I wouldn’t want to make this discussion philosophical. This is not just a question of belief alone. As a professional, one should anticipate and set expectations realistic. There should be a desire, passion and concerted planning and efforts to deliver high quality. It shouldn’t remain as a desire alone. Reality has to be understood and addressed. Just like believing and running a “Six Sigma” program in an organization may not make every process to operate at six sigm level Quality, driving zero defect thought process need not mean that the processes will become 100% defect free!

20 hours ago, R Rajesh said:

AGAINST

 

No system can be fool proof. Achieving zero defect is not practically possible. This is why every organisation has a Service Level Agreement (SLA)  with its customers in a range. such as  >95 % or  > 98 %, when it talks about defects free system . No organisation says 100% which is totally out of the equation. The customers also are aware and they are ok to this. Thats the reality everyone knows . This is also precisely the reason, why a process improvement methodology such as Six Sigma says , "minimise the variation" and not "Eliminate the variation" , which is practically not possible.  One may think that this zero defect is not achievable/possible only where human element is involved. What if automation/Robot is involved in some activities. Say for instance , take Robots which do complex operations across industries.  Imagine a robot is helping a doctor in a complex medical operation  . The robot can do the operation and can complete it successfully. The question is cannot it fail ? Can it malfunction atleast once in its lifetime ? Quite possible !!  The hospital , therefore will always say that ... ... "Our Success rate is high for that type of operation..."   Because of the robot, the success rate will be high and the failure rate will be extremely low, which is what needed for the human being. But nevertheless still you cannot get rid of the rarest failure in this case . 

I would like to share a story that I came across on Linked in and allow the intellect to decide. 

 

The story goes:

 

David, a frequent visitor to Japan, explained to me the Japanese attitude to perfection....

According to David: IBM, the American computer giant, had decided to test Japanese manufacturing capabilities by placing a trial order for some computer component.

In the specifications IBM had spelt out that they would accept only three defective parts per 10,000. This had stressed the Japanese manufacturer... How? Why?

On the exact date of delivery, the parts arrived at the doorstep of IBM. The shipment was accompanied with a hand written letter:

“We Japanese people have had a very difficult time understanding IBM business practices, etc, etc, etc...

However, with great difficulty, the three defective parts per 10,000 have been separately manufactured. They have been included in the consignment in a separate packaging, with bold instructions – DEFECTIVE PIECES, AS PER REQUIREMENT. NOT FOR USE. We hope this pleases you.”

 

This indicates that "One Country" can implement a Zero defect policy even for a computer component, though the SLA stated that 3 defective parts per 10,000 are acceptable.  

This also reminds me about the Mumbai "Dabbawalas" accuracy.  Would we like to eat someone else's tiffan box unlike the movie "Lunch Box". 

 

In both cases we might take these as granted or even comment that "Oh, its Japan you see!.  But what brings them accolades is the accuracy, detailing, dedication and all the synonyms that they implement while delivering.  

ZD was conceptualized as a management methodology to continuously reduce and work towards eliminating all types of wastes in an organization. Obviously the idea is to reduce overall costs without compromising Quality. It has not specified any limit, hence  there is tendency to for the literal implication of zero defect. Many fundamental disciplines need to be understood and complied across organization and imbibed into the org culture to drive this program. Many companies have embarked on this journey without the due detailing and ended up seeing costs go up. So, it is not just ensuring a defect free output, but balancing all processes to operate optimally and efficiently.

 

It was many years later that the concept of Six Sigma came up with a quantification of the defect levels, and as we know, it is greater than zero. So if zero defect was literally "zero" defect program, why should the world move 'backwards'  to a program that defines a higher rate of defect?

For

 

I believe Zero defect is achievable for an activity.  This activity would differ from industry to industry. 

One of the best example of zero defect is USB SLOTS - IT is designed  in a manner that it eliminates the possibility of error.

It is possible to implement fix with assumption and in a environment which is less prone to manual intervention. 

Is Zero defect required for a given process could be assessed first. If yes, then it is a journey to achieve it. It would involve some cost, effort, time, expertise etc.. Is the zero defect worth all this is the question. Eg: Six sigma levels are not required for all the processes. Some processes might be ok with a 3 sigma or even lower levels depending on the criticality of the output. If not, then it might be good to figure out what level of defect is acceptable and work towards it.. 

