Optimizing efficiency and zero-defect manufacturing with in-process inspection: challenges, benefits, and aerospace application

In this paper, we present a comprehensive study on the implementation of machine vision-enabled in-process quality inspection systems in machining operations. Our objective is to enable zero-defect manufacturing by maximizing efficiency and effectiveness in production processes. We utilize machine vision technology as a transformative tool, playing a vital role in our comparative analysis which reveals its superiority over traditional in-situ approaches in both ideal and challenging real-world scenarios. Through simulation, we demonstrate how machine vision improves the performance of in-line process systems. We also discuss substantial challenges of implementation, such as managing environmental contamination, optimizing machine coordination, accommodating a range of part sizes, and configuring effective coolant delivery systems. Our in-depth analysis of essential factors includes the robustness of machine vision equipment, operator training for machine vision technology, and cost-benefit analysis of its implementation. The research emphasizes machine vision's crucial role in transforming manufacturing setups and enhancing advanced automation systems. The study underscores the immense potential of machine vision in in-process quality inspection to significantly reduce production costs and time, fostering higher manufacturing sustainability and competitive advantage in the era of Industry 4.0.