Zero defect manufacturing: state-of-the-art review, shortcomings and future directions in research

Psarommatis, Foivos; May, Gökan; Dreyfus, Paul-Arthur; Kiritsis, Dimitris

doi:10.1080/00207543.2019.1605228

Cited by 267 publications

(143 citation statements)

References 37 publications

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“…Specifically, taking into account the peculiarities of the operations management field compared to other fields such as medicine, the guidelines provided by Durach, Kembro and Wieland [21] were followed as detailed in the remainder. Moreover, the review articles written by specific authors in this field [22,23] were taken as guidelines.…”

Section: Adopted Methodologymentioning

confidence: 99%

A review on the characteristics of cyber-physical systems for the future smart factories

Napoleone

Macchi

Pozzetti

2020

Journal of Manufacturing Systems

141

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The emergence of new technologies is providing new ways to compete in the current context of changeable and unpredictable market requirements. The focus of this paper is on Cyber-Physical Systems (CPSs), as one of the most promising transformative technological concept of such a context, thus considered by literature as the building blocks of future smart factories. However, CPSs are still in their conceptualization phase. To this end, much literature effort has been put on their technological characterization, while there is a lack of knowledge on operations management characterization to manage such new systems. To contribute in this latter direction, this paper reviews literature in order to distinguish between technological characteristics of CPSs and operations management characteristics to build future CPS-based smart factories. This paper remarks the need for research on operations management characteristics as these may be the ones actually leading operations managers to the concrete implementation of CPS-based factories in manufacturing.

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Section: Adopted Methodologymentioning

confidence: 99%

A review on the characteristics of cyber-physical systems for the future smart factories

Napoleone

Macchi

Pozzetti

2020

Journal of Manufacturing Systems

141

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“…This concept has been implemented only partially due to numerous technological limitations that were prohibiting its implementation. According, to Psarommatis et al (2020) "currently, with the evolution of Industry 4.0, ZDM concept is easier to be implemented due to the availability of the required amount of data for techniques such as machine learning to work properly but still a lot of effort is needed for better integration and coordination of the capabilities of each technology". Thus, ZDM is now a common manufacturing practice to reduce and minimize the number of defects and errors in a process and to do things right the first time (Wang (2013)).…”

Section: Zero-defect Manufacturingmentioning

confidence: 99%

“…The difference is that a product-oriented ZDM studies the defects on the actual parts and tries to find a solution while on the other hand the process-oriented ZDM studies the defects of the manufacturing equipment, and based on that can evaluate whether the manufactured products are good or not. The latter one lays within the predictive maintenance concept (Psarommatis et al (2020)).…”

Section: Zero-defect Manufacturingmentioning

confidence: 99%

Formal Scheduling Method for Zero-Defect Manufacturing

Grobler-Dębska

Kucharska

Baranowski

2021

Preprint

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Zero-defect manufacturing (ZDM) is a concept of quality management that recently exhibits a renewal of interest. It aims to improve the process efficiency and the product quality while eliminating defects and minimizing process errors. Most of ZDM applications focus on using the technological achievements of Industry 4.0 to detect and predict defects, forgetting to optimize the schedule on the production line. This paper proposes a formal approach for solving scheduling problems with unexpected events as extension of general frameworks for ZDM strategy. We propose formal method to create predictive-reactive schedule for problems with defect detection and repair. Our formal model combines defect detection, heuristics construction and decision support. We illustrate our results with examples.

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“…As explained in Psarommatis et al (2019), the ZDM fulfills four missions: detect, repair, prevent, and predict. The first three missions are shared with the current quality philosophies.…”

Section: Evolution Toward Zdmmentioning

confidence: 99%

Product Quality Improvement Policies in Industry 4.0: Characteristics, Enabling Factors, Barriers, and Evolution Toward Zero Defect Manufacturing

Psarommatis

Prouvost

May

et al. 2020

Front. Comput. Sci.

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In the competitive market of manufacturing, quality is a criterion of primary importance in order to win market share. Quality improvement must be coupled with performance point of view. Lean Manufacturing, Six Sigma, Lean Six Sigma, Total Quality Management, Theory of Constraints, and their combination are philosophies dedicated to this goal. This study is a literature review on the implementation of these philosophies to improve quality of processes and products in a system, and also covers the commonalities and differences with Zero Defect Manufacturing (ZDM) philosophy. In this study, 45 articles have been analyzed. These articles have been selected by a research on several scientific libraries with specific keywords. The methodology is based on a list of information extracted from each paper. The data searched are on the tool selections, critical factors of implementations and the benefits obtained from them. Based on the review and analysis of the literature and practices, we provide the top 10 main components of the tools used for quality improvement, enabling factors, benefits, and barriers to implementation. Moreover, we present and discuss categorization of quality improvement methods and the way toward ZDM. The need of standardized toolkits for different levels of maturity in quality management systems and a better education have been enlightened. Thanks to technological improvement in information flow management, ZDM seems close to be achieved even though some new risks and wastes have to be taken care of within the implementation.

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Zero defect manufacturing: state-of-the-art review, shortcomings and future directions in research

Cited by 267 publications

References 37 publications

A review on the characteristics of cyber-physical systems for the future smart factories

A review on the characteristics of cyber-physical systems for the future smart factories

Formal Scheduling Method for Zero-Defect Manufacturing

Product Quality Improvement Policies in Industry 4.0: Characteristics, Enabling Factors, Barriers, and Evolution Toward Zero Defect Manufacturing

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