A method and apparatus is disclosed for 'intelligent' control (410) of production processes such as machining, casting, heat treating and welding. The key enabler of such control is of an electro-optical (25, 95, 305, 405) or other suitable sensor type. The sensor is generally of non contact type, capable of rapidly and accurately acquiring data from parts and the tools used to produce the parts in a production 'in-process' environment. Systems are disclosed to control not only the instant operation, but those processes connected therewith, both upstream and downstream. Data bases are generated and knowledge bases are used. Application of the invention can improve quality and productivity, and allow the production of parts which have unusual or individual material characteristics (1000-1008).