How To Achieve The Zero Defect?

kokil Garg

Is it really possible to achieve zero-defect? The big and small industrialists are looking for the answer to this one big question. Well, zero error or ideal system is just a theoretical talk.

In a practical scenario, it is not possible to completely get rid of errors in the system. It is not practical to achieve zero error in the system. It is not possible to do the production that completely errors free. 

Why Quality Plays An Imperative Role?

The biggest fear of industrialists is errors and dysfunctions. All business owners are looking for different ways to achieve zero defects. Therefore, they put in a lot of effort to reduce the probability of errors. It is very important for all business owners to improve production quality.

If it is not done properly, then no business owners can keep pace with the various competitors. In the cut-throat global competition, it is very difficult for all business owners to expand the customer base and get more profit. The good quality products and services are not an option!

Nowadays, it has become a necessity. The defects in the products are penalized in various different ways. The defects in the products leave a negative impact on the cost of production. If the volume of defective products starts increasing, then it will lead to the generation of monster waste.

The waste will be in terms of cost, resources, energy, and time as well. It will also affect the image of the brand. You should adopt the right technique and try to reach the zero defects. While implementing the new technique, your main objective should be to reach the zero defect.

The various organizations choose a good quality based approach so that the errors reduce and production increases. It is recommended to choose a good quality approach on the basis of regular audits and continuous improvements.  The digital work instruction software also helps in increasing product quality and reducing the number of defective products. 

Implement Good Techniques At The Starting 

The unit that is used to measure the bad quality in the production is ppm. This unit will help in determining the number of defected pieces per million products manufactured every year. This unit is also known as the DPMO.

The DPMO is an abbreviation for the defects by millions of opportunities. This defective product manufactured at the production unit is measured by the automotive businesses and aerospace industries. The DPMO is used as the benchmark to measure the quality of products generated at the manufacturing plant.  

So, the main objective of all business owners should be reducing the ppm or DPMO.  When the simplest expression of ppm or DPMO is achieved, then it indicates that the quality of the manufactured products has increased significantly.

When the DPMO value reduces, then it will start approaching the zero defects. In simple terms, the ideal production model is one that limits the affected unit for the first time.

If the defective units are less, then it will help in leaving a good first impression on the customers and also increase the profit value. You should adopt a good model so that the number of returns and rejection can be reduced.

In a practical scenario, the level of failure varies significantly from one manufacturing unit to another. It is also dependent on manufacturers and specific activities.  At some manufacturing units, the threshold maybe 5 to 10 ppm while in other manufacturing units, it may be 50 ppm.

When the different techniques are implemented to reduce the defects, then the biggest thing to consider is the optimum use of the reduction in the defaulted unit, the customer satisfaction level increases significantly. 

Digitization To Decrease The Number Of Defects 

Nowadays, one of the wisely proposed techniques to reduce the number of failures is the digitalization of various production and monitoring tools. The digital solutions for the manufacturing of various products will help in detecting the faults much earlier.

If the fault is identified at the starting point, then it will reduce the hectic and expenditure. It is very important to determine the origin of the fault and help to find out a better solution to improve the production quality.

The technique of achieving zero defects also indicates the responsiveness and getting accurate tools. High responsiveness and the right tools such as a digital factory will help in improving the cycle of manufacturing.  

The process of digitization will help in pushing the number of defects towards the zero direction. You can also implement t various other techniques to reduce the number of defaulted products such as providing training to employees, digitization of work instructions, etc. Thus the digitization also plays a vital role in reducing the value of ppm or DPMO.  The digitization will help in production quality.

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