Vastupal Vashisth

Control limits indicates voice of process. They are based on the past performance. On the other hand specification limits are the voice of customer. If variation increases and control limits shifts gradually and becoming wider but seems to be process is in control throughout entire period of process. We can say that it is possible to a process to be incapable of meeting a specification while remaining in statistical control. Predictably, We are making a product out of spec.

Hello Rajesh I would like you to please go through all previous replies on the topic for clear understanding of the debate as well as topic. And I would like to say yes, ZD changes from situation to situation, it's the way that how we are doing interpretation of it. I already mentioned about this and lot many examples. About 85%efficiency that is defined by us, and if a machine can produces and designed for maximum production of 15 products per minute and there is no chance that anyone can demand even 16 products per minute because it is designed to get only 15and yes to achieve that 15 will be treated as ZD. You mentioned that a customer wants 95%defects free and you are giving 98%. He will be delighted that's great but I would like to say who will demand only 95% defect free. All will need 100% defect free. You are saying software, suppose that software is used in cars for display panel and your expectations is 95 but getting 98,you are saying you will accept 2 defective out of 100 and accept and Install this software in two cars and these will give definitely trouble to customer and I am sure you will not be agree to buy that car if that software not working car will not be able to start of doing anything. So sir, I would like to say customer will want always defect free products and yes it is achievable practically possible. I would request you to please go through previous replies of all the people for clear understanding rather than Internet urls.

Hi Rajesh Thanks for your input Sir you mentioned that it will help in minimising variation, what elements a company wants and where does this minimum variation leads to?it leads to deliver good quality products or to achieve targets as per decided. Need to say Zero Defect is different for everyone, for example a production department has a target of machine efficiency of 85%,so for for the department zero defect is to achieve this 85%efficiency. If its not done why we using all techniques and there is no point remaining if improvements not done. We focus to achieve our target if 85% because we know can achieve it, it may be possible some breakdown happens, May be due to tool, due to machine, but we try to reduce all and try to achieve target of 85%,in this each and every supportive depth has their own target of downtime within 15%, so every department tries to maintain that and yes it has happened many times that production department achieves it's target otherwise delivery would have been failed and overall delay in all process. So for production department achievung the target is zero defect so zero defect is the way how we are doing interpretation of it. It doesn't mean that hive 100% in all cases, it changes from situation to situation, like in above example if any says he wants 100% efficiency of machine bit everyone knows it can't be possible 100% because there are losses involved directly or indirectly that's why targets are fixed which is achievable and some challenging. Same case with organisations targets of their revenue generation and profit making, they also decide on past experience and future expectation. So for them to achieve that target is ZD. And that's the point sir who would want a defective outcome so to stop defective outcome everyone will do some improvements and will ensure to deliver good products and delivery of good products leads to give good results and to meet targets as per decided. Another example I would like to give, a manufacturing company has a rejection target of 0.3% so for the company to achieve this target will be treated as zero defect in their own language. Company will do process improvement, try to maintain processes and many more to chic ethics because company knows that it can be achieved. In summary I would like to say zero defect is achievable and it is defined by everyone in their own language an depends how we are doing interpretation of it. This is possible by process re engineering, continous improvements, lean techniques an d much more... And sir, it is the demand of current industries setup to give best results and to achieve decided targets and to upgrade according to time to sustain in market. Nothing is going to achieve by making only desires to achieve of any thing.

Not agree with you sir,if you see other side of the picture there are various example, various processes and various industry and fields where ZD is achieved and people are working towards it. There is nothing impractical, it is achievable and various lean techniques and continous improvement, Process re engineering are some of methods by which organisation try to achieve it because they know they can achieve it and deliver best quality products to customers. You are mentioning that ZD is impractical and not achieved anyhow means everything that we are having with us is flowout with defects from companies. And these defects can be any sevierty. Then why anyone driving a car if he knows that it has any number of defects, why we are travelling through aeroplane when we know it has defects, it's a case of life and death. We know companies are working very hard towards safety of people and they are working meeting their standards and norms which is defined by regulatory bodies, ISO standards and they are ensuring that defects not pass to customers and they give best services to customers.

100%right kavitha, ZD is possible by process re engineering, as well as by continous improvement, technology upgrading, focusing on work rather than on slogans...

