Is zero defects possible? We are dealing with 25 to 30 parameters

A

Andrews

#1
Is zero defects possible? If so, what are the steps.

We are dealing with around 300 parameters each having minimum 25 to 30 parameters to be met.

We find it difficult to maintain zero defect for all parameters. Any thoughts???
 
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Wes Bucey

Quite Involved in Discussions
#2
Re: Is zero defect possible?

Is zero defects possible? If so, what are the steps.

We are dealing with around 300 parameters each having minimum 25 to 30 parameters to be met.

We find it difficult to maintain zero defect for all parameters. Any thoughts???
I'm a little confused - you used the word "parameters" in two different senses. How do parameters have parameters?

In general, absolute perfection (zero defects) is impossible unless the specs are much wider than the process capabilities.

For example, an old Brown & Sharpe lathe may have trouble holding a specification of plus or minus five ten-thousandths of an inch on diameter, but a modern Swiss turning center would have little trouble with holding plus or minus one ten-thousandth of an inch on diameter.
 
Last edited:

Marc

Hunkered Down for the Duration with a Mask on...
Staff member
Admin
#3
Re: Is zero defects possible?

Do you mean with respect to can a process be designed so that it produces 0 defects, or do you mean can you ensuer defect free product is shipped?

In my opinion, in 'real life', *most* processes can never be designed/made so 'perfect' that there is never a nonconforming product produced.
 
J

John Nabors - 2009

#4
Re: Is zero defects possible? We are dealing with around 300 parameters

Andrews-

If you mean zero defects internally, forget about it. If you mean zero defects to the customer, that's an admirable goal.

I once worked for an auto industry company that had the tightest quality program I've yet seen. We achieved about 7-8 ppm external escapes and I would like to see the organization that could do any better than that.

Regards -John
 

Helmut Jilling

Auditor / Consultant
#5
Re: Is zero defects possible? We are dealing with around 300 parameters

Andrews-

If you mean zero defects internally, forget about it. If you mean zero defects to the customer, that's an admirable goal.

I once worked for an auto industry company that had the tightest quality program I've yet seen. We achieved about 7-8 ppm external escapes and I would like to see the organization that could do any better than that.

Regards -John

There are some companies in some industries that maintain between 0-10 ppm on a regular basis. At that point, the numbers represent world class performance (let's not debate that term again, huh, guys?).

I think it does not matter whether zero defects are theoretically possible or not. Let's say you make your goal zero defects, and you don't completely hit it but you get much closer than you are now. That would be a good thing, wouldn't it?

Go for IT! :applause:
 
F

fireonce

#6
Re: Is zero defects possible? We are dealing with around 300 parameters

I think Zero Defect is a theory/method of quality management,in fact,"zero defect" is our goal.We can improve our quality level little by little by zero defect idea.
 
A

Andrews

#7
Re: Is zero defects possible?

Is zero defects possible? If so, what are the steps.

We are dealing with around 300 parameters each having minimum 25 to 30 parameters to be met.

We find it difficult to maintain zero defect for all parameters. Any thoughts???
Sorry for the typographical error.

What I meant was we are dealing with around 300 parts each having minimum 25 to 30 parameters that have to meet customer spec....

We maintain around 100-150 ppm for customer but at our final inspection stage and the different stages of process we are maintaining 5000 ppm.

a)How can we work towards zero defect?

b) Is zero defect only at customer end?

Thanks......
 

Helmut Jilling

Auditor / Consultant
#9
Re: Is zero defects possible?

Sorry for the typographical error.

What I meant was we are dealing with around 300 parts each having minimum 25 to 30 parameters that have to meet customer spec....

We maintain around 100-150 ppm for customer but at our final inspection stage and the different stages of process we are maintaining 5000 ppm.

a)How can we work towards zero defect?

b) Is zero defect only at customer end?

Thanks......

Don't overthink this. You can make zero defect a goal for any processes you want, and it can be internal or at the customer end. The external customer end might be the first goal to achieve.

How to work toward it is by controlling each process and process output better.

1. Define each process clearly. What criteria are important? (cl 4.1.c)

2. Align the criteria between each supplier and customer (internally). (cl 4.1.b)

3. Measure these criteria (cl 4.1.e). Track your performance for each. Communicate to the people involved so they can see how they are doing. Press for improvements.

4. Check the failures in each process. Eliminate special causes. Investigate root causes and eliminate them. Train people to higher skills so they are PROFICIENT, not merely competent.

5. Continue to do this, over and over. It is the PDCA cycle, over and over. A continuing spiral of improvement.
 
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