ZERO DEFECT MANUFACTURING 

Pareto Diagram

Cause & Effect Diagram 

Scatter Diagram 

ZERO DEFECT IN MANUFACTURING

Zero Defect Manufacturing is a quality concept to manufacture with zero defects & eliminate waste associated with defects “Zero” is the goal, based on the discipline that defects are prevented by controlling the process. No finger-pointing takes place. It recognizes that it is natural for people to make mistakes.

To implement zero defects, you have to be aware of the quality management system (QMS) for tracking your progress. Build mechanisms into your systems and methods of operating that provide continuous feedback. This allows you to act quickly when quality performance degrades. There are some approaches that are intact with the Zero defect.

The Seven Basic Tools of Quality (also known as 7 QC Tools) originated in Japan when the country was undergoing a major quality revolution and had become a mandatory topic as part of Japanese’s industrial training program. These tools which consisted of simple graphical and statistical techniques were helpful in solving critical quality-related issues. These tools were often referred to as Seven Basics Tools of Quality because these tools could be implemented by any person with very basic training in statistics and were simple to apply to solve quality-related complex issues.

Pareto diagram

1) Pareto Diagram

Cause & Effect Diagram

2) Cause & Effect Diagram

Histogram

3) Histogram

Control Charts

4) Control Charts

Scatter Diagrams

5) Scatter Diagrams

Graphs

6) Graphs

Check List

7) Check Sheet

GUIDELINES & TECHNIQUES

There are no step-by-step instructions for achieving zero defects, and there is no magic combination of elements that will result in them. There are, however, some guidelines and techniques to use when you decide you are ready to embrace the zero defects in the manufacturing concept.

  • Understand what your customers expect in terms of quality. Design systems that support zero defects where it matters, but don’t over-design if the end-user just doesn’t care.
  • Zero defects require a proactive approach. If you wait for flaws to emerge you are too late.
  • Learn poka-yoke (POH-kay YOH-kay.) Invented in the 1960s by Shigeo Shingo of Japan, it translates to “prevent  inadvertent mistakes.” It’s an approach that emphasizes designing systems that make defects almost impossible or, if they can’t be avoided, easy to detect and address. To implement zero defects, you have to have strong systems in place.

MANUFACTURING EXCELLENCE IMPLEMENTATION PROCESS

OBJECTIVE : 

Zero Defect: Developing a product that has no defects but ensuring the quality standards and reducing the defects to a level of zero in your projects.

EXAMPLES

  • Quality Management System Awareness
  • Quality Performance (Quality KPI Development &  Tracking )
  • Non-Conformities Identification & CAPA Implementation
  • Workplace Audit
  • 7 QC Tools & 7 Management Tools
  • Problem Solving & Poka Yoke
  • Root Cause Analysis

OBJECTIVE : 

Employee Engagement: To improve workplace conditions that drive engagement and enhance employee sense of well-being.

EXAMPLES

  • Basic 5S Awareness
  • 1S, 2S Implementation
  • Workplace Visual Management (Visual Factory)
  • Kaizen Strategy Implementation
  • Suggestion Scheme
  • Innovative Leaders

    OBJECTIVE : 

    Zero Breakdown: Maintenance is all about working for the ultimate goal with a winning maintenance strategy.

    EXAMPLES

    • My Machine Campaign
    • CLIT
    • Machine Utilization Monitoring
    • Machine Losses Reduction
    • Breakdown Analysis
    • Preventive Maintenance
    • 3S ,4S & 5S for Machine & Office area

    OBJECTIVE : 

    Zero Waste: To eliminate waste across entire waste value chains to the fullest extent possible through reuse and recycling. Zero Waste is more than just a problem of disposal but a need to reduce harm encompassing the entire life cycle of a product.

    EXAMPLES

    • Time & Motion Study
    • Lean Layouting
    • ZCA (Zero Cost Automation) & LCA (Low-Cost Automation)
    • Material Handling Optimization
    • OEE/ OLE

    OBJECTIVE : 

    Zero Accident: The risk of falling, risks related to electricity or handling of machinery, road hazards, and more. Every day, the awareness of each and every employee is essential to avoid accidents in the workplace and to prevent occupational illnesses.

    EXAMPLES

    • OH & S Management System Implementation
    • Safety KPIs
    • Workplace & Safety
    • HIRA
    • Safety Signage Standardization

    OBJECTIVE : 

    Zero Fatigue: Fatigue is a workplace hazard and can be associated with the safety and health of the worker. It affects the health and safety of the employee.

    EXAMPLES

    • Scope Defining
    • Workplace Ergonomics Analysis different Technical Score (REBA, RULA, WAS, HARM, NIOSH, JSI, KIM, EAWS, RAMP)
    • OFI(Opportunities of Improvements) Points Sharing
    • Support in Workplace Design Modification
    • Final Audit

    OBJECTIVE : 

    Zero Effect: To make the production process, product, environment friendly and good enough for social well-being and sustainability of the environment.

    EXAMPLES

    • Environment Policy
    • Effect Impact Analysis & Life Cycle Assessment
    • Energy Cost Optimisation
    • Waste Management & Control

    OBJECTIVE : 

    Zero Loss: Zero Loss” is an aim/attempt to overcome such losses or minimize their effect up to great extent in order to reduce the manufacturing cost

    EXAMPLES

    • Advance Lean Practices Implementation
    • Manpower Rationalization
    • Design & Process FMEA
    • APQP
    • Line Balancing

    OBJECTIVE : 

    Zero Delivery / Failure: To accomplish the task within the lead time without failure in inventory time, WIP storage, logistics cost, and mapping of the steps a company takes to complete a certain process.

    EXAMPLES

    • Value Stream Mapping
    • Value Supply Chain Management
    • Inventory Analysis & Management
    • Process Mapping (BPM/BPR)

    OBJECTIVE : 

    • 100% Sustenance

     

    EXAMPLES

    • Employee Training & Re-Training
    • DOJO Set-up
    • Training Content