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Procedia CIRP 120 (2023) 99–104

56th CIRP Conference on Manufacturing Systems

Science and technology roadmap towards robotic in-line quality inspection

for implementing zero-defect manufacturing
Victor Azamfireia,, Foivos Psarommatisb,c
a MälardalenUniversity, School of Innovation, Design, and Engineering, Hamngatan 15, 6320, Eskilstuna, Sweden
b OsloUniversity, SIRIUS, Centre for Scalable Data Access, Gaustadalleen 23B, 0373, Oslo, Norway
c Research Center on Production Engineering and Management (CIGIP), Universitat Politècnica de València, Spain

* Corresponding author. Tel.: +46-736621635. E-mail address: victor.azamfirei@mdu.se

Abstract
The current manufacturing climate is characterised by the offering of customisable or one-of-a-kind products at mass production prices while
complying with sustainability demands. Consequently, modern manufacturing companies are employing more and more industrial robots to
increase flexibility and productivity. Nonetheless, for manufacturing companies to achieve true sustainability, a Zero-Defect Manufacturing (ZDM)
approach is needed. Such an approach implies applying emerging technologies for quality inspection and improvement, as no system is perfect
or free from deviations. Science and Technology (S&T) roadmaps are employed as decision aids to improve the coordination of activities and
resources in increasingly complex and uncertain environments. This paper presents a S&T roadmap to guide all-size companies towards ZDM
through advanced robotics for in-line quality inspection. The Key Performance Indicators (KPIs) and progress metrics for robotic in-line quality
inspection towards ZDM are outlined.
© 2023 The Authors. Published by Elsevier B.V.
This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0)
Peer-review under responsibility of the scientific committee of the 56th CIRP International Conference on Manufacturing Systems 2023

Keywords: Zero-Defect Manufacturing; ZDM; robotics; sensors; quality inspection; in-line;

1. Introduction quality of the products was maintained and consistent as well as

The current manufacturing landscape is characterised by
increased competition, product complexity, and environmental
requirements. Companies need to produce high-quality com-
plex, customised, or one-of-a-kind products, leading to frequent
and necessary changes in the production control, while simul-
taneously improving productivity [1]. These changes must be
implemented efficiently so that companies survive the chang-
ing market requirements [2]. Furthermore, with the rise of
re-commerce, customers are focusing on buying used goods,
renting, and shopping online or secondhand [3]. Products must
not only meet independent customer demands, but also have
a certain level of quality, cost, and environmental impact. To
achieve true sustainability, companies must balance economic
growth with social and ecological.
Quality control and inspection have always been a critical
part of the manufacturing process, as they can significantly
affect the profitability and sustainability of a manufacturing
company, something very important for the contemporary man-
ufacturing domain. These processes helped ensure that the
continuously improved. Companies must produce high-quality
complex, customised or one-of-a-kind products, leading to
frequent and necessary changes in production control while
simultaneously improving productivity. These changes must
be implemented efficiently to ensure companies survive the
changing market requirements. These factors pushed industries
to integrate more industrial robots, as they are the preferred
machine for increasing flexibility. Furthermore, ‘eyes’ for such
machines will be needed to increase their autonomy. An in-
crease in advanced sensors is expected to meet all the demands
that complex products and new materials might present. How-
ever, human operators will always be needed for faster and more
efficient programming of the robots and supervising the process
[4].
One of the most promising strategies today is called ZDM
[5, 6]. This strategy has the goal to decrease and mitigate
failures within manufacturing processes and “to do things right
in the first time”, in other words, to eliminate defective parts
during production. ZDM is a disruptive concept that is able
to entirely reshape the manufacturing ideology. ZDM can be
implemented in two different approaches. The product-oriented

2212-8271 © 2023 The Authors. Published by Elsevier B.V.

