Integrated Zero Defect Manufacturing Solution for High Value Adding Multi-Stage Manufacturing Systems

Advanced manufacturing companies are confronted with the challenge of managing product quality objectives while minimising resource utilisation and waste. Zero defect manufacturing (ZDM) represents a contemporary paradigm that goes beyond traditional six-sigma approaches, particularly within Europe’s highly technology-intensive and strategically important manufacturing sectors. However, the successful implementation of ZDM in the industry hinges on the adoption of innovative defect management and control methods, as well as the use of cutting-edge technologies for in-line inspection. Additionally, the integration of knowledge management and ICT tools is vital for intelligent and sustainable decision-making. To address these needs, the EU-funded ForZDM project aims to develop and demonstrate tools that facilitate the swift deployment of ZDM solutions within the manufacturing sector.

Objective

Manufacturing companies are continuously facing the challenge of operating their manufacturing processes and systems in order to deliver the required production rates of high quality products of increasing complexity, with limited use and waste of resources. “Zero Defect Manufacturing” (ZDM) is a recent paradigm aiming at going beyond traditional six-sigma approaches in highly technology intensive and strategic European manufacturing sectors through new knowledge-based approaches. The ZDM paradigm is of key importance to manage production quality targets in advanced manufacturing industries. The implementation of this paradigm in industry requires innovative defect management and control methods, novel technologies for in-line inspection and integration of knowledge management and ICT tools for smart and sustainable decisions in complex industrial scenarios, which are not available in the market. The aim of the ForZDM project is to develop and demonstrate tools to support the rapid deployment of ZDM solutions in industry and design more competitive and robust multi-stage manufacturing systems. The proposed ZDM approach is based on the combined adoption of new knowledge-based data-gathering and root-cause analysis solutions to reduce the generation of defects as well as new on-line defect management and improved production traceability solutions to mitigate the propagation of defects along the production line stages. This will be achieved through the proper integration of innovative enabling technologies, such as cyber-physical systems, selective inspection, advanced analytics and integrated process and part-flow control solutions.

Partners

• ENKI S.R.L.
• Construcciones y Auxiliar de Ferrocarriles SA
• GKN Aerospace Norway AS
• ABF-Industrielle Automation GmbH
• Fundacion Tecnalia Research & Innovation
• Ideko S Coop
• Montronix GmBH
• Marposs Societa Per Azioni
• Enginsoft Nordic AB
• NXTControl GmBH
• University of Stuttgart
• MASMEC SpA