An Initial Model for Zero Defect Manufacturing

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.