Data Reliability and Digitally-enhanced Quality Management for Zero Defect Manufacturing in Smart Factories and Ecosystems
Program: H2020
Ref. No.: 958363
Contract signing date: 10/08/2020
Date of execution: 01/10/2020-31/03/2024
Smart factories are characterised by smart processes and smart manufacturing systems that involve interlinked smart machines, smart tools and smart products as well as smart logistics operations. These generate large amounts of data, which can be used for analysis and fault prevention, as well as for the optimisation of the quality of manufacturing processes and products. However, a major challenge for manufacturing is the quality and reliability of data. Industry 4.0 requires the creation, manipulation and sharing of very large amounts of digital data. Many companies understand the need for these data-rich processes and technologies, but do not understand how to initiate them, what data to capture, how to establish confidence in such data and indeed how to best use it once captured. This applies across the majority of manufacturing sectors, including automotive, medical devices, and household appliances, for example. To address the challenge of data reliability, the sensors, actuators and instruments used at various levels of integration in the manufacturing process – often operating under adverse physical conditions – need to provide adequate levels of data accuracy and precision. Measurement traceability should ensure optimal manufacturing quality. Furthermore, suitable modelling and simulation approaches and data fusion techniques are needed to interpret and use sensor/actuator data in smart factories. As such, DAT4.ZERO aims to develop and implement a Digitally-enhanced Quality Management (DQM) system, characterized by real-time feedback and feed-forward loops using robust, quality assured data that offers a huge potential for the advancement of the Zero Defect Manufacturing (ZDM) paradigm.
At the heart of DAT4.ZERO is a DQM System that gathers and organizes data from a Distributed Multi-sensor Network, which, when combined with a DQM Toolkit and Modeling and Simulation Layer, and when further integrated with existing Cyber-Physical Systems (CPS), offers adequate levels of data accuracy and precision for effective decision-support and problem-solving – utilizing smart, dynamic feedback and feed-forward mechanisms to contribute towards the achievement of a near zero-defect level of manufacturing in smart factories and their ecosystems. This shall be achieved through:
– Integrating smart, cost-effective sensors and actuators for process simulation, monitoring and control;
– Showcasing real-time data validation and integrity strategies within actual production lines;
– Demonstrating innovative data management strategies as an integrated approach to ZDM;
– Developing strategies for rapid line qualification and reconfiguration.
DAT4.ZERO aims for the realization and implementation of a DQM system for ZDM that is deployed into 5 distinct industrial pilot lines. As such, DAT4.ZERO addresses the following primary objective:
O1: To develop and demonstrate an innovative DQM system and deployment strategy for supporting European manufacturing industry in realizing a near-zero defect level of manufacturing in highly dynamic, high-value, high-mix, low-volume production contexts.
This will be achieved through the following objectives:
O2: The effective selection and integration of sensors and actuators for process monitoring and control within intra- and inter-organizational production processes, systems and networks;
O3: Developing a DQM platform with an architecture that provides reliable and secure data management and knowledge extraction to ensure integrity of data;
O4: Creating strategies for advanced, real-time data analysis and modelling – exploiting artificial intelligence (AI) and CPS capabilities combined with smart human-in-the-loop technologies for rapid qualification, configuration, adaptation and reconfiguration of multi-stage process chains within and across organizational boundaries;
O5: Integrating O1-O4 in five industrial demonstrator use cases and developing optimized metrology and control strategies applicable to multiple domains/sectors, demonstrating first pass yield improvements, improved product quality and improved data reliability.
Overall, DAT4.ZERO will support the European factories of the future by:
– Increasing equipment productivity through rapid detection and correction of product- and process-errors;
– Reduction of ramp-up time;
– Decreasing time-to-market of existing and evolving high-value products;
– Increasing product quality, also reducing quality costs, scrap, and rework.
This will also make cost-benefit / investment analysis simpler and more practical for the European manufacturing industry of the future.
TOTAL PROJECT BUDGET: 11,815,903.75 €.
TOTAL BUDGET ITAINNOVA: 441.250,00 €.
TOTAL PROJECT FINANCING: 9,886,512.63 €.
TOTAL FINANCING ITANNOVA: 441.250,00 €.
This action is co-financed by the DATA4ZERO project whose reference number is 958363 and is marked in the H2020 program, 100% financed by the European Union.
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