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QU4LITY | Digital Reality in Zero Defect Manufacturing

01-01-2019

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31-07-2022

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Pathways
Collaborative Product-Service Factories Pathway
Result items:
Pilot - GHI Real-time cognitive hot stamping furnace 4.0
Pilot - GHI Real-time cognitive hot stamping furnace 4.0

As it is described on the Autonomous Smart Factories, in this use case, in addition to the tools that make possible to improve and optimize the manufacturing connected process, it also intends to highly reduce the defective manufacturing increasing the product lifecycle control loop, improving the manufacturing process thanks to the information provided through the product quality control process.

Product-Service Innovation
Result items:
Pilot - GHI Real-time cognitive hot stamping furnace 4.0
Pilot - GHI Real-time cognitive hot stamping furnace 4.0

In this use case, GHI and Innovalia will share data in a trust manner through an IDS connector, so that GHI will be able to find correlation between the quality of the parts and the furnace operation parameters.

Closed loop PSS Design (Connected to users data)
Result items:
Pilot - GHI Real-time cognitive hot stamping furnace 4.0
Pilot - GHI Real-time cognitive hot stamping furnace 4.0
Service Innovation and new Business Models
Result items:
Pilot - Danobat Digital Machine for zero-defects at high precision cutting/grinding
Pilot - Danobat Digital Machine for zero-defects at high precision cutting/grinding

Through the developments considered in this business case, the machine tool supplier obtains new digitally enabled solutions for the provision of smart services supported on digital platforms. 

Pilot - GHI Real-time cognitive hot stamping furnace 4.0
Pilot - GHI Real-time cognitive hot stamping furnace 4.0

By the time this sharing data solution has been devise just for the use case, but also a business model in here can emerge as GHI is getting more restrictions with customers that do not want to give the governance of their process data.

ZDMP | Zero Defect Manufacturing Platform

01-01-2019

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30-06-2023

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Pathways
Collaborative Product-Service Factories Pathway
Result items:
Construction supply chain: quality control at construction site and quality traceability
Construction supply chain: quality control at construction site and quality traceability

The suppliers of material to the construction side should be able to timely deliver the data about the quality of materials and, if needed, provide a replacement avoiding significant delays. Even, if the quality of materials is according to specification, accidents leading to material defects can happen during the shipment or on the construction side. Thus, it is important to constantly track the situation to react on the changing circumstances. For the construction company, on the other, hand, is important to align the material shipments to keep up with the schedule.

Engine block manufacturing: Defects detection and prediction in aluminium injection and machining operations
Engine block manufacturing: Defects detection and prediction in aluminium injection and machining operations

Sse-cases offer an additional services for quality assessment and prediction based on the aggregated data from the participating industrial partners (Martinrea Honsel (MRHS) and FORD) that will be provided by the ZDMP platform. In this case, the service covers only specific product lifecycle stage, when the product – aluminium cylinder blocks, is produced and arrives at FORD to be used in engine production, as the defected blocks are filtered both at MRHS and FORD. Thus, the goal is to reduce the amount of defected parts through collaboration between two industrial partners.

Engine block manufacturing: Defects reduction by the optimization of the machining process
Engine block manufacturing: Defects reduction by the optimization of the machining process

During the production process, various deviations from the normal functioning of the machining equipment can arise in the given use-case. It is important that ETXE equipment manufacturer could provide a service addressing the whole life cycle of the product (machining equipment) supported by ZDMP platform. The service has the aim of keeping the high efficiency of the machines through detection of abnormalities and quick recovery to the efficient state.

Moulds manufacturing: Process alert system for machine tool failure prevention and Smart process parameter tuning
Moulds manufacturing: Process alert system for machine tool failure prevention and Smart process parameter tuning

The quality assessment of the products is performed by the FORM industrial partner that utilizes equipment delivered by FIDIA. Degradation in the equipment performance can cause significant quality drop on the FORM side. In order to avoid this, ZDMP platform aggregates the process and equipment data and performs analysis to identify the defects occurring, as well as to detect possible equipment degradation. Analysis of equipment degradation is preformed in cooperation with equipment suppliers.

Steel tubes: production monitor
Steel tubes: production monitor

In order to enable the required automation level for the quality check of the manufacturing process, the necessary equipment will be updated with the ZDMP tools and corresponding services.

Stone tiles: equipment wear detection
Stone tiles: equipment wear detection

This use-case offers additional update to the stone cutting machine through the cutting blades quality control, identifying wearing out. Moreover, the CEI machines allow users to customize the shape and form of products through different moulds and ZDMP provides support for more efficient material usage through more efficient projection of the moulds.

Product-Service Innovation
Result items:
Construction supply chain: quality control at construction site and quality traceability
Construction supply chain: quality control at construction site and quality traceability
Closed loop PSS Design (Connected to users data)
Result items:
Engine block manufacturing: Defects reduction by the optimization of the machining process
Engine block manufacturing: Defects reduction by the optimization of the machining process

The data generated within the FORD facility are shared with the equipment supplier ETXE with assistance of the ZDMP platform. The local instance of the ZDMP platform is hosted on the FORD side ensuring data protection and confidentiality, while the communication with ETXE is granted. The raw data, as well as aggregated knowledge by ZDMP platform are shared with ETXE for to introduce the recommendations on production process optimization.

Moulds manufacturing: Process alert system for machine tool failure prevention and Smart process parameter tuning
Moulds manufacturing: Process alert system for machine tool failure prevention and Smart process parameter tuning

The ZDMP platform acquires the process and equipment data from FORM and provides a set of innovative services, namely: (i) parameter adjustment, (ii) operator alerting in case of defect, (iii) correlation among various parameters related to equipment and parameters selected. In the case, when equipment manufacturers need to be involved in the problem solving, data can be securely shared through ZDMP platform.

Service Innovation and new Business Models
Result items:
Construction supply chain: quality control at construction site and quality traceability
Construction supply chain: quality control at construction site and quality traceability

This use-case only includes only 3 industrial partners. However, the model is scalable and can be applied, to the case with more partners, for instance, the material suppliers. Moreover, different access levels and roles allow effectively regulate type and amount of information one or another partner can get access to.

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