5 hours ago, Anupama said:

I would like to share a story that I came across on Linked in and allow the intellect to decide. 

 

The story goes:

 

David, a frequent visitor to Japan, explained to me the Japanese attitude to perfection....

According to David: IBM, the American computer giant, had decided to test Japanese manufacturing capabilities by placing a trial order for some computer component.

In the specifications IBM had spelt out that they would accept only three defective parts per 10,000. This had stressed the Japanese manufacturer... How? Why?

On the exact date of delivery, the parts arrived at the doorstep of IBM. The shipment was accompanied with a hand written letter:

“We Japanese people have had a very difficult time understanding IBM business practices, etc, etc, etc...

However, with great difficulty, the three defective parts per 10,000 have been separately manufactured. They have been included in the consignment in a separate packaging, with bold instructions – DEFECTIVE PIECES, AS PER REQUIREMENT. NOT FOR USE. We hope this pleases you.”

 

This indicates that "One Country" can implement a Zero defect policy even for a computer component, though the SLA stated that 3 defective parts per 10,000 are acceptable.  

This also reminds me about the Mumbai "Dabbawalas" accuracy.  Would we like to eat someone else's tiffan box unlike the movie "Lunch Box". 

 

In both cases we might take these as granted or even comment that "Oh, its Japan you see!.  But what brings them accolades is the accuracy, detailing, dedication and all the synonyms that they implement while delivering.  

Good story really which I have also heard. Having said that there are few things which I would like to share. First of all, a country can have a stand/principle of zero defect policy. But the challenge is to have that implemented which is what am trying to insist. The second one is we always equate the dabbawalahs to operating at six sigma level. If we go by that way, it says minimise the variation(and therefore defects) and not eliminate it. So the rarest of failures can happen. 

Just now, R Rajesh said:

Good story really which I have also heard. Having said that there are few things which I would like to share. First of all, a country can have a stand/principle of zero defect policy. But the challenge is to have that implemented which is what am trying to insist. The second one is we always equate the dabbawalahs to operating at six sigma level. If we go by that way, it says minimise the variation(and therefore defects) and not eliminate it. So the rarest of failures can happen. 

Even Nasa which is supposed to operate at higher levels of Sigma as we probably would have heard and seen has failures in its mission. 

FOR: zero defect can be achieved.

It starts with definition of zero defect. Voice of Customer, field problems, capability of process (service or manufacturing), etc determine what is acceptable level of defect (with tolerances) & what is not and this forms the basis of definition of zero defect. It also depends on whether the user or customer recognises the defect or impacted by it. If not, it is as good as zero defect for a product or service or result.

16 hours ago, Anupama said:

I would like to share a story that I came across on Linked in and allow the intellect to decide. 

 

The story goes:

 

David, a frequent visitor to Japan, explained to me the Japanese attitude to perfection....

According to David: IBM, the American computer giant, had decided to test Japanese manufacturing capabilities by placing a trial order for some computer component.

In the specifications IBM had spelt out that they would accept only three defective parts per 10,000. This had stressed the Japanese manufacturer... How? Why?

On the exact date of delivery, the parts arrived at the doorstep of IBM. The shipment was accompanied with a hand written letter:

“We Japanese people have had a very difficult time understanding IBM business practices, etc, etc, etc...

However, with great difficulty, the three defective parts per 10,000 have been separately manufactured. They have been included in the consignment in a separate packaging, with bold instructions – DEFECTIVE PIECES, AS PER REQUIREMENT. NOT FOR USE. We hope this pleases you.”

 

This indicates that "One Country" can implement a Zero defect policy even for a computer component, though the SLA stated that 3 defective parts per 10,000 are acceptable.  

This also reminds me about the Mumbai "Dabbawalas" accuracy.  Would we like to eat someone else's tiffan box unlike the movie "Lunch Box". 

 

In both cases we might take these as granted or even comment that "Oh, its Japan you see!.  But what brings them accolades is the accuracy, detailing, dedication and all the synonyms that they implement while delivering.  

Well, this story probably we all have heard, and stories are stories and good hear... Like Mr Vijay Malya - "the king of  good times" and it some times inspires us that is the benefit but I just have a simple quuestion for any mass production(except short span/only few batch production) is INFINITY sigma possible? Because only INFINITY sigma gives us a REAL zero defect environment whic is nearly impossible. In my last post I hae given some real life examples too. I actually wanted to quote some other posts too who said zero defect is possible under some condition, well these conditions are the considerations of acceptable level, say 95% zero defect, 5% error or considerations, when we are taking that acceptable levels, yes it might be achievable.

