  Growing individualization of products up to lot-size-1 and high volatility of
product mixes lead to new challenges in the manufacturing domain, including the
need for frequent reconfiguration of the system and reacting to changing
orders. Thus, apart from functional aspects, safety aspects of the production
system as well as product quality assurance aspects must be addressed for
flexible and reconfigurable manufacturing systems at runtime. To cope with the
mentioned challenges, we present an integrated model-based approach SQUADfps
(machine Safety and product QUAlity for flexible proDuction systems) to support
the automatic conduct of the risk assessment of flexible production scenarios
in terms of safety as well as the process-FMEA to ensure that the requirements
w.r.t. the quality of the production process and the resulting product are met.
Our approach is based on a meta-model which captures all information needed to
conduct both risk assessment and process-FMEA dynamically during the runtime,
and thus enables flexible manufacturing scenarios with frequent changes of the
production system and orders up to a lot-size of one while guaranteeing safety
and product quality requirements. The automatically generated results will
assist human in making further decisions. To demonstrate the feasibility of our
approach, we apply it to a case study.
