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We Help Operations Managers to Conceive and Actualize Their Industrial Visions Based on the Lean Manufacturing Culture

We Help Operations Managers to Conceive and Actualize Their Industrial Visions Based on the Lean Manufacturing Culture

Zero defect is a concept that can be viewed as a quest of perfection to improve quality at minimum cost possible.

Zero Defect is a term coined by Mr. Philip Crosby in his book ‘Absolutes of Quality Management’. A defect can be defined as a non-conformance of a quality characteristic to its required specification. Thus, leading to waste which in return increases its cost of poor quality. Zero defect is a concept to ensure that ‘there is no waste existing in a project’.

The idea of Zero defects can be explained as that every employee should "do things right the first time."

Adopting Zero Defects:

  • Zero defect concept is a top-down approach. Thus, the management of an organization should be committed to it.
  • The top management needs to adopt the concept of Change Management. One must recognize that zero defects require significant change in the old ways the job was performed.
  • Organization must understand the specifications to receive the quality as asked by the customer. Systems with zero defect concept should be designed where it is required.
  • As Zero defects is a proactive approach, an organization should not wait till the defects occurs by itself.
  • Organizations can form several “Quality circles” teams of workers or operator who are involve in production to identify defects and its causes.
  • “Quality is Free” organization must understand the term and its value. “Cost of Quality” should not be greater than Production Cost.
  • An organization should have a structure which helps it to receive continuous feedback of the operating systems. This helps to act quickly whenever any defect occurs.
  • Building a structure of reward system when zero defect is achieved by the employees. This helps in motivating people towards quality conscious environment.
  • Understanding that Zero defect concept is a continual improvement cycle system needs to adapt as per the changing requirements.
  • Some suggested tools for adopting zero defects are Problem solving tools, 7QC tools Poka Yoke etc.

Implementing Zero defects comes with very good results like.

  • Improved Customer Satisfaction.
  • Less defect leads to less scrap (discarded product) and less repair or rework.
  • Less cost investment in Quality Instruments and equipment.
  • Less manpower required for inspections.
  • Overall, lesser “Cost of Quality”.
  • Reduction of waste and Cost of production.

Learn more about: Zero-defects
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