 

Few more JAPANIES example here- 

1. Toyota is one of the leading six sigma practicing compnay recalled 5.8 million cars over faulty Takata airbags last year. 

2. Honda recalled 1.15 milon cars for sensor issue.

3.  Toyota, Honda, Hyundai all the company recalled their cars for safety issue in different parts of the golbe in this current year only.

 

I support Mr Venugopal's logics/posts in the current topic.

 

Conclusion: zero defect possible in theory/or short span/few batch production but if we take real life business and a PERFECT zero defect it is nearly impossible to reach INFINITY sigma to achieve it. 

Hi All,

 

Good to see the hot discussion.

 

@ Rajesh R -  in the previous questions, most of us answered saying with employee engagement and motivation, acheiving zero defect is possible.  but now arguing it is not possible. ok. If you talk about SLA, then the customer requires your product with highest quality spec set by the client lets say >95% and 98%. But my argument is , if you consistently deliver a product with 100% quality which means zero defect, will the client not accept it? 

 

The client will be happy with the quality and service that we provide. If we consistently satisfy the customer, the sales and profit would increase.

 

Overall, having zero defect concept is always beneficial to the organisation. It is achievable.

Against Zero Defect is achievable:-

I agree that Zero defect is a concept rather than target

It should be used for motivating people to achieve zero defects. It drives continuous improvement activities.

However, the question is ZERO defect is achievable or not.

To achieve zero defect we need to eliminate waste from the process. Waste means any unproductive activity that does not add value to the product. Eliminating all those Non-value added activates/waste is practically impossible.

The question is not about the concept; it is about actually achieving zero defect. Therefore, my vote is against

On 12/7/2017 at 6:00 PM, Vastupal Vashisth said:

FOR

I would like to say that zero defect is achievable but it depends on how we are doing its interpretation.  Theoretically and practically it is not possible to achieve zero defect.  But I would say zero defect means get things right at first time. So we can achieve zero defect.  For example if I talk about to finish the project.  During finishing of project we have so many steps which are having their own deadlines and conditions. If we are completing all steps in time with all requirements and finish our project on time we can say that there was no defect because whatever has been planned earlier is achieved now.  Also lean manufacturing and continous improvement focus on preventive maintainance to reduce and eliminate waste activities so that we can achieve our targets.

 

1 hour ago, Kavitha Sundar said:

Hi All,

 

Good to see the hot discussion.

 

@ Rajesh R -  in the previous questions, most of us answered saying with employee engagement and motivation, acheiving zero defect is possible.  but now arguing it is not possible. ok. If you talk about SLA, then the customer requires your product with highest quality spec set by the client lets say >95% and 98%. But my argument is , if you consistently deliver a product with 100% quality which means zero defect, will the client not accept it? 

 

The client will be happy with the quality and service that we provide. If we consistently satisfy the customer, the sales and profit would increase.

 

Overall, having zero defect concept is always beneficial to the organisation. It is achievable.

Against:-

 

Hi Kavitha,

Previous question was about the concept and slogans that help motivate people.

I completely agree with you that Zero defect concept is always beneficial to organization.

but here the question is whether it is achievable or not. it has only two answers to it. either "yes" or either "No".

and most will agree with it that it is practically not possible to achieve Zero defect.

I am not quoting anyone specifically, but taking the points generally, that I read across.

 

“To err is human” (individual & process) became an accepted form of working and gave rise to negligence. 

 

No errors can be accepted for an activity. Good.  If there are errors for an activity - action will be taken. (Probably a post-mortem).

 

What is action?

A planned activity is called action.

 

What is activity?

A routine and mundane thing that we do on a daily basis is called activity.

 

 In the past, errors were not acceptable.  The activity itself was planned with proper actions (both logical and analytical).

 

I want to highlight another important dimension of the human aspect. The human values of being truthful and integral.  These qualities mainly brought in the deep sense of satisfaction. 

 

"A man had chiselled a stone into an idol which was about 30 feet and there was a slight crack on the nose of the idol.  He borrowed time for another idol. People around him asked, "why don’t you go ahead with the same idol, with the height of 30 feet who will ever notice a small crack"?.  The man replied “I will”, and he went ahead with a new stone."

