Zero defects

Zero defects
See also
Total quality control Quality assurance Quality control Quality cost Total productive maintenance Cost of poor quality Line balancing Statistical process control Quality

The zero defect method assumes that one can aim to eliminate deficiencies entirely thanks to proper organization of processes, training of personnel, and maintenance of infrastructure.

Zero defects idea

This process was used for the first time in the armaments industry, where it worked perfectly well. Later, this method was popularized in civil industries. It gave rise to a number of methods that combine management principles and statistics.

The zero defect method is a process aimed at eliminating errors, defects that take place in enterprises. Each organization aims to produce a product of the highest quality that meets the expectations of customers. The value of resources and skills that the company had in the past does not necessarily have to be reflected and useful in the future. "However, the value of resources and skills should be considered mainly in the context of their impact on achieving adequate economic results."

Zero defects in practice

In practice, the company's specific resources and skills should contribute to better results than competitors. If we assume that in a specific business activity based on the production of products or provision of services there are such elements as:

• the purpose of the activity,
• incurred expenditures related to the means of performing tasks,
• results of operations,

The time in which expenditures are incurred and the results are output, we can assume that the effectiveness of this activity will be expressed in the degree of achieving the goal as well as the mutual relationship between the results and expenditures at some time.

Current problems of zero defects

In the present conditions of the organization's functioning, it is not enough to research and assess the effects of work obtained by employees at a given time, but it is necessary to study the conditions affecting these results and the analysis - the cause and effect of changing factors. It is necessary to consider and analyze the given situation, which was the reason for such and not other company results, regardless of whether it concerns success or defects in the production process. It is assumed that the employee is able to produce a certain thing flawlessly only the first time. However, attention should be paid to factors and tools that are needed by the employee in the production process. "The effectiveness of work depends on many factors that can be divided into two basic groups:

• external factors in relation to the enterprise,
• internal factors.

When comparing the result achieved with the intended one, it is worth asking yourself the reason for this condition. Sources of irregularities may be at the stage of accomplishing the goal as well as earlier stages, including also at the stage of formulating the goal.

To capture the errors you have to follow the entire process. "The action is then rationally rational when it is consistent with objectively existing conditions and means, i.e. with objective truth from a given range of objectivity." 3 The causes of defects are also imperfections of the process, and among them can be mentioned, for example: erroneous resulting from mistakes mistakes made by inadvertently. To eliminate mistakes, employees should be encouraged to pay more attention to their work, so that new similar defects do not arise.

Summary

The Zero Defects method belongs to the group of methods used in the organization in order to eliminate all kinds of errors, e.g. production errors, as well as to improve quality. The improvement of the quality of work as well as the quality of the resulting products contributes significantly to eliminating all kinds of defects in the production process.

Examples of Zero defects

1. Quality control in manufacturing:

• Quality control in manufacturing involves establishing a set of processes, procedures, and standards to reduce errors and defects in the production process. This can include things like quality assurance inspections, quality audits, and the use of statistical process control. By ensuring that each step of the manufacturing process meets set standards, manufacturers can work towards eliminating defects and producing higher quality products.

1. Software testing:

• Software testing is the process of validating and verifying that a program or application works as intended. This includes testing for bugs, defects, and errors in the code. By performing rigorous testing, development teams can reduce the number of defects that are present in the final product and ensure a higher quality product.

1. Inventory management:

• Inventory management is the process of controlling and tracking stock levels in order to ensure that products are available when needed. By maintaining accurate records of stock levels, organizations can reduce the amount of waste due to expired or obsolete products, and avoid the costs associated with ordering too much or too little inventory. This helps to reduce defects by ensuring that the right products are available when needed.

Advantages of Zero defects

The zero defect method has several advantages, including improved customer satisfaction and decreased costs. Specifically, these advantages include:

• Increased efficiency - By focusing on catching and eliminating errors as early as possible, the zero defect method ensures that processes are running more efficiently. This means that fewer resources are being wasted and more is being done with less.
• Improved quality - By aiming to eliminate defects entirely, the quality of products and services is improved. This means that customers receive better quality goods and services, increasing their satisfaction.
• Reduced costs - By eliminating defects and increasing efficiency, the zero defect method reduces costs. This is due to fewer resources being wasted and fewer errors, leading to fewer defects and a decrease in waste.

Limitations of Zero defects

The zero defect method is a useful tool in reducing defects in a product or process, but has its limitations. These include:

• The cost of implementation: Achieving a zero defect standard requires a significant investment in time, money and resources. It also necessitates ongoing monitoring and maintenance of systems, processes and personnel.
• Unrealistic expectations: It is not always possible to achieve zero defects, as no system is perfect and human error can still occur.
• Inadequate preparation: If the necessary steps to prevent defects are not taken, such as providing employees with the right training, the zero defect system can fail.
• Not applicable for all processes: Some processes require a certain level of defects, or the cost of achieving zero defects is too high. In these cases, the zero defect system is not applicable.

Other approaches related to Zero defects

The Zero Defects method is just one of several approaches to achieving quality assurance in a variety of industries. Other approaches include:

• Total Quality Management (TQM) - TQM is an approach that seeks to maximize customer satisfaction by incorporating quality control measures into the design and production processes. It is an ongoing process that requires an organization to have a culture dedicated to recognizing and correcting potential problems.
• Six Sigma - Six Sigma is a systematic approach used to improve processes and reduce defects. This approach relies on data-driven decision-making and utilizes metrics such as defects per million opportunities (DPMO) to track and measure progress.
• ISO 9001 - ISO 9001 is an international standard of quality management. It is used to ensure that organizations are providing the best possible product or service in terms of quality, reliability, and performance.
• Lean Manufacturing - Lean Manufacturing is an approach that focuses on reducing waste in production processes. This approach emphasizes maximizing efficiency, minimizing waste, and increasing customer value.

In conclusion, the Zero Defects approach is just one approach to achieving quality assurance. Other approaches such as TQM, Six Sigma, ISO 9001, and Lean Manufacturing can also be employed to achieve the same goal.

References

• Schneiderman, A. M. (1986). Optimum quality costs and zero defects: are they contradictory concepts. Quality Progress, 19(11), 28-31.
• Taguchi, G., & Clausing, D. (1990). Robust quality. Harvard business review, 68(1), 65-75.
• Karlsson, C., & Åhlström, P. (1996). Assessing changes towards lean production. International Journal of Operations & Production Management, 16(2), 24-41.