Zero defects is not a program. It is a condition in quality management where the processes are streamlined and wastage is controlled to ensure minimal waste. It is not a state which actually has zero wastage. Zero defects are not completely achievable but it is an initiative taken by the business to make sure that the quality standards are well-maintained and the defects are reduced to the most possible extent.
There are 4 important elements to this theory.
- Quality is important to assure that all the important factors of production are taken care of making way for good processes and procedures.
- Quality must be given equal importance and must be set right. It doesn’t make sense that the company starts with its production and then tries to figure out the quality standards. The number of defects detected must be minimal, if not it will cost a huge amount to the business to set everything right.
- Quality is money. The business has to ascertain its waste, production, and profits in monetary terms to compare the data.
- The company must keep zero defects as its target and must try to reach the state of perfection though it is practically impossible to attain such a state.
Will it really benefit the organization?
One of the biggest advantages of this concept is that it tries to align all the required processes in a correct manner. This results in ensuring that the firm does not suffer any major damage or loss and thus saves costs. It also leads to waste reduction as it is constantly monitored and controlled.
Better quality means delighted customers and repeat customers. This end of the day translates to long-term customer relationships and more profits for the company.
But the business must be careful that the strict environment which is created to ensure zero defects does not lead to reduced morale of its employees. Constant improvement must be rightly encouraged which will sum up to living the goal of zero defects.
Disadvantages of Zero Defect
Technically it is difficult to achieve zero defect. There will be a chance of a negative impact on performance because of the time and resources committed to zero defect. It may affect the full supply chain negatively when the other manufacturer has a different definition of zero defect.
How to adopt Zero Defects
There are no proven instructions to achieve zero defects. Following are the few guidelines that need to be followed to adopt zero defects
- Identify the quality issues that consuming more budget.
- Initially, the company has to identify the changes to be done in the process by recognizing the proper way to do things
- Understand clearly the needs of customers in terms of quality. Try your best to meet it
- The company has to encourage its employees to get quality products by motivating, pledging, challenging, telling the importance of teamwork, and giving rewards
- Create a qualified team for quality improvement
- We know ‘prevention is better than cure’. It is better to prevent the mistake by having strong designing systems that do not allow you to make mistake
- Carefully monitor your process so that you can identify the root cause of the defect and take immediate action on it
- Take corrective action to remove the defect causes
- Keep on doing all these things to achieve zero defect
We know that technically it is impossible to have zero defects. But based on the quality targets and customer requirements we can set an acceptable quality level for the products and services. It is necessary to measure quality in terms of money.
Get more definitions about Zero Defects and other ERP related terms here.