Zero Defect- Smc

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What is it?

• Pioneered by Philip Crosby

• Aims to reduce and minimize the number of defects and errors in a process and to do thingsright the first time.

• The overall effect of achieving zero defects isthe maximization of profitability.



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Principles of zero defect

• Quality is conformance to requirements

• Defect prevention is preferable to qualityinspection and correction

• Zero Defects is the quality standard

• Quality is measured in monetary terms – the

Price of Nonconformance (PONC)



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Advantages

• Cost reduction caused by a decrease in waste.This waste could be both wasted materials andwasted time due to unnecessary rework

• Cost reduction due to the fact that time is now being spent on only producing goods or services that are produced according to the

requirements of consumers.• Building and delivering a finished article that

conforms to consumer requirements at all

times will result in increased customer



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Disadvantages

• A process can be over engineered by anorganisation in its efforts to create zerodefects. Whilst endeavouring to create a

situation of zero defects increasing time andexpense may be spent in an attempt to buildthe perfect process that delivers the perfectfinished product, which in reality may not be possible. For example, a consumer requirement may be a desire to buy a motor car that is 100% reliable, never rusts and

maximises fuel consumption. However, in this’



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HOW DO YOU GET TO ZERO

DEFECTS?

• Management commitment

• Leverage Six Sigma belt knowledge toimprove

Processes

• Understanding FMEA (failure mode and

effects analysis)• To highlight areas of risk to quality

performance

•

Implement “Mistake Proofing” and “Fail Safe”



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A SIMPLE APPROACH



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Zero Defects vs. Six Sigma

Category Zero defects Six Sigma

Purpose Defect prevention Defect management

UnderstandingEveryone understands zero, andeveryone knows what a defect is.

Few people can tell you whatsigma is.

TrainingOnly the normal job training for

the production workers.

Extensive training for thenonproductive, technical, Six

Sigma staff.

Manpower requiredFew or no extra employees are

required. Added Green Belts Black Belts

and other positions.

Cost of operationSmall cost, and that only to

communicate the performancestandards.

High cost for training and addedstaff salaries.

Concept Work right the first time and

every time.Three defects per million

opportunities.

Technology LeadershipStandard quality control toolsplus problem solving methods.

Performance standard No defects are acceptable A few defects are acceptable.

Application Applies to every job in an

organization.Limited to the quality of the

product or service.

Employee involvement Employees can identify problems. No employee involvement.

Zero Defect- Smc

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