Hi Rajesh You mentioned that improve your process will minimise defects is management myth. I strongly disagree with you on this. Even the very basis of any organisation we call it as 5 S implementation, also helps to reduce and minimise defects and prevents us to produce wrong products and stops our failure in various ways. Improving the process is far beyond this which involves a lot of study, lot of technical sports, upgrading to latest technology. There are various industry around us where defects are minised and process improvement is one of the many reasons to deliver defect free products. Why every organisation is focusing on continous improvements which also applies on process also, then I think this will also be management myth. All ISO organisation, standards are focusing on this why?? This is not a management myth sir, this is what is something practical proved by leaders and organisations. You can see examples that there is need to change according to time and technology up gradation to latest techniques to be in the market. If any organisation does tune with latest trends they face a difficult time to sustain in market. See example of Nokia which was stuck with their own operating system but Android was going on in almost every mobile industry, in end it was take over by Microsoft and now they are coming g with android... And same case with blackberry phone. And also same case with hmt also. So it is very necessary to continue improve your process which lead to you get in tune with latest trends and be in market and make profits to grow in future although you need to invest a lot to apply this. If all these management myth then I think every manufacturing industry or any organisation will turn into a garage or some workshop in City where all are mixed and take a lot of time to do anything because nothing is defined properly, what, how, when, where to do any operation. Thanks for your feedback in url but if you see clearly all has mentioned about continous improvement to achieve better and better and achieve zero defects and ZD is different for everyone in their own terms and point of view.

Hi Karthik You right

Hi Rajesh Thanks for your input You mentioned that decide the best and work to achieve it, so what you call it, why you are working to achieve your best? What will you say if you achieve your best, what after then? I want to tell you because all these are targets that you decided and to achieve your targets is zero defect for you and that is what ZD is, who said you achieve 100%. It is different for everyone in his point of view. For example if production machine has a target to produce 5000 parts per shift so to achieve this targets daily is ZD for production members. It's not a management mith but is is reality because it can be achieved.

Hi Atul You said rightly, well explained example, I would like to add in this ZD is the way that we are doing interpretation of it, change from individual to individual, organization to organisations... We can achieve it

100%true

Hi Sumantha As Atul said rightly about defects and defective cause that 5M and one E. These are some causes of defective and to control variation in these. SUMANTHA you also mentioned that now days it doesn't happen anymore, because they have rectified the problem, thats what every organisation doing and they found a solution so that no such issues repeat in future because they want to delight their customers a d they know they can achieve zero defects and solve the problem of money withdrawn and other issues. Every organisation is doing continous improvement and that's the approach to achieve zero defects.

Yes I do agree

Well said Kavitha, it's the way how we are doing interpretation of Achieving zero defect and where we are applying it. There are no many examples like this where 100% defect free products and output available to finish the work or to delight their customers.

Hi Kavitha Rightly said about technology advancements and upgrading. This alps goes with continuous improvement, upgrading with time to time by fulfilling customer expectations and their satisfaction resulting business growth and revenue generation

Yes you are saying right I do agree with you this as you explained its doing things right first time

I do agree with you, even atm machine does not accept card which is inserted in wrong direction. It depends which process and what and how we are seeing it and yes it is achievable.

Well I never said six sigma following companies are achieving zero defect, its the way how we seeing zero defect. It is different for everyone, it's about to their goals, profit, customer delight, changes from individual to individual and organisation to organisations. Its about to continous improvement.. You are saying companies who are delivering faulty products they can't achieve zero defect, I don't agree with this, zero defect is possible everywhere but it will take lone time and need to sustain and continuous improvement with reducing waste by achieving targets and goals that has been decided by keeping all values in mind.

Hello Ronaaq I do agree with you that there are activities where waste is generated and serving this waste as non value adding but on the other side of this if we see clearly these non value adding items sometimes necessary to finish a value adding activity, there are so many examples of the same in manufacturing industries. I would like say that all organisations are working hard rather than struggling to achieve zero defects because they know it is achievable. I agree considering zero defect as concept is brilliant and will help to motivate and inspire people for continuous improvement and that's what any organisation wants, to do continous improvement for better future. Because they know doing continous improvement is the way to succeed in future by keeping low waste and applying lean technique keeping in mind organisation goals. I am not saying six sigma is the only one expect. I don't agree with this because there are industries where we need more sigma than six sigma like aerospace industry we used to have twelve sigma. Because they know they can achieve their targets and can achieve zero defects. I already mentioned that achieving zero defect is possible. It totally depends onany individual or any organisation how they are interpreting it. For some food industry zero effect is to Good quality, for restaurants zero defect is customers delight, for manufacturing industry defect free product and to make profit and to grow, for a teacher zero defect may be to have scorecard of every student more than 80%.. And many more so it's the way how we are seeing zero defect and yes it is achievable.

