Methodological Foundations of Product Quality Post-Production Monitoring in the Context of the CALS Concept

Abstract

The high level of defects at the stages of operation of machine-building products reduces its competitiveness. According to the Ministry of Industry and Trade, over 70% of industry enterprises do not have digital control systems at the service stage, although up to 16% of defects appear in the first year of operation. This requires the creation of closed digital quality management circuits based on national standards. The article is devoted to the development of scientific and methodological approaches to the construction of a system of defect post-production monitoring in metal products. The focus is on the integration of operational data with the design and production stages in the unified information space of CALS technologies. In the course of the work, an algorithm for forming a digital footprint of a product based on ERP, MES, and PLM systems was proposed. A probabilistic resource estimation model based on Weibull's law and digital maturity indices has been developed. The methodology was tested at a machine-building enterprise. A model of end-to-end defect control has been created that combines predictive analytics and non-destructive testing methods. The implementation of the proposed solutions resulted in appreciable economic effect. The respond time to deviation in production reduced in half. The number of repeated defects at soldering reduced by 78.8%, while the accuracy of defect prediction increased up to 95.8%.