Zero Defect

The result of robust  Processes

‘Zero Defect’… Is that possible?

Zero Losses: Do not lose any resources in doing things you do not want to achieve. Although the old Masters like Deming, Juran and Crosby have been teaching us the same message over and over again (read the book “Quality Is Free” by Philip B. Crosby) it still is an issue that seems to be hard to be convinced about…

Is it possible to make your processes completely stable?

Today, in a discussion with highly knowledgeable and experienced manufacturing experts I heard this quote:

“There is a balans point where it cost more money to improve the process than it will generate. At that point you have to stop”

Is this True or a Misconception?

Does that mean “Zero Defect” and “fully stable processes” are Utopia?

Zero Defect in a factory with excellent processes

Zero Defect in real life

a German Delphi Site, producing Zero Defect since 2001, was audited by the German CETPM after they strived since seven years for insourcing and excellent processes;

Zero PPM defects, no accidents and less than 3% illness are the result.

1. It can be done

2. The cheapest way to produce is not to make scrap

3. Less illness and accidents are the result of stable processes