Periodic Reporting for period 1 - ZDZW (Non-Destructive Inspection Services for Digitally Enhanced Zero Waste Manufacturing)
Période du rapport: 2022-09-01 au 2024-02-29
ZDZW offers a catalogue of IoT based non-destructive inspection technologies, providing an accurate inline evaluation of key product parameters that have an effect in quality requirements within different technical areas, such as: Part Integrity, Visual Requirements and Thermal Process efficiency. The ZDZW Inspection Solutions follow the concept of Inspection as a service, guaranteeing its cost effectiveness and improved return of investment, offering different types of subscription and pay-per-use models depending on the offered functionalities. To pursue the main goal of reducing defects and the waste generated in manufacturing processes, ZDZW addresses defects and waste reduction in three key areas that cover the entire manufacturing process and product lifecycle: (i) Monitoring and control improvement for process quality assurance, where first-time-right manufacturing rate can be increased, including improved durability properties and reduced waste generation; (ii) digitally enhanced Rework & Repair procedures for necessary part recovery and scrap reduction; and (iii) Continuous Sustainability evaluation to ensure the efficient use of materials and components across the full production line. ZDZW is strongly supported by collaboration with relevant EU initiatives such as ZDMP and i4Q, providing components and services that enhance key ICT aspects such as interoperability, interlinking, security, data reliability and digital platforms. ZDZW will demonstrate its ZD and ZW approach in 6 Pilots involving production processes with an important waste reduction potential, such as injection moulding, thermoforming, welding and coating, induction hardening, lithography and packaging, involving key industrial sectors as automotive, home appliances, renewable energy, e-health, and food and beverages.
Work related to Integrity Inspection tool has been developed. The development of the first version of the Mechanical Hardness Inspector Application has been carried out. In addition, the laboratory tests have begun, specifically, the induction hardening test bench has been used for preparing a first set of samples treated at different conditions of heating (power and time) and also cooling (water flow rate). These samples have been sent to characterize the hardness and microstructure obtained after the thermal processing. Also, the supercontinuum laser supplying a spectrum has been finished. Works related to the Phased Array ultrasonic inspection solution for the inspection of multipass welds has been also done, and already 12 samples has been tested.
Work related to Visual Inspection tool has been developed. The main purpose of the tasks carried out was (1) to consolidate the requirements and functionalities of the Visual Inspection solutions to be developed and (2) start the definition of these solutions: applications to be created, its architecture, mock-ups, and dataset. Additionally, a list of additional consultancy services has been established to accompany the deployment of each solution. Some of these services include feasibility analysis, hardware installation, or specific model training.
Work related to Thermal Inspection tool has been carried out. The main objective is to build Thermal Inspection Suit by developing non-destructive thermal inspection solutions for its usage in different heat transfer processes. The main purpose is to identify (1) the requirements and functionalities of Thermal Inspection Suit to be developed and (2) start the definition of the thermal inspection solutions: applications to be created, its architectural design, user mock-ups and dataset features. Functional Specification and Schematic Pilot Requirements Diagrams have been prepared to define the functional specifications. To identify the solutions which will build Thermal Inspection Suit, a common roadmap established with the other technical work package leaders to define the aspects of the applications developed.
Additionally, the preparatory works for interoperability and integration of the developed solutions has been carried out. In general, a big part of the activity in this period, has been related to define the initial set of documents for the software: mockups, requirements, software specification, top ten features, etc. A significant amount of time has also been dedicated to prepare plenaries and meetings, presentations, demos and the deliverables including the on-line documentation.
To conclude, piloting and demonstration works also started. Work is divided in 4 phases. Phase 1 'Pilot Implementation definition, planning and KPI validation Criteria' made the detailed definition of the Pilot and plan its development and implementation. In addition, this phase also collected the users’ requirements and validation criteria to be assessed in terms of univocally determined real values of defined KPIs. In phase 2 'Pilot industrial scenario establishment', a clear overview of the industrial sector of the pilot’s cases was translated into common constraints and criteria. Environmental barriers and possible obstacles were identified to be tackled during the development phases. These first two phases are already completed. Next step will be to start working on the third phase 'ZDZW Solutions Implementation'.
Work related to Visual Inspection tool has been developed. The main purpose of the tasks carried out was (1) to consolidate the requirements and functionalities of the Visual Inspection solutions to be developed and (2) start the definition of these solutions: applications to be created, its architecture, mock-ups, and dataset. Additionally, a list of additional consultancy services has been established to accompany the deployment of each solution. Some of these services include feasibility analysis, hardware installation, or specific model training.
Work related to Thermal Inspection tool has been carried out. The main objective is to build Thermal Inspection Suit by developing non-destructive thermal inspection solutions for its usage in different heat transfer processes. The main purpose is to identify (1) the requirements and functionalities of Thermal Inspection Suit to be developed and (2) start the definition of the thermal inspection solutions: applications to be created, its architectural design, user mock-ups and dataset features. Functional Specification and Schematic Pilot Requirements Diagrams have been prepared to define the functional specifications. To identify the solutions which will build Thermal Inspection Suit, a common roadmap established with the other technical work package leaders to define the aspects of the applications developed.
Additionally, the preparatory works for interoperability and integration of the developed solutions has been carried out. In general, a big part of the activity in this period, has been related to define the initial set of documents for the software: mockups, requirements, software specification, top ten features, etc. A significant amount of time has also been dedicated to prepare plenaries and meetings, presentations, demos and the deliverables including the on-line documentation.
To conclude, piloting and demonstration works also started. Work is divided in 4 phases. Phase 1 'Pilot Implementation definition, planning and KPI validation Criteria' made the detailed definition of the Pilot and plan its development and implementation. In addition, this phase also collected the users’ requirements and validation criteria to be assessed in terms of univocally determined real values of defined KPIs. In phase 2 'Pilot industrial scenario establishment', a clear overview of the industrial sector of the pilot’s cases was translated into common constraints and criteria. Environmental barriers and possible obstacles were identified to be tackled during the development phases. These first two phases are already completed. Next step will be to start working on the third phase 'ZDZW Solutions Implementation'.
The project will target types of waste or discarded material from identified defective products or components that cannot be easily reworked or recycled without significant effort, addressing the full production line or system, with the aim of reducing defects and manufacturing waste.
The application of ZDZW Integrity Inspection solutions will contribute to prevent the generation of defects and consequently increase process efficiency and sustainability.
The application of ZDZW Visual Inspection Suite will contribute to prevent the generation of defects and consequently increase process efficiency and sustainability.
The application of ZDZW Thermal Inspection Suite will contribute to detect prevent the generation of defects and while reducing avoiding the usage of excess of material.
The integration ZDZW solutions in a cloud computing platform will ensure services interoperability and interlinking, thus, allowing large data sets stemming from all sorts of production process and material to be analysed and shared between sites. Research must build on existing standards or contribute to standardisation
The application of ZDZW Integrity Inspection solutions will contribute to prevent the generation of defects and consequently increase process efficiency and sustainability.
The application of ZDZW Visual Inspection Suite will contribute to prevent the generation of defects and consequently increase process efficiency and sustainability.
The application of ZDZW Thermal Inspection Suite will contribute to detect prevent the generation of defects and while reducing avoiding the usage of excess of material.
The integration ZDZW solutions in a cloud computing platform will ensure services interoperability and interlinking, thus, allowing large data sets stemming from all sorts of production process and material to be analysed and shared between sites. Research must build on existing standards or contribute to standardisation