The intelligent manufacturing system is a system capable to design, monitor, control and optimize the whole production process of a manufacturing product. The past few decades have seen a trend towards the establishment of intelligent manufacturing systems capable of using advanced knowledge-based and intelligence techniques in aiding critical operative procedures on manufacturing shop-floors. The next generation of manufacturing systems will be described as new intelligent reconfigurable manufacturing systems which realize a dynamic fusion of human and machine intelligence, manufacturing knowledge and state-of-the-art design techniques. This may lead to low-cost self-optimizing integrated machines. It will include fault-tolerant advanced predictive maintenance facilities for producing high-quality error-free workpieces using conventional and advanced manufacturing processes. This research work focuses on the development of innovative techniques in order to realize an intelligent manufacturing system able to automatically optimize the manufacturing process. The main working areas are focused on the development of systems for: 1) automatic generation, testing, optimization and preliminary verification through realistic simulation of NC part programs; 2) automatic compensation of geometrical and dimensional inaccuracies based on adaptation of the workpiece 3D model; 3) advanced monitoring and control of manufacturing processes