Towards Zero Defect Manufacturing paradigm: A review of the state-of-the-art methods and open challenges

• Published in: Computers in industry Vol. 134; p. 103548
• Main Authors: Caiazzo, Bianca, Di Nardo, Mario, Murino, Teresa, Petrillo, Alberto, Piccirillo, Gianluca, Santini, Stefania
• Format: Journal Article
• Language: English
• Published: Elsevier B.V 01.01.2022
• Subjects: Detection; Prediction; Prevention; Quality control; Quality improvement; Repair; Review; Smart factories; State-Of-The-Art; Zero Defect Manufacturing (ZDM); Prevention; Quality improvement; Smart factories; Prediction; Quality control; Zero Defect Manufacturing (ZDM); State-Of-The-Art; Review; Detection; Repair
• ISSN: 0166-3615; 1872-6194
• DOI: 10.1016/j.compind.2021.103548

Nowadays, Internet-of-Things (IoT), big data, and cloud computing technologies allow increasing the throughput and quality of manufacturing systems, bringing to the rise of the Industry 4.0 paradigm. The aim is to leverage the ICT technologies to achieve a flexible customised production with reduced time while avoiding resources waste. In this framework, Zero-Defect Manufacturing (ZDM) concept plays a crucial role in guaranteeing the minimisation of defects and errors in industry processes by trying to act at the first time properly. Due to its importance, this topic has received greater attention during the last two years by the technical literature. Given the increasing number of research works and the several approaches suggested by researcher interested into the topic, this study aims at providing a literature overview of the current trends in the ZDM field from 2018 to 2020. The focus of the work is to provide a state-of-the-art about ZDM strategies, i.e. Detection, Repair, Prediction and Prevention, by analyzing the related most significant works, thus providing a single-strategy analysis and the corresponding most frequently used methods. A brief bibliometric study corroborates the general research patterns and the relevant aspects emerging from each single-strategy analysis. Finally, based on the conducted study, we point out the shortcomings present in the current technical literature to target the future research directions in the ZDM field. •We perform a systematic review of the technical literature in the appraised time period for each of the ZDM strategies, namely, Detection, Prediction, Prevention and Repair.•We describe their advantages and aims for each of these latter and the most significant critical findings of the related works.•A bibliometric analysis of all the selected works is conducted so to highlight the importance of the topic for the industry during the last years.•A discussion of the shortcoming and of the open challenges are given.