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


3) Histogram

Control Charts

4) Control Charts

Scatter Diagrams

5) Scatter Diagrams


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.