A practical guide for implementing Zero Defect Manufacturing in new or existing manufacturing systems

Abstract

The approach to achieving zero defects by using Industry 4.0 technologies is what constitutes Zero Defect Manufacturing (ZDM). However, its implementation is not a simple task since it requires careful design and new methods. The current literature on zero defect manufacturing lacks methods, tools, and guidelines for a successful shift toward ZDM implementation in manufacturing facilities aligned with the recent advancements in enabling technologies as well as data-driven approaches and models. In this paper, we propose a step-by-step practical implementation guide for achieving zero defects in modern manufacturing facilities. While considering the links with various ZDM strategies, this guide can be applied to both new and existing production systems. The proposed method has been tested with an industrial example that concerns the manufacturing of an electronics board in the case of a European semiconductors manufacturer. We demonstrated, using this industrial example, that the multi-criteria approach that has been proposed may effectively evaluate the potential risk of defects for each stage of manufacturing and the extent to which ZDM adoption is required.