 

These were the qualities in the past for which zero defects were practical.  Compromises of these values have depleted in the quality of work and now we call them as accepted norm and impossible in practicality.  This is one of the main reason for which we do not experience job satisfaction, though the infrastructure and the perks given are much much better and bigger.

 

Had the Takata Company been more truthful in the delivered air bags back in 2004 and addressed it knowing the implications, the brand would have earned the trust and Goodwill.  Let’s take the current Max Hospital license which stands cancelled.    Had the doctors been little more responsible and sensitive, probably it would have been a different scenario altogether. 

18 minutes ago, Ronaaq said:

Against:-

 

Hi Kavitha,

Previous question was about the concept and slogans that help motivate people.

I completely agree with you that Zero defect concept is always beneficial to organization.

but here the question is whether it is achievable or not. it has only two answers to it. either "yes" or either "No".

and most will agree with it that it is practically not possible to achieve Zero defect.

Hi Ronaq, 

 

I understand the question. thanks for explaining it again. but my argument here is even in the slogans, we had two different statements- one supporting zero defect and another against zero defect. 

 

Just to remind ambassadors who are not supporting the zero defects achievable - it is achievable. the question is about possible or not? it does not talk about the cost involved in achieving, technology, six sigma tools, etc.

 

Hence my argument is zero defect is definitely possible, with all employees motivated and engaged in doing things first time right, quality assurance with high inspection quality, technology to identify and correct the errors automatically with good amount of cost investment.

 

thanks

Kavitha 

3 minutes ago, Kavitha Sundar said:

Hi Ronaq, 

 

I understand the question. thanks for explaining it again. but my argument here is even in the slogans, we had two different statements- one supporting zero defect and another against zero defect. 

 

Just to remind ambassadors who are not supporting the zero defects achievable - it is achievable. the question is about possible or not? it does not talk about the cost involved in achieving, technology, six sigma tools, etc.

 

Hence my argument is zero defect is definitely possible, with all employees motivated and engaged in doing things first time right, quality assurance with high inspection quality, technology to identify and correct the errors automatically with good amount of cost investment.

 

thanks

Kavitha 

I do agree with Kavitha,  debate is on zero defect achievable or not,  we are not thinking about cost involved in this.  We can achieve it by motivating and giving training and can always do better and better.  Organisation want to delight their customer sometimes cost is not that factor. The brand name,  image also valuable in the market of the organisation.  We can reduce our water and can do better and deliver best products which actually customer wants to have.

Its all about how we are doing interpretation of zero defect. 

36 minutes ago, Ronaaq said:

Against:-

 

Hi Kavitha,

Previous question was about the concept and slogans that help motivate people.

I completely agree with you that Zero defect concept is always beneficial to organization.

but here the question is whether it is achievable or not. it has only two answers to it. either "yes" or either "No".

and most will agree with it that it is practically not possible to achieve Zero defect.

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. 

2 hours ago, Sumanta Das said:

Well, this story probably we all have heard, and stories are stories and good hear... Like Mr Vijay Malya - "the king of  good times" and it some times inspires us that is the benefit but I just have a simple quuestion for any mass production(except short span/only few batch production) is INFINITY sigma possible? Because only INFINITY sigma gives us a REAL zero defect environment whic is nearly impossible. In my last post I hae given some real life examples too. I actually wanted to quote some other posts too who said zero defect is possible under some condition, well these conditions are the considerations of acceptable level, say 95% zero defect, 5% error or considerations, when we are taking that acceptable levels, yes it might be achievable.

 

Few more JAPANIES example here- 

1. Toyota is one of the leading six sigma practicing compnay recalled 5.8 million cars over faulty Takata airbags last year. 

2. Honda recalled 1.15 milon cars for sensor issue.

3.  Toyota, Honda, Hyundai all the company recalled their cars for safety issue in different parts of the golbe in this current year only.

 

I support Mr Venugopal's logics/posts in the current topic.

 

Conclusion: zero defect possible in theory/or short span/few batch production but if we take real life business and a PERFECT zero defect it is nearly impossible to reach INFINITY sigma to achieve it. 

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. 

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.  

46 minutes ago, Vastupal Vashisth said:

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. 

