Application of Quality 4.0 (Q4.0) and Industrial Internet of Things (IIoT) in Agricultural Manufacturing Industry

Abstract

The objective of this research is to apply Quality 4.0 (Q4.0) concept in Agriculture 4.0 (A4.0) to digitize the traditional quality management (QM) system and demonstrate the effectiveness of zero-defect manufacturing (ZDM) in the agricultural part manufacturing industry. An autonomous quality management system was developed based on the ZDM system using the Industrial Internet of Things (IIoT). Both traditional and autonomous quality management systems were evaluated using six-sigma quality indicators and machining and inspection cost analysis. The ZDM resulted in a significant improvement in the quality of CARD148 manufacturing, increasing the manufacturing process from a low level of sigma to a high level of sigma (0.75 to 5.10 sigma). The component rejection rate was reduced by a high percentage, leading to significant economic benefits and a significant reduction in machining cost. The process yield was also increased to a high percentage. The developed ZDM was found to be consistent in improving the quality of the turning process, with notable increases in tool life and reduction in inspection cost. The total component cost was reduced significantly, while the PPM value increased notably. While this study focuses on agriculture-related manufacturing organizations, the developed ZDM has potential for other machining industries to improve sigma levels, particularly in industries such as automotive and medical.