MUPROD

Innovative proactive Quality Control system for in-process multi-stage defect reduction

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 Obiettivo del progetto (Objective)

'This project aims at developing an innovative Quality Control System that will drastically change the current concept of End Of Line quality control, going beyond currently established methodologies such as Six-sigma and SPC. It will prevent the generation of defects within the process at single stage and the propagation of defects between processes at multi-stage system level. This Quality Control System will be proactive, offering three different solution strategies to avoid End of Line defects: (i) elimination of the predicted defect through adjustment of process characteristics by proactively intervening on the inputs to the process (process parameters, etc.), (ii) on-line reworking of the product in order to eliminate the defect, (iii) on-line workpiece repair through defect elimination at consecutive process stages. Technological developments will be based on the design and development of new hardware technologies, techniques and software solutions that in turn are based on real-time multi-data gathering by the integration of new sensor and inspection equipment, development of intelligent actuators and the of new monitoring and prognosis knowledge-based models. To develop a universal system able to be integrated into different production processes, its feasibility will be demonstrated in machining and assembly processes at both macro and micro product scales. The integration of the in-process Quality Control system into the production chain will minimize the amount of defective part production, reaching process capability values of more than 2.0 in mass production, and equivalent reduction of defect amount in small-lots and customized product manufacturing. Application domains will include emerging strategic European sectors such as the production of electrical engines for sustainable mobility, large-part manufacturing for the wind power sector and the production of customized micro-intravascular catheters as high value medical products for the aging society.'

Introduzione (Teaser)

Manufacturers aspire to zero defects and minimal manufacturing wastage from their production lines. An EU initiative developed the hardware and software required for zero-defect parts with minimal scrap, helping to ensure sustainable and competitive manufacturing.

Descrizione progetto (Article)

Defects generated during manufacturing are currently detected offline during the final production stage, causing tremendous loss of time and money and producing undesirable scrap. To avoid such end-of-line failures, the EU-funded http://www.muprod.eu/ (MUPROD) (Innovative proactive quality control system for in-process multi-stage defect reduction) project set out to develop a new integrated quality control solution to increase product quality and competitiveness.

The system aims for reliable and sustainable production with a near-zero defect and scrap target. It consists of sensors and actuators and its controlling software enables real-time multi-data gathering and analysis. Performance monitoring of the various steps in manufacturing processes is uninterrupted. This helps to mitigate defects within or between processes and to enhance their robustness.

MUPROD developed new hardware and software solutions that incorporate technological, modelling and methodological innovations into integrated quality control systems for production. It also developed novel sensor and inspection equipment, monitoring and prognosis knowledge-based models, intelligent fixtures and decision-making tools. The sensors and inspection methods automatically take action when faults are detected by the advanced monitoring and diagnostic systems.

To validate the technological solutions, the project carried out demonstration activities through real-life use cases from the automotive, customised medicine and green energy industries. The field testing proved the feasibility of zero-defect manufacturing for sustainable and competitive European production.

MUPROD introduced monitoring tools for the production line that can counteract and fix defects quicker and sooner. This will result in the reduction of costs and less downtime and wastage while producing higher quality and safer products.