Zero Defects

Dear Terry,

 

Thank you for your comments on my Blog. 

 

Learning from Dr. Shingo and Mr. Ohno, I try to keep things very simple.  Zero defects is simply zero defects; at first, not a single defect leaves the plant and then not a single defect is produced.

 

Can it be possible?  I think so.  Does it happen for Toyota? Not yet?  Will they get there?  I don't think anything less is acceptable to them.

But , many Japanese companies claim to produce no defects. They feel they are able to fully control the process.  Even more importantly zero defects must become a believable target. 

 

I have a dear friend in Japan, a great teacher, that absolutely believes in zero defects.  He teaches it and takes you through a step by step approach to get there. 

Of course, it is a journey until attained and then you move on to other things. 

Unfortunately, many managers are stuck with a goal less than zero.  It gives them an out. It means that some of your customers will surely be disappointed.  I don't want to disapppoint anyone.   

If you are prepared to jump from a tall building, you better believe that you can fly.  I would not even consider that anything less than zero should be our goal.

From Terry Bignoche

 

I greatly appreciate your approach to asking workers for ideas and encouraging responsible action for improvements. As you know, the action always involves some experimentation which is where learning thrives. As "lean" is a journey rather than a destination, I also think "zero defects" may be more of a journey as well. To determine if you are "lean" or there are "zero defects" doesn't one have to use data +/or opinion as the basis? By some measures one may have a claim to have reached either destination which could lead to complacency if one is not careful. This doesn't suggest you don't get on the journey and celebrate successes along the way. I just wanted to share some thoughts in this forum because you have helped my thinking so much along my path.
Thanks!
Terry Begnoche