“ A best practice or principle of a successful team, it means the project team commits to do work at the highest quality possible at the time it is being done, and each team member is individually responsible for helping achieve the desired level of quality. The zero-defect mindset does not mean that the deployed solution must be “perfect” with literally no defects; rather, it establishes perfection as a consistent goal for the team to strive for.”

…..Viewed in a broad sense

A QUALITY MANAGEMENT SYSTEM TO REALIZE ANY IDEA BY THE APPLICATION OF 6 ‘M’s.

(Ishikawa’s Fish-Bone Diagram used for Error-Cause Analysis)

Material Man Machine

IDEA REALITY

Methods Mission Measurements

-employees’ commitment employees’ commitment

- optimum utilization of resources- optimum utilization of resources

- control & elimination of defects- control & elimination of defects

- quality of products & services- quality of products & services

PP- Preparation, Planning, Perseverance - Preparation, Planning, Perseverance

EE- Effective and Efficient Execution - Effective and Efficient Execution

RR- Right Person/ Process/ Time- Right Person/ Process/ Time

FF- Factual Approach to Decision Making- Factual Approach to Decision Making

EE- Error Prevention / Elimination- Error Prevention / Elimination

CC- Creativity, Co-operation, Co-ordination, - Creativity, Co-operation, Co-ordination, Cost Cost Control, Continual improvement & Control, Continual improvement &

Customer Focus Customer Focus (6 ‘C’s Principle)(6 ‘C’s Principle)TT- Total Quality Management & Team work- Total Quality Management & Team work

I I - Imagination, Insight, Inspection- Imagination, Insight, Inspection

OO- Objective-oriented Operations- Objective-oriented Operations

NN- No Scrap & No Rework- No Scrap & No Rework

…………. . A MOVING TARGETA MOVING TARGET

IT IS THE POWER TO WHICH AN IDEA IS IT IS THE POWER TO WHICH AN IDEA IS RAISED BY THE APPLICATION OF 6 ‘M’s RAISED BY THE APPLICATION OF 6 ‘M’s AND EVALUATED AGAINST AND EVALUATED AGAINST

IndividualIndividual

Socio-economicSocio-economic

OrganisationalOrganisational

NEEDS.NEEDS.

ZDA IDENTIFIES AS

Sure SupervisionWilling WorkmanshipIntelligent InspectionMotivated ManagementMeticulous MeasurementsEfficient ExecutionDream Designing

efforts deciding the degree of excellence of a

DROWNED idea

Justification Design Issues Issues

Implementation Process

Issues Measurements Issues

Resistance to Change

THESE ARE ATTITUDINAL PROBLEMS AND ZERO DEFECT ANALOGY BRINGS ABOUT AN ATTITUDINAL CHANGE IN THE PEOPLE OF THE ORGANISATIONS OPTING FOR IT.

ANY ONE WHO TREATS

QUALITYQUALITY SOLELY AS A RATIONAL EXERCISE

MISSES AN ESSENTIAL TRUTH.

IT’S BOTH RATIONALRATIONAL AND EMOTIONALEMOTIONAL TOO.

IT TOUCHES BOTH :

THE HEARTHEART & THE

HEADHEAD.

- PREVENTION IS BETTER THAN CURE.

- THROUGH PARTICIPATION, INVOLVEMENT & COMMITMENT IS ESSENTIAL AT ALL LEVELS IN THE ORGANISATION.

- SUCCESS IS NOT THE DESTINATION BUT A JOURNEY.

- DICTIONARY IS THE ONLY PLACE WHERE ‘SUCCESS’ COMES BEFORE ‘WORK’.

- CUSTOMER VALUE IS INCIDENTAL .

THE THRUST OF ZDA IS TO ATTAIN ZERO DEFECTS

AND ACCEPT NOTHING ‘ NEAR TO IT’.

II dentifydentifynstructnstructnspectnspectnspirenspire

- Scientific Management: Finding the best way to do a job

- Group Dynamics: Enlisting and organising the power of group experience

- Training and development: Investing in human capital

- Achievement motivation: People get satisfaction from accomplishment

- Employee Involvement: Employees should be involved in the decision making process

- The New Leadership Theory: Inspiring and empowering people to act

- Strategic Planning: Determining in advance what and how to accomplish the set targets

AT THE WORKER LEVEL:AT THE WORKER LEVEL:

Identify the causes of defectsIdentify the causes of defects

-- Error- cause analysisError- cause analysis - Grade defects in the order of merits - Grade defects in the order of merits - Error- cause removal- Error- cause removal - Ask for suggestions- Ask for suggestions

AT THE SUPERVISOR LEVEL:AT THE SUPERVISOR LEVEL:

Instruct error-free performanceInstruct error-free performance

-- Explain zero defect limits to the workers Explain zero defect limits to the workers - Show how to do the job right the first time - Show how to do the job right the first time - Employ the right man at the right place- Employ the right man at the right place - Train skills- Train skills - Give recognition to ZD performers- Give recognition to ZD performers

AT THE INSPECTOR LEVEL:AT THE INSPECTOR LEVEL:

Inspect work as it is being doneInspect work as it is being done

-- Proper inspection at each stage/ phase Proper inspection at each stage/ phase

- Explain inspection techniques - Explain inspection techniques

- Establish goals for quality effectiveness- Establish goals for quality effectiveness

AT THE MANAGEMENT LEVEL:AT THE MANAGEMENT LEVEL:

Inspire and motivate employeesInspire and motivate employees

-- Use build-up campaign Use build-up campaign - Show employees the importance of work - Show employees the importance of work - Report on progress- Report on progress - Sell zero defects- Sell zero defects - Job enrichment- Job enrichment

1.1. Clearly define Clearly define Quality Quality ObjectivesObjectives..

2.2. FormForm a a Quality Action Quality Action TeamTeam in order to F A D E in order to F A D E

(focus, analyze, develop (focus, analyze, develop & execute) ZD program.& execute) ZD program.

3. Give proper educationand training to employees(to develop in them theability to work in selfdirected teams, to have theknowledge that what theydo will make the differenceand faith in them is to beshown to give them theconfidence that good workwill be recognized andrewarded).

4.4. Foster sharing ofFoster sharing of

information byinformation by

management on management on

successful qualitysuccessful quality

strategies.strategies.

5. Organise activities5. Organise activities

for inspiring, directingfor inspiring, directing

and sustainingand sustaining

AppropriateAppropriate

employeeemployee

behaviour (to fulfillbehaviour (to fulfill

The purpose of theThe purpose of the

strategic systems).strategic systems).

6.6. Motivate employees Motivate employees through formal and through formal and informal mechanisms to informal mechanisms to reinforce all role reinforce all role accomplishments and to accomplishments and to help building the link help building the link between strategy and between strategy and operations by attempting operations by attempting to ensure that people to ensure that people behave appropriately to behave appropriately to execute the strategy.execute the strategy.

6.6. Use ‘Kaizen’ and Use ‘Kaizen’ and

‘Innovation’ for ‘Innovation’ for continual continual improvement.improvement.

7.7. Celebration of ZD Celebration of ZD performance and performance and striving for the next striving for the next cycle.cycle.

REMEMBER THAT -REMEMBER THAT - NOT ALL MEASUREMENTS ARE NOT ALL MEASUREMENTS ARE TAKEN WITH A SET OF CALIPERS IN TAKEN WITH A SET OF CALIPERS IN HAND.HAND.

??