Industry 4.0 and Zero-Defects Manufacturing: an insight on a new industrial era

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Industry 4.0 created the right conditions for the concept of Zero-Defects Manufacturing (ZDM) to develop as a subject of interest and industrial breakthrough achievement. LMS, partner of the STREAM-0D project, highlights the main techniques and methods involved in the ZDM process.


As Industry 4.0 got more and more mature, the concept of Zero-Defect Manufacturing (ZDM) became a subject of interest. The need for achieving ZDM is driven by the aim to minimize and eliminate product quality defects and process errors. Traditional quality control methods developed through the last couple of decades, such as the Statistical Process Control or the Six Sigma method, have shown serious limitations in highly changeable production contexts characterized by customized batches, small quantities (or even unique products) and in-line/on-line product inspections.


New techniques and methods

The emergence of Industry 4.0 created the right conditions for the concept of ZDM to find a well-grounded base for its establishment as an industrial breakthrough achievement. Such conditions involve the huge steps made in techniques and methods namely, real-time modeling and simulation, intelligent and self-adaptive process control and quality management and, additionally, innovative measurement and inspection technologies. Furthermore, the adoption of data mining and data analytics methods, using real time data captured through advanced monitoring systems throughout the whole manufacturing line, gave the ability to generate an unprecedented amount of information and knowledge.



A new era

STREAM-0D project comes as a solution for achieving Zero-Defect Manufacturing. The STREAM-0D solution combines the above techniques and methods, in an attempt to identify possible defect patterns during the manufacturing processes and by exploiting the capabilities of smart and innovative adaptive control methods, to prevent and eliminate the manufacturing of defective products.

Ultimately, the STREAM-0D solution and to that extend the concept of ZDM, under the scope of Industry 4.0, promises a zero-defect production environment, lower production cost, reduced production time and the increase of productivity, and evidently the reduction of wastes and scrap along with the increase of resource and energy efficiency.

Accomplishing all the aforementioned challenge, will form a strong base towards sustainability.


This article by Demetris Petrides, Alexios Papapacharalampopoulos and Panos Stavropoulosis of the Laboratory for Manufacturing Systems and Automation (LMS) – Department of Mechanical Engineering and Aeronautics (University of Patras, Greece) is part of the Bits of STREAM-0D series of contributions from the project’s consortium partners. Periodically, on STREAM-0D channels, a different topic will be given prominence, along with videos featuring members involved in the project.

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