Operation Management

1. Global Management Solutions
Zero Defect Programme

2. Introduction
 It is a philosophy that believes in defect
prevention rather than finding and fixing defects.
 It centres on the belief that most human errors
are caused due to a lack of attention, rather than
a lack of knowledge.
 It emerges as a major step towards the
elimination of rework, scrap, repair and other
wasteful activities.
 Sometimes, poka yoke is also termed zero

3. Basic Philosophy
 Zero defect is a personal habit developed over a
period of time.
 Daily oath-taking to not allow errors, delay,
wastage, breakdowns and accidents to take
place.
 Defects are manifestations of worker’s errors,
which are primarily due to three reasons:
1. Lack of know-how or knowledge about the job
or machinery
2. Lack of proper physical facilities and
engineering support
3. Lack of attention

4.  The crux of the ZD programme is in motivating
employees to prevent committing mistakes by
developing and nurturing a constant, consistent and
conscious desire to do the job right the first time,
every time.
 ZD is simply a movement to assure that each
individual, from the CEO to the peon, irrespective of
position, realizes the individual’s importance in the
production of the organization's goods and services .
 The attainability of ZD is directly proportional to the
attitude and desire

5. Advantages
 Improves productivity.
 Significantly improves the image of the company
in the market as the products are defect free.
 Improves product quality significantly
 Changes the attitudes of the employees towards
work and the company
 Improves the morale of employees
 Improves team building and participation

6. Limitations
 It is strictly applicable only when loyalty towards
the company exists
 It is retained by motivational mechanisms
 It has a high chance of failure and backfiring if not
implemented properly
 It is mostly applicable where the workforce is
highly responsible, efficiency , educated, properly
trained.
 It overemphasizes the importance of the
operator’s or worker’s attention to perfection