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ZDMP | Zero Defect Manufacturing Platform

01-01-2019

-

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.

Service-enabled Product Design
Result items:
Construction supply chain: quality control at construction site and quality traceability
Construction supply chain: quality control at construction site and quality traceability
Service orient. Product Design (integration of PLM and CRM)
Result items:
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

The service proposed doesn’t require big hardware installation, but rather makes use of the data gathered from already installed field level devices (sensors, smart meters, cameras) having the supportive or supplementary role in the production process. However, the added value is in reduction of the number of defected parts or products through extensive utilization of the data-rich environment.

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