A Rank Model of Casting Non-Conformity Detection Methods in the Context of Industry 4.0

In the face of ongoing market changes, multifaceted quality analyses contribute to ensuring production continuity, increasing the quality of the products offered and maintaining a stable market position. The aim of the research was to create a unified rank model for detection methods in the identification of aluminium casting non-conformities, in line with the paradigms of the fourth industrial revolution. The originality of the model enables the creation of a rank for the effectiveness of total inspection points allowing for the optimisation of detection methods. Verification of the model was carried out against the production process of aluminium casting. The model included the integration of non-destructive testing (NDT) methods and the analysis of critical product non-conformities, along with the determination of the level of effectiveness and efficiency of inspection points. The resulting ranking of detection methods indicated the NDT method as the most effective, which was influenced by the significant detection of critical non-conformities and the automation of the process. The study observed little difference in the visual inspection and measurement efficiency parameters, which was due to the identifiability of non-conformities with a lower degree of significance and the low level of inspection cost. Further research will look at the implications of the model in other production processes.