Simulation in Real Time for Manufacturing with Zero Defects


STREAM-0D has the ambition to tackle one of the main challenges of the manufacturing industry: reaching a zero-defect production. STREAM-0D technology is based on the integration of multiphysics simulation models linked with measurement devices in the production workflow, which enable the control of the most important manufacturing parameters in real-time.

STREAM-0D uses Reduced Order Models, which are multi-physics simulation models able to predict the product quality indicators in response to these critical input parameters. The models are fed with actual data from online measurements: based on the model prediction, they allow workers to control the critical steps of the line so to adjust the product to the exact design specifications, or to quickly change specifications for producing customized batches.

Reduced Order Modelling is a new generation of techniques which allow us to obtain parametric solutions of complex models that can be particularized in real time for any value of the parameters. The models run so fast that they can be executed on tablets or smart phones. ROM will be used to transform complex models into the real-time capable models that can be integrated in the production line. Moreover, the online deployment of ROMs and data gathering systems will generate big data which will be exploited through data analysis techniques for further improving the process. The project will show proof-of-concept demonstrations in three real process chains of the automotive sector, covering different types of production methods, products, materials and manufacturing processes.

The STREAM-0D system is currently being designed and tested in three real process chains of the automotive sector, covering different types of production methods, products, materials, and manufacturing processes.

The STREAM-0D solution will therefore help manufacturing industries to reach the following high-level objectives:

  • Higher product quality with low variability aiming at zero defects
  • Short product development cycles, with high production line re-configurability
  • Lower manufacturing costs
More information
Web resources:
Start date: 01-10-2016
End date: 31-03-2020
Total budget - Public funding: 5 186 110,00 Euro - 4 159 145,00 Euro
Call topic: Zero-defect strategies at system level for multi-stage manufacturing in production lines (FoF.2016.03)
Twitter: @stream0d
Infografica Stream0D.png
Infografica2 Stream0D.png