Zero Defect Manufacturing (ZDM) aims to go beyond traditional lean management and Six Sigma by using artificial intelligence, IoT, big data, and digital twin simulation to advance quality in Industry 4.0 cyber-physical production systems and, as we move forward, Industry 5.0. ZDM approaches target zero defects in production. To date, manufacturing in Europe and ZDM strategies have focused on reducing defects by integrating in-line and off-line quality monitoring solutions at shop-floor level. In recent years, research on quality control and AI-driven tools for smart manufacturing under the Industry 4.0 paradigm has provided a solid framework for minimising rework and promoting first-time-right schemes. However, these strategies often lack a clear focus on sustainability alongside product quality, limiting the EU industry’s ability to adapt to the challenges reflected in the UN 2030 Agenda and the Sustainable Development Goals (SDGs).
openZDM addresses this gap by delivering an open digital platform that integrates existing R&D solutions into a state-of-the-art system supporting zero-defect processes across production networks, with a strong focus on sustainable manufacturing. The platform builds on the Reference Architecture Model for Industry 4.0 (RAMI 4.0) and the Asset Administration Shell (AAS), which are essential for interoperability and intra-factory quality management. Beyond RAMI 4.0/AAS-based interoperability, the project incorporates non-destructive inspection (NDI) methods and data-driven quality assessment techniques for online defect detection and quality evaluation. Digital twins are a key enabling technology, supporting online process adaptation, simulation, and waste reduction through “as-designed” and “as-implemented” data services. The openZDM concept combines (i) the open platform for continuous quality assessment and control, (ii) digital twins for online process adaptation, (iii) NDI systems for defect identification using different technologies, (iv) data analytics for real-time monitoring and prediction, and (v) a decision-making module that evaluates alternative process reconfigurations via the digital twin. Its novelty lies in treating quality assessment and control not as external add-ons, but as integral functions of the cyber-physical production system. Finally, openZDM advances the state of the art in manufacturing reconfiguration by using explainable AI for real-time, in-line root-cause analysis, supporting trustworthy intelligent systems aligned with both Industry 4.0 and Industry 5.0. Overall, the methodology promotes sustainable manufacturing by preventing waste through increased flexibility and adaptive control, contributing to circular-economy objectives as well as pollution prevention and control.
The openZDM framework helps manufacturers increase their business value in the following key aspects:
• Increase organisational flexibility and the capacity to continuously control quality and innovate.
• Increase cost savings through waste reduction.
• Promote sustainability through online process control and adaptation.
• Improve quality through data analytics and on-demand decision support, increasing efficiency.
• Increase productivity and competitiveness.
Beyond its core research and innovation objectives, openZDM also targets cross-cutting outcomes, including: (a) contributions to ZDM standardisation through participation in the release of CWA 18230:2025, and (b) skills development via online training tutorials and technical articles on enabling technologies.
