Reference architecture for the industrial implementation of Zero-Defect Manufacturing strategies

Maria Chiara Magnanini, Marcello Colledani, Davide Caputo
2020 Procedia CIRP  
In today's business environment, the trend towards more product variety and customization is unbroken. Due to this development, the need of agile and reconfigurable production systems emerged to cope with various products and product families. To design and optimize production systems as well as to choose the optimal product matches, product analysis methods are needed. Indeed, most of the known methods aim to analyze a product or one product family on the physical level. Different product
more » ... ies, however, may differ largely in terms of the number and nature of components. This fact impedes an efficient comparison and choice of appropriate product family combinations for the production system. A new methodology is proposed to analyze existing products in view of their functional and physical architecture. The aim is to cluster these products in new assembly oriented product families for the optimization of existing assembly lines and the creation of future reconfigurable assembly systems. Based on Datum Flow Chain, the physical structure of the products is analyzed. Functional subassemblies are identified, and a functional analysis is performed. Moreover, a hybrid functional and physical architecture graph (HyFPAG) is the output which depicts the similarity between product families by providing design support to both, production system planners and product designers. An illustrative example of a nail-clipper is used to explain the proposed methodology. An industrial case study on two product families of steering columns of thyssenkrupp Presta France is then carried out to give a first industrial evaluation of the proposed approach. Abstract In recent years, digitalization has enhanced the implementation of more complex architectures for the management and control of manufacturing systems. In particular, Manufacturing Execution Systems (MES) acquired relevance as central software module for the application of advanced Zero-Defect Manufacturing (ZDM) strategies, aiming at achieving improved production quality performance at industrial level. ZDM-strategies ground on the gathering of production and quality data from heterogeneous sources and on their integration with information at multiple factory levels. This paper presents a reference architecture and the related software modules to properly support the implementation of advanced ZDM strategies in complex industrial contexts. Abstract In recent years, digitalization has enhanced the implementation of more complex architectures for the management and control of manufacturing systems. In particular, Manufacturing Execution Systems (MES) acquired relevance as central software module for the application of advanced Zero-Defect Manufacturing (ZDM) strategies, aiming at achieving improved production quality performance at industrial level. ZDM-strategies ground on the gathering of production and quality data from heterogeneous sources and on their integration with information at multiple factory levels. This paper presents a reference architecture and the related software modules to properly support the implementation of advanced ZDM strategies in complex industrial contexts.
doi:10.1016/j.procir.2020.05.154 fatcat:xa7ucgrbyzc7dlhhok653kgxdi