Real-Time Rule-Based Monitoring Tool to Achieve Zero Defect Manufacturing

Julio Costa, Alexandre O. Júnior, José Barbosa, Gleifer V. Alves, André Pinz Borges, Gisela García, Rui Pires, Paulo Leitao

Abstract: The demands of innovative production systems are shifting from mass production to the creation of smaller quantities with a focus on high quality. To achieve these evolving demands, Zero Defect Manufacturing has emerged as a key paradigm. This approach requires an innovative architectural monitoring tool where real-time data is continuously gathered and analysed to predict defects and assess their potential impacts. It also necessitates the seamless integration of diverse data sources, advanced processing algorithms, and Digital Twins to align with industrial requirements. In this paper we present a real-time, rule-based monitoring tool applied to a real-world car manufacturing use case. The tool successfully generated early alerts for quality deviations, enabling production engineers to shift from a reactive to a proactive approach by detecting potential quality issues early in the process.