Stellin, Tommaso

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Projects

• Manufacturing Error-free Goods at First Time

  
  (Third Party Funds Group – Sub project)
  Abstract

  Today, Europe's leading position in manufacturing of high-precision metal parts is being threatened by developed non-EU countries that catch up quickly on product quality at low cost. If no further action is taken, loss of jobs and GDP are at risk.To face global competition, a breakthrough is needed in tackling the following 4 challenges:1) High number of defects2) Many costly, energy suming finishing operations are needed.3) tinuous trend for higher quality, smaller features, lower costs, at simultaneous demand for customised products.4) Six-Sigma methodology reaches its limits for these complex processes (multi step / customised).MEGaFiT will realise this essential breakthrough.The primary goal of MEGaFiT is to develop and integrate all necessary technologies which create the basis to reduce the number of defects in manufacturing of complex high-precision metal parts. This will be achieved by developing and integrating in-depth process knowledge, in-line measurement and real-time adaptive process trol. Proof will be given on pilot production lines in industrial settings.MEGaFiT will do this with a sortium of partners best-in-class in these fields. The methodology that will be used to come to efficient realisation is the following: (1) Define and describe the process (2) Measure actual process performance (3) Identify potential adaptive trol solutions (4) Design adaptive trol solutions and (5) Verify the adaptive trol solution.This methodology will result in reduction of: defects from 5-15% to 20%; material and energy sumption by >20%; and number of finishing operations by >35%.The knowledge-based MEGaFiT results are also applicable in different sectors, leading to low defects, despite customization trends. MEGaFiT will therefore help in assuring a competitive and sustainable European manufacturing industry.
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