Zero Defect Manufacturing: A Product and Plant Oriented Lifecycle Approach

Abstract

The EU project IFaCOM has the objectives to achieve near zero defect level of manufacturing for all kinds of manufacturing. The IFaCOM focus on feedback loops for the zero defect manufacturing approaches is within the shop floor and the manufacturing related activities. Both real-time and knowledge based loops are covered. Zero defect manufacturing also has an extended life cycle oriented process focus. In addition a combination or integrated view to the product and factory life cycle models is important.This paper will focus on a part and plant lifecycle approach to achieve the best possible practice to zero defect manufacturing. Descriptions of which data or indicators that can be necessary to collect from the processes and where in the product lifecycle they can be used for improvements are important issues. It is also required to follow both the lifecycle for the manufactured product and the lifecycle for the plant that perform the manufacturing. This includes development and descriptions of a framework for an integrated product-plant lifecycle model. Advanced enterprise modeling methods and tools (e.g. GERAM) are important architectures for such a framework.The manufacturing phase of the lifecycle is the central part, but feedback to design, engineering, in addition to information flows to maintenance and recycling are important to cover all issues to perform zero defect manufacturing. The Enterprise model architectures are extended to cover the needs for a Zero Defect Lifecycle oriented integrated plant- product model.