This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0)
Peer-review under responsibility of the scientific committee of the 56th CIRP International Conference on Manufacturing Systems 2023
10.1016/j.procir.2023.08.018
100 Victor Azamfirei et al. / Procedia CIRP 120 (2023) 99–104
ZDM and the process-oriented ZDM [6, 7]. Defect prevention
and preventive maintenance are two research areas that ‘com-
pete’ directly with quality inspection as a whole. The idea is
that defects are produced by machines and by controlling the
state the production will be stable within tolerances. ZDM’s
human-centric approach could result in fresh insights and
quality improvements because human behavior has a big impact
on manufacturing quality [6]. Despite the trend of the past years
to remove humans from the production environment in order to
prevent human error, research shows that incorporating humans
to the production but with different roles can actually boost
efficiency [8].
Modern manufacturing trends aim to improve production
efficiency, quality, and impact. Mass customisation provides
tailored products, sustainability preserves the environment,
automation boosts efficiency and reduces errors, and
human-centred ZDM prioritises worker well-being. By
integrating these trends, manufacturers can create an efficient,
sustainable, and customer and worker-centric production
system To our knowledge, a S&T roadmap in the field
aggregating such ideas is missing. This paper presents a S&T
roadmap to guide all-size companies towards ZDM through
advanced robotics for in-line quality inspection. The KPIs
and progress metrics for robotic in-line quality inspection to
towards ZDM are identified.
This paper is structured as follows. Section 2 explains
the research method for this work. Section 3 introduces the
encountered sciences and technologies and presents the S&T
roadmap on robotic in-line quality inspection systems. Sec-
tion 4 discusses the proposed roadmap and its challenges.
Finally, Section 5 summarises the scientific and practitioner
contribution of the article and presents future steps towards
ZDM.
2. Methodology
A ‘roadmap’ is typically a plan of paths or routes that exist
(or could exist) in a specific geographic area. Kostoff and
Schaller [9] describes that ‘roadmap’ is a popular metaphor
for planning S&T resources. Furthermore, Rober Galvin, for-
mer Motorola chairman, advocates for S&T roadmaps as “an
extended look at the future of a chosen field of inquiry com-
posed from the collective knowledge and imagination of the
brightest drivers of change in that field”. S&T roadmaps are
used in industry, government, and academia to depict the
structural relationships among science, technology, and appli-
cations. Roadmaps are employed as decision aids to improve
the coordination of activities and resources in increasingly
complex and uncertain environments [9].
Science mapping focuses on recent knowledge development
in the field, trends, and predictions. Science is mapped based on
recent Research and Development (R&D) projects. Technology
mapping focuses on available and future materials, machines, as
well as computers and their models. There should always exist
a need for converted science or further developed technology.
This S&T roadmap has followed a hybrid approach, where
literature reviews, bibliometric analyses, and experts’ opinions
in the fields are combined. Using the Scopus database, three
different groups were used in our search strings, consisting of
(i) “bibliometric OR review OR survey” AND (ii) “inspection
OR detect OR measure OR metrology” AND (iii) “manufactur-
ing”. The steps followed in this S&T roadmap were to identify
‘technology areas’ and ‘research directions’ relevant in terms of
impacts towards in-line quality inspection and towards ZDM.
After the identification of technology areas of (i) measurement
unit, e.g. sensors, (ii) computation, and (iii) connectivity; the
aim of the S&T roadmap was to identify expected features.
Expected Features of Technology Area are relevant technol-
ogy characteristics expected to become available in the future
thanks to R&D efforts.
3. Literature review
In this section, selected papers and EU projects in ZDM and
robotic in-line quality inspection are reviewed using literature
content analysis. The results are presented under ‘technology’
and ‘science’.
3.1. Technology
Imkamp et al. [2] presented the Manufacturing Metrology
Roadmap. They highlighted the importance of peacemaking
among measurements and Information Communication Tech-
nology (ICT) for the development of Industry 4.0 concept.
Matheson et al. [10] reviewed the application of human-robot
collaboration in the manufacturing industry. They identified
that human-robot collaboration not only doubled productivity
compared to manual assembly but also decreased the number
of defects to zero. They highlighted that future work should
also focus on human-centred manufacturing, where fatigue and
intention are monitored. Urhal et al. [11] reviewed the usage
of robotics for additive manufacturing. In their study, they
concluded that robotic systems are ideal for creating large parts
despite their limited accuracy. Furthermore, robotics allows
the usage of the same working space by multiple robots;
thus, multiple techniques, such as quality inspection, can be
performed in parallel. Psarommatis et al. [6] reviewed the
state-of-the-art of ZDM and highlighted the importance of
shifting from local to global solutions while considering the
role of people and human activities in manufacturing. Azamfirei
et al. [12] reviewed quality inspection protocols and proposed
a multi-layer framework for ZDM, characterised by holistic
data, intelligent control system, and connectivity. Babic et al.
[13] reviewed the usage of image-based quality inspection in
smart manufacturing. Out of their 224 reviewed paper, 78 used
‘defect detection’ techniques, 59 automated the process through
