top of page

How to Design a manufacturing system for achieving Zero Defect Manufacturing (ZDM)?

The implementation of #ZDM is not a simple task as it requires careful #design and more importantly new methods. #ZDM is composed of four main# strategies: #Detect and #Predict that are the #triggering #ZDM strategies, and the #Repair and #Prevent that are the #action ZDM strategies. The three ZDM pair strategies are “Detect-Repair”, “Detect-Prevent” and “Predict-Prevent”. The main difference of ZDM with the traditional quality assurance methodologies is the fact that #ZDM ensures 100% of the products are inspected via any method, either detection or prediction. It is impossible to achieve ZDM if not all the products are inspected. In traditional quality improvement methods such as Six Sigma, Lean manufacturing, Lean Six Sigma, Theory of Constraints, and Total Quality Management, the analysis starts after the production has started and defects or quality issues start occurring. In #Zerofect we use the #design for #ZDM approach which is going one step further and considers critical design factors from the beginning for achieving ZDM and not while the production is running.

In #Zerofect we have developed a #practical #guide with the steps to be followed for implementing #ZDM into manufacturing systems. Those steps can be implemented in both #existing and #new production systems. In the developed implementation guide, we have defined two sets of parameters: product analysis parameters, and ZDM strategies key control parameters.

If you have some of the following questions then our method is ideal for you and you are one step closer to #ZDM :

· How can ZDM implementation be integrated into a new manufacturing system?

· How can ZDM implementation be integrated into an existing manufacturing system?

· What are the steps to follow for ZDM implementation?

· What are the restrictions for ZDM implementation?

There is a differentiation between the design of a new system and the implementation of #ZDM in an existing manufacturing system. The difference lies in the fact that when the system pre-exists and produces the product there are more available data and therefore the #design for #ZDM can be more accurate and straightforward. More specifically, when the manufacturing system pre-exists, data such as the defect rate at each manufacturing stage and specific KPIs are available that can assist in the design for ZDM process. However, when a manufacturing system is designed from the beginning, the only available data are historical data from other or similar processes that can be used to assist in the design of the quality assurance implementation. The first information that is required is to identify the most optimum ZDM approach: product-oriented, process-oriented or hybrid. The ZDM approach determines from which point the ZDM process starts: from the product or the process.

Regardless of the ZDM approach, the product analysis is the same, the bill of materials (#BoM) and bill of processes (#BoP). Each task of the #BoP is analyzed and combined with aspects of BoM and #sustainability and the #BoP tasks are ranked based on the impact that a defect will cause at this manufacturing stage and therefore the ranking reveals the need of each for #ZDM implementation.

After the #ranking of the tasks and starting from the task with the highest impact if defected, the three ZDM pair strategies are investigated to calculate the performance of each #ZDM pair strategy to each product task. Based on the produced ZDM #performance #maps, the proper #ZDM technology will be developed or selected and will be deployed.

The #product #analysis is a critical step for the #sustainable design of a manufacturing system. Performing detailed analysis for each manufacturing stage might be very time consuming and costly. Also, implementing ZDM to all the manufacturing processes of a product can be extremely costly and significantly reduce the performance of the system, and thus careful design is required. Therefore, ZDM should be implemented with priority to the highly risky tasks, and partial ZDM is applied to some other tasks to assure Zero Defects. #Partial ZDM refers to the implementation of single ZDM strategies and not as a pair. More specifically, the ZDM strategies that can be implemented alone are the “Detection” and “Prediction”. Implementing those strategies alone in low-risk tasks will ensure 100% of accepted product at the end of the manufacturing process.


bottom of page