How can we ship zero defectives? Zero Defects Sampling?

[Andrews]

One of our customers says we have to establish the " production and quality system to provide a product with zero defects" .We are trying our best to provide zero defect products but has anyone achieved this target. What should be done to ensure zero defect products.

Zero defect sampling does not help as far as I am concerned. What do the forum users feel?

Even if we make the process deliver zero defects, how can we prove it?

[M Greenaway]

If you ever make a process that delivers zero defects you have created a unique process in the history of mankind - well done.

[Mike S.]

Looks like we found something we can (mostly) agree on, Martin!

IMHO most industrial mfg. or service processes cannot in the real world, over a long period of time, produce zero defects. Maybe, just maybe, if the tolerances of the customer were super-wide open and the product super simple, but how many times does that happen?

A "production and quality system to provide a product with zero defects"? I'd ask the customer how they have decided to achieve that -- ask them and their "wisdom" to educate you.

JMHO

[M Greenaway]

Mike

Over-engineering does take place, but normally not to such an extent as never supplying defects due to tolerances being hugely wide in comparison to process capability.

Most companies would be happy with a process that performs within +/- 3 standard deviations. Leading companies who supply critical products to very stringent customers (such as automotive) would be happy perhaps with +/- 6 standard deviations, and would probably be considered 'World Class'.

[Douglas E. Purdy]

Any Phil Crosby enthusiasts out there, or Graduates of his Quality College? I think you realists have distorted the customer's intent. Hopefully you can make defect free product! Now as to some product having a defect, you may be able to talk about the level of quality (e.g., Parts Per Million) but your quality management system should be able to provide defect free product to the customer! Or am I missing something here?

[M Greenaway]

Sorry I think you are missing something.

I am more of a Deming enthusiast, i.e. avoid exhortations in the work place, and dont set unachievable targets !

[Douglas E. Purdy]

I don't know, I like all the Quality Gurus (Deming, Juran, and even Crosby) they have good principles to build a Quality Management System. But saying that you can not create a system where you are competent that only so many defects would be present, is someone I would not likely choose as a supplier.

As a "Shy Browser" this will be it from me!

[M Greenaway]

Douglas

Admittedly I do not know the full content of Crosby's Zero Defects system, however by the title I have always imagined that it meant producing totally defect free product - I dont believe that can be done. As for having a consistent output of 'nearly' defect free then yes that can be done, and is our never ending goal to improve on.

But is zero defects achievable ?

Have you witnessed this ??