The quality of a product is dependent on both facilities/equipment and manufacturing processes. Any error or disorder in facilities and processes can cause a catastrophic failure. To avoid such failures, a zero- defect manufacturing (ZDM) system is necessary in order to increase the reliability and safety of manufacturing systems and reach zero-defect quality of products. One of the major challenges for ZDM is the analysis of massive raw datasets. This type of analysis needs an automated and self-organized decision making system. Data mining (DM) is an effective methodology for discovering interesting knowledge within a huge datasets. It plays an important role in developing a ZDM system. The paper presents a general framework of ZDM and explains how to apply DM approaches to manufacture the products with zero-defect. This paper also discusses 3 ongoing projects demonstrating the practice of using DM approaches for reaching the goal of ZDM.
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Modern manufacturing is driven by the rapid technological changes. High-value manufacturing processes are increasingly moving towards flexible, intelligent production systems. These systems involve the inter- play of novel technologies, advanced materials, in-line analysis and information comminution technology (ICT), dual working of people and automated systems, and precision engineered products and systems, etc. The productivity, performance and quality of products are affected by the conditions of machines, manufacturing processes and manufacturing decision making. In current competitive market, to achieve zero-defect products in manufacturing becomes a necessity to gain customers and market share. Most manufacturing companies, regardless of sizes, usually operate in data-rich environments. Powerful data acquisition systems are implemented in all enterprises worldwide. Accurate and complex datasets are stored in databases at various stages of manufacturing. These datasets are related to products, machines, materials, processes, inventories, sales, markets, etc. Valuable information and knowledge can be extracted from these datasets, including patterns, trends, associations, dependencies and rules.
The word of zero-defect was introduced in the early 1960s in connection with the US Army Perishing Missile System [2, 3]. It is now a common manufacturing practice to reduce and minimize the number of defects and errors in a process and to do things right in the first time. The ultimate aim is to reduce the number of defected products to zero. However, zero-defect means zero failures during operation but not necessarily zero imperfections, blemishes, or nonconformities [4, 5]. During the 1990s, large automotive enterprises tried to cut costs by reducing their quality inspection processes and demanding their suppliers to dramatically improve the quality of their supplies. This eventually results in demands for the zero-defect standard and is then implemented all over the world.
The concept of zero-defect can be practically utilized in any manufacturing environment to improve quality and reduce cost. However, implementation of zero-defect requires the right conditions. There are two reasons to pursue zero-defect quality products and processes. The one is safety. The other is customer expectation. To achieve ZDM, new cost-efficient tools for quality monitoring and optimization with multi-resolution, multivariate and auto-correlated data have to be developed.
Most of methodologies mentioned above are concentrated on the quality of finished product and the product condition in the manufacturing process. However, with these methods, it may not achieve ZDM. If there is a failure in the manufacturing process, some defects of the product might be generated and the cost may increase significantly. Thus, the condition of the equipment should be considered and the degradation of performance should be predicted.
Based on the concept IFDAPS, Department of Production and Quality Engineering, NTNU, as an EU project coordinator, has launched a ZDM practice: IFaCOM (Intelligent Fault Correction and self Optimising Manufacturing systems, FoF NMP-285489). The vision of IFaCOM is to achieve zero-defect manufacturing for different manufacturing branches, with emphasis on production of high value parts, on large variety custom design manufacturing and high performance products.
Quality is essential to success. In the competitive environment, quality is no longer a differentiating factor, it is a basic requirement. ZF customers expect reliable, zero-defect products and services.
It is Sperry Automatics Company's policy to obtain a clear understanding of each customer's quality specifications and standards and to assure that appropriate measures are taken to manufacture products which confirm to these standards and economically verify that these standards are being met. We are committed to produce products to a zero-defect level which shall be based on mutually developed engineering, material, and testing standards which reflect customer needs and the statistically measured capabilities of Sperry Automatics' procedures.
Sperry Automatics recognizes that "zero-defect" requires: Commitment and leadership of top management, personnel trained and committed to defect prevention methodology, plant equipment and working environment compatible with zero-defect quality, and suppliers who are equally capable and committed to zero-defect quality.
In the 2 years that the online validation has been in use, there have never been any defects or reporting risks due to autoverification. We believe that for both intermediate and self-built autoverification systems, online validation is a useful tool for controlling the risks of autoverification and improving the quality of reports. The detailed process for this method can serve as reference for the development and implementation of LIS-based autoverification systems.
Suppliers to BMTS Technology are therefore subject to careful selection that pursues the aim of developing partnerships over the long term. We are demanding, particularly where quality is concerned, because we operate within the framework of certified quality-management systems and pursue zero-defect strategies for our customers. That's why we employ reliable and trustworthy supplier management with consistently high quality. We rely on systematic cost work.
Quality Maintenance is the sixth pillar of TPM and aims to assure zero defect conditions. It does this by understanding and controlling the process interactions between manpower, material, machines and methods that could enable defects to occur. The key is to prevent defects from being produced in the first place, rather than installing rigorous inspection systems to detect the defect after it has been produced.
The first phase aims to eliminate quality issues by analysing the defects, so that optimum conditions can be defined that prevent defects occurring. Then, the current state is investigated and improvements are implemented. 2ff7e9595c