SciTransfer
ZDZW · Project

IoT-Based Inspection Services to Reduce Factory Waste and Improve Product Quality

manufacturingPilotedTRL 6

Imagine having a high-tech scanner on your assembly line that catches mistakes before a part is ruined. Instead of throwing away a whole batch of products, these tools tell you exactly how to fix a part to save it. It is like having a digital health check for every single item moving through the factory.

By the numbers
6
Pilots involving production processes
31
Consortium partners
71%
Industry ratio in consortium
The business problem

What needed solving

Manufacturers face high costs and environmental impact due to product defects that lead to scrapped materials. Current inspection methods are often too slow or destructive to allow for efficient rework and repair.

The solution

What was built

A catalogue of IoT-based non-destructive inspection tools and a digital ecosystem for 'Inspection as a Service'. This includes monitoring systems for process quality and digitally guided repair procedures.

Audience

Who needs this

Automotive parts manufacturersRenewable energy equipment producersIndustrial packaging companiesMedical device manufacturersHome appliance producers
Business applications

Who can put this to work

Automotive
enterprise
Target: Vehicle component manufacturer

If you are a vehicle component manufacturer dealing with high scrap rates in welding or coating — this project developed IoT inspection suites that increase the first-time-right manufacturing rate. This reduces the amount of wasted raw material and improves part durability.

Renewable Energy
mid-size
Target: Wind turbine or solar panel producer

If you are a renewable energy equipment producer dealing with quality failures in large-scale components — this project developed non-destructive inspection services that allow for digitally enhanced repair. This prevents expensive parts from being scrapped and ensures long-term reliability.

Food and Beverages
SME
Target: Packaging plant

If you are a packaging plant dealing with inefficient material use and defects — this project developed continuous sustainability evaluation tools. This ensures materials are used efficiently across the production line to lower waste costs.

Frequently asked

Quick answers

How is the service priced for the end user?

The project uses an 'Inspection as a Service' model. Based on available project data, it offers different subscription and pay-per-use models depending on the specific functionalities needed.

Is this technology tested at an industrial scale?

Yes, the project demonstrates its approach through 6 Pilots involving real production processes such as injection moulding, thermoforming, and welding.

How is the intellectual property or licensing handled?

Based on available project data, specific licensing terms are not listed, but the project is coordinated by IKERLAN S. COOP and involves 31 partners across 10 countries.

Can this be integrated into existing factory software?

Yes, the project focuses on a digital ecosystem and collaborates with EU initiatives like ZDMP and i4Q to ensure interoperability and data reliability.

When will the results be fully available?

The project period runs from 2022-09-01 to 2025-08-31, meaning full results and pilot outcomes are expected by late 2025.

Consortium

Who built it

The consortium is heavily weighted toward industrial application, with a 71% industry ratio consisting of 22 companies, including 15 SMEs. This strong commercial presence, spanning 10 countries and 31 total partners, suggests the project is driven by real-world market needs rather than purely academic research.

How to reach the team

Contact IKERLAN S. COOP in Spain

Next steps

Talk to the team behind this work.

Contact us to connect with the ZDZW consortium for pilot implementation.

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