This project addresses the challenge of mfg industry to deliver high-quality products at the necessary production rates while minimizing waste and energy consumption, maximizing efficiency and ROI. openZDM project is an Innovation Action that will develop and demonstrate in 5 representative production lines an open platform designed to realize ZDM. The platform integrates advanced ICT solutions & innovative non-destructive testing, setting the foundations for an innovative solution applicable to a large variety of mfg industries. The 5 pilots represent the largest part of the EU's manufacturing sector, geographically (including plants in northern and southern areas of Europe), technologically (fully & semi automated, and manual processes) and from their value chain positioning (including Tier 1, Tier 2 suppliers, technology suppliers and OEMs). Furthermore, the choice of partners has been done considering strategic sectors for the green transition, in particular two energy intensive production processes (glass bottles, steel suspension arms), one process strategic for the electrification (production of batteries), one process consuming renewable materials (wood based panels) and one highly digitalized automotive assembly plant. The project aims to develop a digital platform that builds on the state-of-the-art RAMI 4.0 and Asset Administration Shell (AAS) to implement intra-factory quality management practices, applicable to these different production environments. In addition several non-destructive inspection (NDI) methods and data-driven quality assessment techniques are considered for online defect identification and quality assessment, distributed at various stages along the manufacturing line. Finally, the Digital Twin and the related services is a key enabling technology for online process adaptation & prediction/prevention of defects, to achieve waste reduction and improved efficiency, aiming to significantly improve the production sustainability of CPPSs.

As part of the green, circular and digital transformation of the European manufacturing community, it is extremely important that data-driven digital manufacturing processes urgently incorporate innovative and active resiliency strategies at production and supply chain levels to maintain their sovereignty and competitiveness levels, respecting European digital values (excellence, privacy, trust) to improve individual and value chain flexibility. In order to achieve long-term resilience to reorganise supply chains or speed up decision making to dealt with any disruption, it is imperative to ensure the implementation of distributed data-intensive intelligent and dynamic industrial decision support, augmentation and automation processes, integrating Artificial Intelligence (smart anticipation) and Intelligent Automation (rapid response) capabilities in Human-Automation symbiosis. Hence, only businesses that can articulate their data, based on AI, digital thread and digital twin solutions, will be able to react rapidly to external shocks. RE4DY mission is to demonstrate that the European industry can jointly build unique data-driven digital value networks 4.0 to sustain competitive advantages through digital continuity and sovereign data spaces across all phases of product and process lifecycle, proposing ?Data as a Product? core concept to facilitate the implementation of digital continuity across digital threads, data spaces, digital twin workflows and AI/ML/Data pipelines. This concept leverages resiliency on top of advanced manufacturing digital processes and value ecosystems supporting the development and implementation of digital continuity, so distributed data management solutions implemented to deal with factory resiliency can be immediately and seamlessly reused to enhance connected factory and value network level processes.

Multi-stage manufacturing, which is typical in important industrial sectors such as automotive, house hold appliance and semiconductor manufacturing just to name few, is inherently complex. The main idea of GO0D MAN project is to integrate and combine process and quality control for a multi –stage manufacturing production into a distributed system architecture built on agent-based Cyber-Physical Systems (CPS) and smart inspection tools designed to support Zero-Defect Manufacturing (ZDM) strategies. Data analytics tools provide a mean for knowledge build-up, system control and ZDM management. Real time and early identification of deviations and trends, performed at local level, allow to prevent the generation of defects at single stage and their propagation to down-stream processes, enabling the global system to be predictive (early detection of process faults) and proactive (self-adaptation to different conditions). The GO0D MAN project is based on the results of previous successful EU projects and integrates them to realize and deploy a Zero Defect Manufacturing framework for multi-stage production lines, in collaboration with industry partners, a system integrator, two technology providers and three end users. The use cases are representative of key European industrial sectors and have different types of multi-stage production systems: the first use case concerns highly automated serial mass production of automotive components, the second use case is about batch production of high precision mechanical components for automotive electro valves, the third use case produces professional customized products such as ovens for restaurants. Successful completion of this project will provide a replicable system architecture for ZDM. The results will be broadly applicable in a variety of industries to improve the overall quality and productivity of production systems.