Reduced order models for uncertainty management and zero-defect control in seal manufacturing

Reaching a zero-defect manufacturing is one of the biggest challenge for the current manufacturing industry. One of the barriers to overcome is to handle appropriately the uncertainty propagation across manufacturing lines, that hinder the development of accurate control systems. Within this framework, we introduce a non-intrusive method for uncertainty management that relies on a Monte Carlo approach building on a deterministic parametric real-time simulation model. The real-time simulation model is a Reduced Order Model (ROM) based on a generalized Canonical Polyadic Decomposition. The method is introduced using an industrial test case as demonstrator, namely car door/body seals manufacturing by means of continuous coextrusion of a metal strip and various types of rubber. The resulting model is used to unify uncertainty management of: (i) aleatory and epistemic origin, and (ii) material characterization and process parameters.