Abstract
This paper investigates an initial model for Zero Defect Manufacturing (ZDM) using a cost function where the operation and condition of a production process are reflected, and the quality of the output/product and the production process (as well as safety aspects) can be considered. The outset of the study is based on empirical data collected from five manufacturing companies, and proposes an initial model for ZDM with an Industry 4.0 perspective. The initial ZDM model has a generic setup for a real-life system and its replication as a digital twin using system models based on a representation of a generic production process with its connected control system, and potential interconnections between unit processes. It is based on concepts from system theory of dynamic systems and principles from condition monitoring and fault detection. In that way the model is deemed as highly generalizable for manufacturing and process industry companies as well as for some critical infrastructures with production and distribution systems. The proposed model with its cost function setup is analyzed and discussed in the context of ZDM. It is concluded that production processes in the manufacturing and process industry can be made more intelligent and interoperable using this approach. Improved sustainability, competitiveness, efficiency and profitability of companies are foreseen welcomed secondary effects. Finally, the proposed ZDM model further develops the ZDM by adding to it a systematic approach based on a solid mathematical foundation.
Highlights
Zero Defect Manufacturing (ZDM) was coined during the later part of the 1980s, with the intent to minimize the defects in the output from various production processes
The main challenges associated with ZDM have been to integrate large amounts of information from many sources, the need to develop advanced technology and methods, the modeling of ZDM, and timely computing [2]
The aim of the paper is to propose, analyze and discuss an initial model for ZDM, with a clear Industry 4.0 perspective, applied to the production in the manufacturing and process industries. It is based on the third cycle in an action research effort conducted at five companies, mainly in manufacturing with both discrete- and continuous sub-processes as part of the main production process
Summary
Zero Defect Manufacturing (ZDM) was coined during the later part of the 1980s, with the intent to minimize (or cancel) the defects in the output from various production processes It is sprung out of the early work by Stewart and Deming (cf [1]) and later became an important component of Total. The main challenges associated with ZDM have been to integrate large amounts of information from many sources, the need to develop advanced technology and methods, the modeling of ZDM, and timely (on-line or in real-time) computing [2] These issues have been confirmed by a recent ZDM research study with six participating manufacturing and process industry companies [3]. This may have hindered new and radical changes in the development of new products and services [13]
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