MEGAFIT · Manufacturing Error-free Goods at First Time

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 consuming finishing operations are needed.3)Continuous 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 control. Proof will be given on pilot production lines in industrial settings.MEGaFiT will do this with a consortium 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 control solutions (4) Design adaptive control solutions and (5) Verify the adaptive control solution.This methodology will result in reduction of: defects from 5-15% to <1%; cost by >20%; material and energy consumption 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.