Abstract
Zero Defect Manufacturing is a disruptive concept that has the potential to entirely reshape the manufacturing ideology. Building on the same quality management philosophy that underpins both lean production and Six Sigma, the Zero Defect Manufacturing paradigm has in recent years developed significantly, given the onset of Industry 4.0 and the increasing maturity of its digital technologies. In this paper, we review contemporary advances in Zero Defect Manufacturing using structured literature review. We explore emergent themes and present important directions for future development in this continuously emerging field of research and practice. We highlight two specific Zero Defect Manufacturing strategy types: defect prevention, and defect compensation; as well as identify two important themes for future ZDM research, namely advancing ZDM research (particularly with a view to progressing from zero-defect processes to zero-waste value chain strategies) and overcoming the global application challenges of ZDM (with emphasis on cyber-security and the extension of defect prevention and compensation strategies to less explored manufacturing processes).
Highlights
An increasing emphasis on sustainable production requires that manufacturing companies continuously deliver higher quality pro ducts of increasing complexity at lower cost, while simultaneously limiting the use of resources within entire industrial ecosystems (Colledani et al, 2014a)
We discovered several articles that presented Artificial Intelligence (AI) (Zurita et al, 2016; Chiariotti et al, 2018; O’Brien and Humphries, 2019; Escobar et al, 2020) and digital twin (Papacharalampopoulos, Stavropoulos and Petrides, 2020; Pombo et al, 2020; Psarommatis, 2021) approaches to Zero Defect Manufacturing (ZDM), though there was an abundance of lit erature that discusses more the architecture and monitoring systems perspectives of ZDM
Feedback control loops are usually implemented at single-process levels to detect and repair defects, even when the production system is complex and includes more than one stage or machines, as depicted in Fig. 10: Traditional quality strategies keep separate the analysis of pro duct data, which come from inspection processes, and process data, which comes from in-situ monitoring solutions
Summary
An increasing emphasis on sustainable production requires that manufacturing companies continuously deliver higher quality pro ducts of increasing complexity at lower cost, while simultaneously limiting the use (and waste) of resources within entire industrial ecosystems (Colledani et al, 2014a). Zero Defect Manufacturing (ZDM) has emerged as a means of moving closer to achieving an organization's "first-time-right" quality strategy (Raabe et al, 2017). Crosby, who was at that time a quality control department manager on the Pershing Missile program at the Martin Company (Harwood, 1993). ZDM is an emerging paradigm that goes beyond traditional quality approaches such as Lean Production and Six Sigma. A plethora of emerging key enabling technologies, such as in-line data gathering solutions, data storage and commu nication standards, data analytics tools and digital manufacturing technologies have begun to offer new opportunities for ZDM (Eger et al, 2018), enabling organizations to move even closer to achieving the vision of zero defects. We bring out pertinent factors and useful insights into the contemporary advances in ZDM and identify several inter esting research gaps which serve as avenues for future research within this important and emerging field of research
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