is mainly from their monolithic design of control systems. Some new developments in Information Technology (IT) bring new opportunities to overcome the inflexibility that shadowed control systems for years.

Component-based software development gains its popularity in 1990's. However, some well-known drawbacks, such as complexity and poor real-time features counteract its advantages in developing reconfigurable control system. New emerging Extensible Markup Language (XML) and Web Services, which are based on non-proprietary format, can eliminate the interoperability problems that traditional software technologies are incompetent to accomplish. Another new development in IT that affects the manufacturing sector is the advent of agent technology. The characteristics of agent-based systems include autonomous, cooperative, extendible nature that can be advantageous in different shop floor activities.

This dissertation presents an innovative control architecture, entitled Component-based Intelligent Control Architecture (CICA), designed for system-level control of RMS. Software components and open-standard integration technologies together are able to provide a reconfigurable software structure, whereas agent-based paradigm can add the reconfigurability into the control logic of CICA. Since an agent-based system cannot guarantee the best global performance, agents in the reference architecture are used to be exception handlers. Some widely neglected problems associated with agent-based system such as communication load and local interest conflicts are also studied. The experimental results reveal the advantage of new agent-based decision making system over the existing methodologies. The proposed control system provides the reconfigurability that lacks in current manufacturing control systems. The CICA control architecture is promising to bring the flexibility in manufacturing systems based on experimental tests performed.