 

50 minutes ago, Vastupal Vashisth said:

I do agree with Kavitha,  debate is on zero defect achievable or not,  we are not thinking about cost involved in this.  We can achieve it by motivating and giving training and can always do better and better.  Organisation want to delight their customer sometimes cost is not that factor. The brand name,  image also valuable in the market of the organisation.  We can reduce our water and can do better and deliver best products which actually customer wants to have.

Its all about how we are doing interpretation of zero defect. 

 

57 minutes ago, Kavitha Sundar said:

Hi Ronaq, 

 

I understand the question. thanks for explaining it again. but my argument here is even in the slogans, we had two different statements- one supporting zero defect and another against zero defect. 

 

Just to remind ambassadors who are not supporting the zero defects achievable - it is achievable. the question is about possible or not? it does not talk about the cost involved in achieving, technology, six sigma tools, etc.

 

Hence my argument is zero defect is definitely possible, with all employees motivated and engaged in doing things first time right, quality assurance with high inspection quality, technology to identify and correct the errors automatically with good amount of cost investment.

 

thanks

Kavitha 

 

 

Against:-

 

Zero defect is a Nirvana stage.

When there is no waste, no unwanted activities in process of making a product.

No matter how much money you invest, there will always be some waste generated/ some activity that is a not adding any value to the product.

 

You take any organization with world class equipment,processes, technologies. They are still struggling to achieve Zero Defect, because it is practically impossible.

 

I am not telling that Organization should stop working to achieve zero defect.

Considering "Zero defect" as a concept is brilliant. It motivates and drives people for continuous improvement.

 

If Zero defect is possible why do organization struggle to achieve 6sigma level. i.e 3.4 DPMO.

why don't they target higher sigma level where there is 0 DPMO.

six sigma is only one aspect of Zero Defect

 

 

 

 

 

 

 

1 hour ago, Vastupal Vashisth said:

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.  

Yes, always “tend” towards ZD, which means reduce wastes. What is considered value adding today may not be so in future, due to tech and process advancements. The pursuit will continue, and expectations will also keep raising its bar.

3 hours ago, Vastupal Vashisth said:

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. 

Yes... I gave the example because after crossing all those sigma steps still faulty cars or products are coming. Toyota is famous, almost all Japanies companies are.... they invested a lot of time and money and skill set to prevent it but failed. Beacuse there is always a chance of error/faluty products, no one can eliminate that 100%. Hence.....

I have voted for an "yes" when the same question was asked with an YES/ NO option. That is because , going by the definition of a defect – “Frailty or shortcoming that prevents an item from being complete, desirable. Effective, safe, or of merit, or makes it to malfunction or fail in it’s purpose”, It is possible to have a Defect free product .

It is possible if the ideal conditions are provided and ONLY a single unit(Or a very low sample size) is to be produced, which has liberal specifications or so to say has no astringent specifications. This is an ideal scenario- a response to a request for 1 single piece of blank paper to write- I cannot see a defect happening in fulfilling this request.

Having said that , in all practicality, I believe firmly that, As the Principle of uncertainty states “We may significantly modify what we are trying to measure, simply by making an effort to measure it.” What this implies is that the inspections and tests to measure or analyse a process by themselves can actually cause a defect.

Thus, practically, the concept of zero defect is surreal!!

 

6 hours ago, Ronaaq said:

Against Zero Defect is achievable:-

 

I agree that Zero defect is a concept rather than target

 

It should be used for motivating people to achieve zero defects. It drives continuous improvement activities.

 

However, the question is ZERO defect is achievable or not.

 

To achieve zero defect we need to eliminate waste from the process. Waste means any unproductive activity that does not add value to the product. Eliminating all those Non-value added activates/waste is practically impossible.

 

The question is not about the concept; it is about actually achieving zero defect. Therefore, my vote is against

 

 

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. 

2 hours ago, Sumanta Das said:

Yes... I gave the example because after crossing all those sigma steps still faulty cars or products are coming. Toyota is famous, almost all Japanies companies are.... they invested a lot of time and money and skill set to prevent it but failed. Beacuse there is always a chance of error/faluty products, no one can eliminate that 100%. Hence.....

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. 

4 hours ago, Venugopal R said:

Yes, always “tend” towards ZD, which means reduce wastes. What is considered value adding today may not be so in future, due to tech and process advancements. The pursuit will continue, and expectations will also keep raising its bar.

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...