computers and robotic systems, and 30 focused on ‘real-time
inspection’ with a strong correlation among the variables. Liu et
al., [14] reviewed the concept of ‘robot learning’ for smart robot
manufacturing. Thao Ho et al. [15] reviewed the integration of
Augmented Reality (AR) in the Quality Control 4.0 movement.
AR can be used for assisting robot programming (e.g., welding)
 Victor Azamfirei et al. / Procedia CIRP 120 (2023) 99–104
Fig. 1. Technology roadmap for robotic in-line quality inspection
or enhancing operators in performing an in-line quality inspec-
tion. Ramasubramanian et al. [16] reviewed the design of digital
twins for human–robot collaboration and their challenges. Data
acquired from various physical sensors and from virtual sensors
can assist in quality inspection and maintenance of machines
in real time. In a similar topic Dreyfus et al. [17] reviewed
the domain of Virtual Metrology (VM) which involves the use
of production process data to estimate the product’s quality.
This maintains the efficiency of the operation while allowing
for real-time monitoring of the product quality for each unit of
manufacturing.
Barbosa et al. [18] reviewed the interplay between smart
manufacturing and digitalisation of metrology. They identi-
fied four emerging fields, namely (i) digital transformation
of metrological services; (ii) metrology in the analysis of
large amounts of data; (iii) metrology of the communication
systems for digitalisation; and (iv) metrology for simulations
and virtual measuring instruments. Robots improve produc-
tivity in Cyber-Physical System (CPS) applications such as
3D measurement of large-scale parts. Furthermore, in the con-
text of AR enabled quality assurance, the interaction between
the operator and the robot should be enhanced, allowing a
deeper interaction with the production process. Azamfirei et al.
[4] reviewed the application of automation for in-line quality
inspection with ZDM in mind. They highlighted the lack
of cross-field collaboration in the development of advanced
robotic in-line quality inspection solutions. A new quality
inspection framework for ZDM was presented. Fig.1 depicts
the technological and conceptual advances in the field.
3.2. Science: R&D projects
The following EU-funded projects were found to be relevant
for the development of the S&T roadmap. The 2016-2019
project, GO0D MAN, focused on integrating quality control in
multistage manufacturing production as a distributed system
architecture based on CPS using agent-based technology
101
and intelligent inspection tools created to support ZDM.
The 2016-2020 project, Z-Fact0r, introduced five multistage
production-based strategies targeting (i) the early detection of
the defect (Z-DETECT), (ii) the prediction of defect generation
(Z-PREDICT), (iii) the prevention of defect generation by
recalibrating the production line (multistage), as well as defect
propagation in later stages of production (Z-PREVENT),
(iv) the reworking/remanufacturing of the product, if possible,
using additive and subtractive manufacturing techniques
(Z-REPAIR), and (v) the management of the aforementioned
strategies through event modelling, KPIs monitoring, and
real-time decision support (Z-MANAGE). The 2019-2022
project, QU4LITY, aimed to offer ZDM models that are
SME friendly, highly standardised, reliable, and open. The
2019-2023 project, Zero Defect Manufacturing Platform
(ZDMP), combines state-of-the-art ZDM approaches based
on commercial grade or open-source software. The platform
allows end-users to connect existing (and new) devices and
sensors while enabling connections to related information
systems and operational assets. The 2020-2023 project,
Eur3ka, presented a Plug&Respond platform running at scale
to enable effective 4R (Rapid, Reliable, Resilient, and Robust)
manufacturing. The 2020-2024 project, DAT4.ZERO, will
develop a Digitally-enhanced Quality Management (DQM)
system to prevent faults. With the use of smart, dynamic
feedback and feedforward mechanisms, the project will
contribute towards ZDM in smart factories. The DQM system
combines smart sensors and actuators with existing large data
sets to monitor process parameters such as temperature and
vibration during machining operations to ensure a correct
quality output. New measuring equipment will also be
used to collect data that will feed into intelligent decision
support to optimise manufacturing in smart factories and
their ecosystems, which are characterised by smart logistics
operations. The 2021-2023 project, I4Q, developed a Reliable
Industrial Data Services solution based on Internet of Things
(IoT). The solution will manage a large amount of industrial
102 Victor Azamfirei et al. / Procedia CIRP 120 (2023) 99–104
Fig. 2. Concepts extracted from EU projects in ZDM that affect the roadmap for robotic in-line quality inspection
data and include simulation and optimisation tools for the
continuous qualification of the manufacturing line process,
quality diagnosis, reconfiguration and certification to ensure
high manufacturing efficiency, leading to an integrated
approach to ZDM. The 2022-2025 project, OPENZDM, aims
to develop an open platform that uses advanced ICT solutions
and Non-Destructive Testing (NDT) to help companies
realise ZDM in a cyber-physical manufacturing process.
This will allow for a large reduction in wasted resources
and energy consumption while also helping manufacturers
provide high-quality products. The 2022-2025 project,
RE4DY, proposes the ‘data as a product’ core concept to
facilitate the implementation of digital continuity in digital
threads, data spaces, Digital Twin (DT) workflows, and
Artificial Intelligence (AI). The 2023-2025 project, PLOOTO,
aims to provide Circular and Resilient Information System
(CRIS) to support manufacturers in their green, digital,
and circular transition. CRIS enables waste reduction and
end-to-end traceability of Secondary Raw Materials through
