Aim is for "Zero Defects" and improved customer experience

1. Defects Vs. Errors
“Aim is for Zero Defects and
improved customer experience”
Anand Subramaniam

2. “Women love us for our defects. If we have
enough of them, they will forgive us
everything, even our gigantic intellects.”
- Oscar Wilde
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3. Defects Vs. Errors
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4. Defects Vs. Errors
 The first step to “Source Inspection” is to
distinguish between Errors and Defects
 “Defects” are the results
 “Errors” are the causes of the results
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5. Zero Defects
 The goal is to understand the concept and
practice of zero defects and how to
develop Poka-yoke to eliminate these
defects
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6. Poka-yoke
 Poka-yoke – methods or devices to
improve product quality and ensure
consistent process results
 Poka-yoke devices:
 Prompt feedback and action as soon as the
defect or error occurs
 Perform 100% auto-inspection
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7. Defect Tracking
 Defect Rates are tracked by:
 Quantity
 Kind
 Percent
 With “Zero Defects” thinking, tracked at:
 The point at which defect is discovered
 The point at which defect occurred
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8. Gemba Motto on Defects
Don’t get it.
Don’t make it.
Don’t send it
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9. Errors Causes
Manufacturing Errors Human Errors
 Processing errors or  Place blame and/or
omissions expect defects
 Catch at final or
 Assembly omissions sampling inspection
or inclusion of the
wrong part
 Make excuses
 Processing wrong
work piece
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10. Mistake Proofing Human Errors
 Eliminate the possibility of the mistake
 Find the root cause and eliminate
 Ask why the process failed
 Apply mistake-proofing device for 100%
inspection
 No defects generated
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11. Mistake Proofing Machine Errors
 Poka-yoke
 A standard – a work method or procedure
 A reliable method includes only those
elements which, when followed, cause a
predictable/desirable result, and when not
followed, result in a predictable defect
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12. Take Away..
 Defects can be prevented
 Error Proofing
 Poka-yoke - to achieve zero defects
 Make it impossible to produce defects
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13. “One of the great defects of English books
printed in the last century is the want of an
index.”
- Lafcadio Hearn
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14. Good Luck
http://www.linkedin.com/in/anandsubramaniam
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