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Digital technologies to optimise zero defect manufacturing

Digital technologies to optimise zero defect manufacturing
  • The consortium of the European project QU4LITY, in which the research centre specialised in Advanced Manufacturing IDEKO participates, will meet in Milan on 25th and 26th February to analyse the progress of the initiative.
  • The QU4LITY project, with a duration of four years, kicked off in 2019, and aims to advance towards the disruptive concept of autonomous quality.

The quality of an industrial product depends on both the equipment used and the manufacturing processes. Any failure in the production plants or in the technology used may cause imperfections. To address this scenario, it is necessary to move forward to new production models, such as the zero-defect manufacturing (ZDM) system, a paradigm that increases the reliability of industrial production processes to meet the most stringent demands in industry.

The European QU4LITY project, in which the technology centre specialising in Advanced Manufacturing IDEKO participates, is framed in this context. The initiative focuses on the application of digital technologies in the new ZDM manufacturing model.

With the mission of evaluating the progress made since its inception, the members of the consortium will meet in Milan on 25 and 26 February. The meeting, which will bring together representatives of the 45 partners that make up the initiative, will serve to learn about the achievements so far and to outline the lines of work for the coming months of the project, which began in January 2019 and will run until December 2022.

“The mission of QU4LITY is to carry out a radical change in current production quality methods to advance toward the disruptive concept of autonomous quality” as Ideko’s project leader Elena Urkia puts it.

In order to achieve this, the project involves manufacturers and suppliers to develop, validate, implement and adopt innovative solutions for cognitive manufacture based on flexibility, self-adaptation, self-learning and intelligent systems of cognitive manufacturing for ZDM.

Specifically, the application of the zero defect production system in high-precision machining is based on the use of machinery whose critical components are fully sensorized to obtain real time information on the status of processes and pieces from which performance patterns are drawn together with conclusions to optimise its effectiveness.

"The objective of the QU4LITY project is to demonstrate in a realistic, measurable and replicable way, a data-based product and service model with zero defects. It also seeks to demonstrate how European industry can build unique and highly customized strategies and competitive advantages on an ecosystem of open platforms," the expert said.

A multidisciplinary project

The initiative addresses issues such as digital connectivity, edge computing, stand-alone manufacturing equipment, real-time data capture solutions for process monitoring and adaptation, and simulation models for the creation of digital twins, among other disciplines.

The participation of IDEKO in this initiative is centred on monitoring the condition of the machine, and analysis of data supplied by sensors fitted on the monitored critical elements, such as headstocks and machine axes.

IDEKO's specific task in this project is to incorporate ZDM services into the digital platform for the development of grinding processes of the Basque machine-tool manufacturer, Danobat, which is also participating in the initiative. 

IDEKO will offer support in a pilot case at line level and in a demonstrator at machine level.

Coordinated by the digital transformation company ATOS and with a budget of 19.5 million euros, QU4LITY can count on the participation of leading manufacturers and suppliers in their sectors such as Siemens or Airbus.

The Mondragon Corporation, several research centres and universities also form part of the consortium, including Frauenhofer FHG, Innovalia and the AIC foundation.

Download info about Qu4lity- Digital technologies to optimise zero defect manufacturing