Identification of the Inspection Specifications for Achieving Zero Defect Manufacturing

Abstract

The contemporary manufacturing landscape is characterized by increased volatility shortened product life cycles and increased degree of product customization. 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, while minimizing the use of resources. They can achieve this with a concept named Zero Defect Manufacturing. This concept implies that inspection is performed to all the parts and therefore they can achieve zero defects. The problem is that inspection can be either time consuming process or a very expensive process. The goal of the current research work is a methodology for the identification of the acceptable inspection specification in order for the production system to stay efficient and at the same time produce non-defected products. In other words the outcome of this paper will be a set of maps that depicts which can be the acceptable inspection characteristics such as inspection time and inspection cost.

Cost-Based Decision Support System: A Dynamic Cost Estimation of Key Performance Indicators in Manufacturing

“…ZDM approach is one of the latest quality assurance paradigms that aims to eliminate defective parts ensuring that customers receive products free from defects and meet their requirements [13]- [15]. In this point should be mentioned that for achieving ZDM all parts need to be inspected for assuring that the quality meets the required levels and if the product is defective to identify if it is repairable or not [52]. In general, poor quality causes loss of operational and material yield.…”

Advances in Production Management Systems: Issues, Trends, and Vision Towards 2030

“…Several authors have looked at different performance metrics. Guillén et al [17] and Cho et al [18] focused on predictive maintenance and quality control; Psarommatis et al [19,20] focused on impact analysis at the factory level. Roda and Macchi [21,22], Roda et al [23], and Polenghi et al [24] focused on risk-oriented, strategic, decision-support systems.…”

“…• Zero Defect Manufacturing (ZDM) -as potential quality problems are detected in products and corrected either in a machine or a process before those problems happen [19,20]. As these machines and processes become more intelligent, detecting in realtime will require the abilities to harvest all relevant data and to use advanced analytics to investigate that data.…”

Virtual metrology as an approach for product quality estimation in Industry 4.0: a systematic review and integrative conceptual framework

“…However, batch control has a major disadvantage in that defective products may reach the consumer, which can result in devastating costs to the company (Cheah, Shahbudin, and Taib 2011;Tannock and Saelem 2007). Systematic control is the optimal practice for ensuring that all products conform to the desired quality characteristics (Psarommatis, Gharaei, and Kiritsis 2020;Psarommatis and Kiritsis 2019). Virtual inspection has become a reality due to modern technological advancements, and it has enabled manufacturers to apply systematic control without the cost and time disadvantages of physical inspection (Psarommatis et al 2020).…”

“…VM was initially developed for the field of semiconductor production. Today, however, VM is of interest to the entire manufacturing domain as it can significantly improve the sustainability of a manufacturing network (Psarommatis 2021;Psarommatis and Kiritsis 2019;Cheng et al 2011;Michl et al 2011). VM is a fairly new concept, which is verified by the fact that the first paper to define VM was published in 2005 (Chen et al 2005).…”