interconnected digital services for real-time decision making,
monitoring and certification of materials and products.
4. Discussion
Poor product quality can cause problems on many levels,
from direct economic losses to damage to the environment
caused by lost resources [19]. Quality management is necessary
for industrial businesses that want to keep or improve their
financial and operational performance. Poor quality can also
hurt a company’s brand and customers’ happiness, according to
[19]. Robotic in-line quality inspection seems to be one of the
most promising quality inspection methods for assuring 100%
quality and at the same time maintain the performance of the
system. Current the Industry 4.0 concept offers a variety of
advanced technologies for both the hardware and the software
for implementing robotic in-line quality inspection. The biggest
challenge on the implementation of in-line robotic quality
inspection is the proper selection of equipment [20, 21] In
addition, customer needs are directly linked to manufacturing
processes, which in turn are directly linked to metrology.
Such needs are characterised by ‘reparable’, ‘updatable’, and
‘one-of-a-kind’ products. Under such market vision, a S&T
roadmap for robotic in-line quality inspection systems is pro-
posed in Fig. 3.
4.1. Science and Technology roadmap
As described in [4], interest in the application of automation
for in-line quality inspection has grown exponentially over the
years. Quality inspection can be separated into two categories
(i) the hardware that ‘actuates’ on the product, ‘measures’,
‘communicates to the system’, and ‘process data’, and (ii) the
software that ‘predicts defects’, ‘control the actuators (robot)’,
‘decides upon conformity’, ‘learns from historical data or
human operators’, and ‘self-optimises’. Implementing ZDM
is vital that quality data processing is a vital process, and
currently, manufacturers face many difficulties on this topic.
One very common problem is data and systems interoperability
[22]. Ontologies serve as a viable solution for interoperability
problems, a recent research work developed the ZDM ontology
to align all in the domain [23], the ontology was developed
based on a set of standardised terms [24].
The integration of technology with human involvement has
the potential to achieve maximum benefits in the manufac-
turing process. Human-robot collaboration and its impact on
productivity and defect reduction highlight the potential of
technology in improving the efficiency of manual tasks. In
addition, the role of human operators should change from
performing repetitive, laborious, and tedious jobs to training,
programming, and supervising robots and the different digital
technologies.
 Victor Azamfirei et al. / Procedia CIRP 120 (2023) 99–104
Fig. 3. Science and Technology roadmap for robotic in-line quality inspection
4.2. KPIs and progression metrics
For manufacturing companies to succeed ZDM, a combi-
nation of low and high level activities and development in
hardware and software is needed, see Fig. 4. In a mid term,
companies need to focus their attention towards detection
of defects. The more data they gather the more they will
understand the real problem. The metric for such progress are
the usage of several sensors, the reach of 100% inspection,
and target accuracy and reliability. Once such metrics are
reached they can focus on reducing the cycle time until reaching
real-time inspection, where quality inspection does not add
additional time to the overall production but rather decreases
it as the ZDM platform can now prevent and predict future
defects. Cost of quality will raise on the short term until
such prediction and prevention algorithms are performing in
an exponential benefit way. For that self-optimisation and
robot-learning are necessary.
5. Conclusions
In this work, we have provided a S&T roadmap for robotic
in-line quality inspection towards ZDM. Through the usage of
literature and EU projects analyses, the ‘concepts’ and ‘tech-
nologies’ necessary for achieving plug&play robotic in-line
quality inspection systems are depicted in terms of hardware
and software as well as mid-term, long-term, and vision. The
study indicates that major effort is placed in the mid- and
long-term horizon on developing the software part of ZDM
103
and robotic in-line quality inspection systems. Though the
core value technologies of such quality inspection systems are
mostly hardware, such developments presents opportunities for
achieving human-robot symbiosis for all size companies as the
majority of projects focus on open source.
The future of robotic in-line quality inspection is charac-
terised by the metrics of 100% inspection, fast, accurate, reli-
able, flexible, connected, holistic, intelligent, and collaborative.
Thus, the KPIs of detection rate, false negative/positive, data
quality and quantity/holisticness, cycle time, predict-inspect
rate, downtime, and cost of quality (predict, inspect, prevent)
were established.
Future work will focus on validating and completing the
S&T roadmap through focus groups with manufacturing prac-
titioners. Additionally, a prioritisation list of encountered tech-
nologies, concepts, KPIs, and progression metrics will also be
developed.
Acknowledgements
The presented work was partially supported by the Automa-
tion Region Research Academy (ARRAY) school founded by
The Knowledge Foundation (KKS) and the projects RE4DY,
Eur3ka, TALON and PLOOTO, EU H2020 projects under
grant agreements No 101058384, 101016175, 101070181 and
101092008 accordingly. The paper reflects the authors’ views,
and the Commission is not responsible for any use that may be
made of the information it contains.
 104 Victor Azamfirei et al. / Procedia CIRP 120 (2023) 99–104
Fig. 4. KPIs and their metric progress for robotic in-line quality inspection systems
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