Development and Implementation of Autonomous Quality Management System (AQMS) in an Automotive Manufacturing using Quality 4.0 Concept– A Case Study

The goal of this research is to use the Quality 4.0 (Q4.0) concept to digitalize the traditional Quality Management System (QMS) and demonstrate the efficiency of the Autonomous Quality Management System (AQMS) in the case organization. The Internet of Things (IoT) concept was used to develop AQMS. The Q4.0 technique was used to digitalize the developed system. Gage repeatability and reproducibility (gage R&R) of traditional and autonomous QMS systems have been evaluated. Both the QMS systems were examined using six-sigma quality indicators, as well as machining and inspection cost analysis. In traditional and autonomous QMS, the gage R&R was found to be 91.60 percent and 0.67 percent, respectively. The special purpose machine (SPM), computer numerical control (CNC), and hydraulic machine production rates were increased by 44.42 percent, 65.60 percent, and 65.76 percent, respectively. The effective deployment of AQMS has reduced the production and inspection costs by 52.16 percent and 78.35 percent. The AQMS process yield has increased from 86.80 percent to 99.99 percent, and the component rejection rate has decreased by 93.70 percent. Overall machining process improved significantly as the sigma level increased from 1.5 to 5.5. The current study's findings are limited to hub bolt products only. In future investigations, the application of AQMS to other types of products will be considered. This study was carried out practically to reflect the effectiveness of the implemented Q4.0 concept in the actual industry scenario.