ZERO DEFECT MINDSET

 

INTRODUCTION

How much do quality failures cost your company?

Quality defects have significant costs associated with them - some of the most obvious being money, time, resources, and lost reputation. And programs to eliminate quality defects can be expensive and time consuming. So, do you insist on eliminating defects entirely no matter the cost? Or, do you accept that a certain, albeit very small, percentage of defects is acceptable, and just accept the costs and learn to live with them?

One of the most influential ideas about this was the notion of "zero defects." This phrase was coined by Philip Crosby in his 1979 book titled, "Quality is Free." His position was that where there are zero defects, there are no costs associated with issues of poor quality; and hence, quality becomes free.

Zero defects is a way of thinking and doing that reinforces the notion that defects are not acceptable, and that everyone should "do things right the first time." The idea here is that with a philosophy of zero defects, you can increase profits both by eliminating the cost of failure and increasing revenues through increased customer satisfaction.

BENEFITS

• Design Defect-free workplaces
• Reduction in human errors, scraps, rework, accidents, etc. 
• Increased productivity
• Improved work conditions
• Improved attitudes at and to work 
• Set up an Error Cause Removable (ECR) Team.
• Lead your market

COURSE OBJECTIVE

Upon completing this course you will be able to:

1. Defects are caused by human factors
2. Human factors psychology focuses on creating and improving products, equipment, machines, and environments to complement human capabilities and maximize performance and safety
3. Getting the best out of human capabilities and limitations for Zero Defects
4. Design procedures and instructions around human capabilities, to avoid employees to adopt dangerous workarounds to get the job done, which could lead to a greater number of incidents or accidents in the future 
5. Search and fix human factor root causes
6. Learn a systematic approach to combat defects to occur or to mitigate severity.
7. Applying the ISO 9001:2015 core concepts to human factors causing defects
   a) Risk based thinking
   b) Process approach
   c) Plan-do-check-act
8. Adopting Zero Defects Policy and system

TARGET GROUP

• HR Officers / Trainers
• Production Supervisors / Engineers
• Quality Supervisors / Engineers
• Industrial / Process Engineering staff

METHODOLOGY

• Classroom lecture
• Group Discussion
• Case studies
• Practical / Gemba on production floor

DURATION – 2 days – 9.00am – 5.00pm

 

CONTENTS

DAY 1

1.      Introduction

2.      What are defects

3.      Measuring the costs of defects

4.      Why defects are made

5.      The study of Human Factors and Defects

6.      What are the four elements of zero defects?

7.      The Concept of Zero Defects in Quality Management

8.      How to prevent errors in manufacturing

1. Design of workplace
2. Design of tools, jugs and fixtures
3. Ergonomics
4. Improving Human Factors culture
5. Improving systems and work competencies

DAY 2

1.      Search for human factor root causes for robust defect control

1. Using directed brainstorming
2. Applying the SHEL Model to an error in your workplace
3. Continue Search of root cause
4. 5 Why Analysis
5. Testing the Human Factor root cause
6. Further mitigation - Failure Mode Effect Analysis DFMEA / PFMEA

2.      Dealing with the Dirty Dozen – zero defect aircraft component manufacturing system

3.      Influencing Operator Motivation to guarantee “first time right” performance

4.      Applying the ISO 9001:2015 core concepts to human factors causing defects

1. Risk based thinking
2. Process approach
3. Plan-do-check-act

5.      Adopting Zero Defect

1. Principles of change management
   
2. Design systems that support zero defects where it matters
3. Zero defects requires a proactive approach
4. Zero defects must be integrated with the corporate culture
5. Learn poka-yoke
6. Build mechanisms into your systems and methods of operating that provide continuous feedback
7. Measure your quality efforts
8. Build quality into your performance expectations
9. Monitor, evaluate, and adapt in a continuous, never-ending cycle

6.      Set up an in-house team for removing error cause (Error Cause Removable Team - ECRT)

7.      CONCLUSION - zero defects is a useful idea if you want to lead your market in terms of quality of delivery

 

TRAINER'S PROFILE

Dr Andrew Jebamani - B.Sc. (Industrial Engineering), MBA, MCIM (UK), LBC - Sensei, PhD

Dr Andrew has an impressive record in the field of Lean Management for over 28 years. He is a senior member of the Society of Manufacturing Engineering, USA and has served the Multinational Companies in the capacity of Industrial Engineering Manager and Manufacturing Manager.   He was also instrumental in the implementation of many Get-Well programs.

Dr Andrew is a trainer and consultant since 1995 and was awarded the Shingo Prize Examiner for Operational Excellence, USA (2007) and Lean Bronze Certification, USA (2008).  In 2011, Dr Andrew was awarded the Lean Manufacturing certification from the University of Michigan, USA. He brings with him a multi-disciplinary approach to the subject of Lean Manufacturing.  Starting from his "hands-on" production experience, he expertly weaves in the new knowledge-driven economy production paradigms to enable participants to appreciate why these techniques are so important in helping companies to compete in the global economy.       

 Dr Andrew in his own capacity, delivers approximately 20 million ringgits annually to his customers through various projects’ gains.

Dr Andrew has an impressive record in the field of Lean Management for over 29 years. He is a senior member of the Society of Manufacturing Engineering, USA and has served the Multinational Companies in the capacity of Industrial Engineering Manager and Manufacturing Manager. He was also instrumental in the implementation of many Get-Well programs.

Dr Andrew is a trainer and consultant since 1995 and was awarded the Shingo Prize Examiner for Operational Excellence, USA (2007) and Lean Bronze Certification, USA (2008). In 2011, Dr Andrew was awarded the Lean Manufacturing certification from the University of Michigan, USA. He brings with him a multi-disciplinary approach to the subject of Lean Manufacturing. Starting from his "hands-on" production experience, he expertly weaves in the new knowledge-driven economy production paradigms to enable participants to appreciate why these techniques are so important in helping companies to compete in the global economy.

Notable he has spoken to many companies in India covering major industrial areas. He was also invited to present similar seminars in China, Thailand, and Vietnam. In November 2003, he was selected by the magazine "The Machinist" as the personality-of-the-month for Lean Manufacturing.

Dr Andrew is a highly capable trainer with a passion to assist companies acquire new management and production techniques to compete globally. He is a leading consultant to the industry specializing in improving productivity with the holistic application of Lean, TQM, Management and Industrial Engineering Techniques. He also holds certificates in Industry 4.0 both local and international.

Lean Business Solutions PLT is certified with HRD Corp - MyCoID LLP0003236LGN. Our trainer, Dr Andrew Jebamani is also certified under the Train-The-Trainer program - # TTT/0364.