Hi You are saying that after crossing all sigma level all Japanese car makeer still fail to stop deliver fault. I want to say that who not fails, why only Japanese car makers, Japanese are the best in world to deliver quality products. About failing then I would like to say every individual, every organisation fails to achieve their goals once or sometimes in their life span, even world's most technical centre NASA and India most technical centre they have also failed during their mission but rather then failed I would like to call it as an experience and getting an opportunity for improvement and that's the approach of any organisation and here comes the role of leanand continous improvement. By controlling all factor they work to achieve best to satisfy their customer and to make profit and grown in future.

Yes Venugopal I do agree with you on your explanation that value adding today may not be so in future. Its a continous process always...

Failing doesn't mean that these Companies are not working towards achieving zero defect. Who wants to pass faulty cars to customers. Its about negligence of the process and they can take action by retracing it, from where the fault was occurred and can eliminate it by doing some kaizen, poka-yoke. Let me give you one example from car industry. Door panel of Two different cars Honda Brio and Honda BRV is similar in profile and size, there was possibility of error that while doing welding and hemming in weldshop, door panel of BRV fixes in place of Brio in the same weld fixture. That is huge problem if this happens door will be expected rejected, after study it was found that there is possibility of delivering wrong panel in weld shop but if we can find out some other method to stop outflow then that should be done. While investigation and stuff it was found that number of holes are different in both panel and some hole are not common, then some poka-yoke done by using those hole, provided a location pin while using the door, it gives a alarming Bell if wrong panel used because it touches the sensor on location pin. By doing all this it has been stopped completely of making faulty door panel and it is 100% sure. So there are number of activities where we can achieve zero defects, I already mentioned that it's the way that we are doing interpretation of it.

Nice to hear Ronaq but I would like add something, even Mr. Crosby has given the concept of zero defect. Concept of ZD means to work for achieving zero defect which is possible only by Eliminating wasteful activities, by doing continuous improvement, and through the lean techniques.. Last but not least some places and process by applying six sigma. Nothing is impossible in this world. To eliminate wasteful activities from a process is possible by having eyes on it, regularly maintain it, by doing 5 S, apply lean techniques and it's not about once you achieved all and stop it's about to sustain it also that's why needs continous improvement. We work to achieve zero defect and it is possible. Every organisation has different meaning of this in their own terminology.

Hello all, It's a hot discussion going in this topic. Everyone is giving his own point of view. I have initially mentioned that zero defect is nothing but it depends that how we are doing interpretation of it. See here in discussion also everyone is giving explain accordingly and give different point of view.we are not talking about a general statement whether it is achievable or not, we are on the topic which is related to all fields services sector, manufacturers, and all other fields. Achieving zero defect is a concept and we can work on it to achieve zero defect by doing continous improvement and reducing wastage. Everywhere we can see examples of failure in their process but it doesn't mean to stop the work and sit quietly but to sustain and succeed in market we need to do continous improvement and upgradation.

Hi Sumanta Thanks for your explanation of the topic. You are giving about failure of airbag, sensor fault. It ok I agree that defect has been passed or caught somewhere in process, so what does it indicates that big companies recalled vehicles. It about the reputation, image of brand because companies still wants to delight their customers. They don't want to take risk of their life, they recalled all vehicles to reconfirm or change the setup so that everyone will be safe who are having airbag and sensor which is produced in the time period when was defective price detected and manufactured. So companies spent a lot of money to handle this, why just to build value in customer eyes so that they can believe on companies and their service because companies not want to give any trouble to their customers. So whatever they did, they have done some improvements to stop outflow of defective pieces. It's all about to work continues to reduce waste and improve continue process day by day and satisfy the customers a dn make profit and growth.

Ho Ronaq you are saying that practical zero defect is not possible to achieve means anyhow some defects will pass to customers anyways means you want to say that companies should stop to work further because they are not capable to stop outflow of defects to customer, it's about how we are seeing zero defect. We can achieve it by continous improvement and through lean techniques. You can see a lot of examples of Technology change of ancient time and present time. Its all about continous improvement we can do achieve better results.