Smart factories are characterised by smart processes, smart machines, smart tools and smart products as well as smart logistics operations. These generate large amounts of data, which can be used for analysis and fault prevention, as well as the optimisation of the quality of manufacturing processes and products. DAT4.ZERO is a Digitally-enhanced Quality Management System (DQM) that gathers and organizes data from a Distributed Multi-sensor Network, which, when combined with a DQM Toolkit and Modeling and Simulation Layer, and further integrated with existing Cyber-Physical Systems (CPS), offers adequate levels of data accuracy and precision for effective decision-support and problem-solving – utilizing smart, dynamic feedback and feed-forward mechanisms to contribute towards the achievement of Zero Defect Manufacturing (ZDM) in smart factories and their ecosystems. The aim is to Integrate smart, cost-effective sensors and actuators for process simulation, monitoring and control; develop real-time data validation and integrity strategies within actual production lines; demonstrate innovative data management strategies as an integrated approach to ZDM; & develop strategies for rapid line qualification and reconfiguration. Deployed in 5 distinct industrial pilot lines we address the following primary objective: Develop and demonstrate an innovative DQM system and deployment strategy for supporting European manufacturing industry in realizing ZDM in highly dynamic, high-value, high-mix, low-volume production contexts, by effective selection and integration of sensors and actuators for process monitoring and control, a DQM platform with an architecture that provides reliable and secure knowledge extraction to ensure integrity of data, & strategies for advanced realtime data analysis and modeling in multiple domains and sectors that will increase quality, reduce ramp-up times and decrease time-to-market.

EU manufacturers are increasingly adopting automation solutions that can improve productivity and reduce costs.Enterprises’ ability to utilize these technologies may be their single most important competitive advantage, and the specific skills, experiences, competences,and flexibility of workers are pivotal to and at the core of this ability.To create a healthy workplace and increase the competitiveness of the manufacturing firms, the creation of an optimal environment for human automation integration and cooperation that harnesses and supports the workers’ capabilities is needed.The HUMAN project,with 12 partners from 6 European countries, aims to define and demonstrate workplaces where automation and human workers operate in harmony to improve the productivity,quality,performance of the factory as well as the worker satisfaction and safety.Objectives to be met are:Improving the integration of humans with their workplace;Enhancing the monitoring and wellbeing of human automation co-operation;Stimulating and advancing human-automation interaction and co-operation for optimal performance and achievement of complex tasks;Establishing adaptable workplaces and tasks to human cognitive and physical skills.These objectives will be achieved by developing and employing physical, conceptual, methodological, technological, and knowledge-based tools. 3 use case companies from the Furniture Manufacturing (ROYO Group), Automation Manufacturing (COMAU), & Defence & Aerospace (AIRBUS) sectors are involved. Proposed advances offered by HUMAN solutions will remove the barriers for:adaptability and flexibility of humans to continuously changing workplaces;alignment of new and complex tasks with human cognitive and physical skills;and synchronization of enterprise goals with human expectations.These advancements will in turn have significant impacts on higher customization capability,productivity,quality,worker satisfaction,and empower competitive position of the EU manufacturers.