Dynamic Re-scheduling: The Key to Efficient Zero Defect Manufacturing - A Comprehensive Study

Zero Defect Manufacturing (ZDM) is the latest approach for quality management (QM). It utilizes the full potential of Industry 4.0 technologies, and in return, can provide more efficient QM, achieving higher quality rates and using fewer resources, leading to sustainable manufacturing. Manufacturing systems are characterized by high uncertainty, and therefore, disruptive events will always be present, alongside inspection, preventive, or predictive maintenance, for example. To this extent, production rescheduling has become an inevitable and crucial implementation. To maintain costs and productivity within reasonable bounds while offering high-quality products, it is essential to utilize a dynamic scheduling tool, which can reschedule operations when these disruptive events occur. The current research effort is concentrated on determining the key parameters that affect the rescheduling problem and defining the implications of such an approach to the entire production system. The proposed approach will be validated through a series of simulations and comparisons with current practices.