Zero Defect and Zero Effect

Zero Defect and Zero Effect

Zero Defect – Manufacture the products with ZERO defective parts

Zero Effect – Manufacture the products without hampering the environment

How to attain Zero Effect – Detect and prevent the errors

Why is it important? – To earn customer satisfaction and loyalty.

There is always a cost with defective products. So it is necessary that we eliminate them.

Consider a product which is manufactured through a series of steps say 4 steps. For Example, manufacturing of a mobile. For most cell phones, there are three key components: a printed circuit that controls the keypad and signal reception, a battery, and screen. In addition to the hardware, software is also required for the phone to operate.

The key steps involved are

1. The case is made

2. The PCB is fabricated is loaded with the software with Operating System

3. PCB is placed in the case

4. The other components of the phone are added: screen, keypad, antenna, microphone, battery and speaker

The cost of an error captured at the raw materials receiving section is far less than the cost of an error caught at the end product. The defective parts are found in the earlier stages it will require less cost than if it detected in the final product. So a trail production could be launched to find out the defectives in each stage and it could be discarded or rectified in that stage itself.

In the long term, we can use statistic models to find out the probability of defects in each stages. If the probability of a defect is too high in a particular stage, then we can do can extensive research on the root cause of the defects. We can either rectify the mistakes or we can reengineer the process, whichever is cost effective. If the probability of error in a particular stage is too low, then we can skip the checking process of that stage as it will save lot of time and money.

Methods to Achieve Zero defect

* Quality check in each and every stage

* Effective...