Monday 10 December 2018

Zero defects: Zero Waste | Zero breakdown | Zero Accident

A Zero waste production can only guarantee zero defects and zero effect. To build this process we need to follow standards and processes. Here we are looking into such measures. You are invited to share your views and comments.


Here are some simple steps for zero concept

  1. Dramatically reduce unplanned maintenance hours.

  2. Double output in just six months.

  3. Boost overall operational, team working ability, and problem solving skills.

  4. Maximize returns on critical manufacturing assets.

  5. Slash change-over time significantly.

  6. Identify typical pitfalls to avoid through TPM and 5S implementation.

  7. Benchmark your equipment performance and workforce agility in handling equipment operations against other industries.

  8. Establish 5S amongst the non-production departments to deploy day-to-day functions that aims towards Zero Defects and highest productivity.

  9. Enhance plant and equipment effectiveness to achieve optimum life cycle of production equipment.

  10. Obtain an increase in production quality, improvement in Overall Equipment Efficiency, and worker efficiency.

  11. Marginally decrease production costs, loss time, emergency dispatches, unplanned maintenance schedules and downtime.

  12. Strategically plan out production capacity to align with customer demand through proper performance measurement tools.

  13. Successfully grasp the "state-of-the-art" philosophy and principals in order to perform at world class level.

  14. Intertwine the Technology, Business and People aspect of the manufacturing world through a cost-saving methodology.

  15. Create a change in culture within the workforce and their daily job scope.


For Production industry it is important that production is not stopped. Hence for that it is important for implementing a TPM or total productive maintenance. Any downtime is a risk to the process.  Thus Focused maintenance is essential to identify important machines and plan their upkeep. Data like MTTR and MTBF should be checked to understand if the machine is capable of running during the entire production cycle or standby arrangement should be arranged. Also any form of waste is a risk to the quality of product specially defects, over processing or too much inventory being involved in process. Based on make to order or make to stock Seven wastes should be analyses and planning should be done to eliminate risk.

Potentiality for Zero Defects

Of all the lean principles, perhaps none is more important than eliminating defects. Human beings, by our design, are prone to make errors. A defect is an error that reaches the customer.  Ideally, we seek to be error free, but we can live with a system that prevents any error from reaching our end customer.


Defects in their minor form, only serve as a nuisance.  The ketchup pack left out of your order of fries, or the garment your find without a price tag when you get in a line with many waiting customers behind you.  A worse from of defect is that which requires a lot of rework adding cost and time to your products and services while eating at the staff doing the work.

In the extreme, defects can cost people their lives.  The sign that falls of the building, the wrong medicine given to a patient, or the truck accident leading to a gas leak or fire.

There are a host of lean tools designed to move processes toward zero defects.  The short list includes the following:

  1. successive operator checks

  2. mistake proofing (hard and soft)

  3. closed loop corrective actions

  4. standard work

  5. recipe cards

  6. Andon

  7. 5 Why's

  8. quality at the source

  9. root cause analysis

  10. A4 problem solving

  11. cause and effect diagram

  12. 7 Quality Tools


The key point, regardless of the tools or concepts used, is that for a system to reach its potential, you must develop a way for the work to be done right as it progresses through the value stream.  Thinking zero defects and then applying zero defect approaches is a great way to start.

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