Application of automation for in-line quality inspection, a zero-defect manufacturing approach

Contemporary manufacturing must prioritise the sustainability of its manufacturing processes and systems. Zero Defect Manufacturing (ZDM) focusses on minimising waste of any kind using data-driven technology, hence enhancing the quality of all manufacturing aspects (product, process, service, etc.). Making things right on the first try is the central tenet of ZDM. In recent years, the application of automation for in-line quality inspection systems has begun to attract the interest of both practitioners and academics because of its capability to detect defects in real-time, and thus adapt the system to disturbances. In this work, we provide a systematic review of the literature on current trends in the application of automation for in-line quality inspection with the ultimate objective of achieving ZDM. Additionally, bibliometric and performance analyses have been performed to gain a complete picture of the field. In this work, we have collected bibliometric data from the most widely referred search engines for academic engineering papers, i.e. Scopus, Web of Science, and IEEE Explorer, involving a total of 145 academic publications from 2011 to 2021. Uniquely for this study, we used three research attributes for the analysis of the selected articles, that is, the level of automation, the condition for quality inspection, and the contribution to ZDM dimensions. The literature suggests that there is a lack of research on the use of in-line detection data for the prediction of defects or repair. Based on the results and our interpretation of the literature, an adapted framework of ZDM (Psarommatis et al., 2020a) and multi-layer quality inspection (Azamfirei et al., 2021a) is presented. •Over the past ten years, interest in automated in-line quality inspection has risen.•Universities from Asia and Europe were found to have the most knowledge on this topic.•99% of the papers clearly showed the level of integration of their inspection system.•Only 1% of the papers focused on theoretical advancement or simulation for the field.•Analysed papers used the principles of ZDM without explicitly mentioning it.•Several departments, with their vast experience in the sector, did not work together.