Zero defects and Zero waste

Thacker Karan H.
T.F.G.P Adipur, mechanical department
Email:karan.thacker99@gmail.com

All kind of economic activity undertaken for the development of economy and society will use some kind of
resources and have some impact on the environment. Therefore, it is necessary to evolve innovative ways to reduce
the consumption of natural resources and develop solutions leading to sustainability of energy use and protection of
global environment. As a matter of fact, any kind of development that is directed towards the development of
economy and the society at large aims at enhancing the quality of life of the people. The requirement of global
market is to produce highest grade quality products corresponding to world class standards. This can be achieved by
providing services which are ecologically superior and economically viable. The efforts must be made to enhance
the efficiency, minimizing waste and optimum use of resources. This paper presents an approach for the industries to
produce zero defect products i.e. products with zero non-conformance/zero non-compliance and zero waste. It is
also essential that during production industries should ensure that they cause zero waste to the environment i.e. zero
air pollution/liquid discharge/ solid waste and zero wastage of natural resources.

Key words- zero defects, zero waste, reuse, reduce, recycle.

1. Introduction
Zero Defects (or ZD) was a management-led program to eliminate defects in industrial production that enjoyed
brief popularity in American industry from 1964 to the early 1970s. Quality expert Philip Crosby later incorporated
it into his "Absolutes of Quality Management" and it enjoyed a renaissance in the American automobile industry
as a performance goal more than as a programin the 1990s. Although applicable to any type of enterprise, it has
been primarily adopted within supply chains wherever large volumes of components are being purchased (common
items such as nuts and bolts are good examples).
Zero Waste is a philosophy that encourages the redesign of resource life cycles so that all products are reused. No
trash is sent to landfills and incinerators. The process recommended is one similar to the way that resources are
reused in nature. The internationally recognized definition of ZERO WASTE adopted by the Zero Waste
International Alliance is:
"Zero Waste is a goal that is ethical, economical, and efficient and visionary, to guide people in changing their
lifestyles and practices to emulate sustainable natural cycles, where all discarded materials are designed to become
resources for others to use.

2. Zero defects

Fig. 1

A. Definition:Zero Defects is a management tool aimed at the reduction of defects through prevention. It is directed at motivating
people to prevent mistakes by developing a constant, conscious desire to do their job right the first time. Zero
Defects: A New Dimension in Quality Assurance
Zero Defects seeks to directly reverse the attitude that the amount of mistakes a worker makes doesn't matter since
inspectors will catch them before they reach the customer. This stands in contrast to activities that affect the worker
directly, such as receiving a paycheck in the correct amount. Zero Defects involves reconditioning the worker "to
take a personal interest in everything he does by convincing him that his job is just as important as the task of the
doctor or the dentist.
B. History:The development of Zero Defects is credited to Philip B. Crosby, a quality control department manager on
the Pershing missile program at the Martin Company, though at least one contemporary reference credits a small,
unnamed group of Martin employees.
Zero Defects is not the first application of motivational techniques to production: During World War II, the War
Department's "E for Excellence" program sought to boost production and minimize waste.
The Cold War resulted in increased spending on the development of defense technology in the 1950s and 1960s.
Because of the safety-critical nature of such technology, particularly weapons systems, the government and defense
firms came to employ hundreds of thousands of people in inspection and monitoring of highly-complex products
assembled from hundreds of thousands of individual parts. This activity routinely uncovered defects in design,
manufacture, and assembly and resulted in an expensive, drawn out cycle of inspection, rework, reinspection, and
retest. Additionally, reports of spectacular missile failures appearing in the press heightened the pressure to eliminate
defects.
In 1961, the Martin Company's Orlando Florida facility embarked on an effort to increase quality awareness and
specifically launched a program to drive down the number of defects in the Pershing missile to one half of
the acceptable quality level in half a year's time. Subsequently, the Army asked that the missile be delivered a month
earlier than the contract date in 1962. Martin marshaled all of its resources to meet this challenge and delivered the
system with no discrepancies in hardware and documentation and were able to demonstrate operation within a day
of the start of setup. After reviewing how Martin was able to overachieve, its management came to the conclusion
that while it had not insisted on perfection in the past, it had in this instance, and that was all that was needed to
attain outstanding product quality.
Management commissioned a team to examine the phenomenon and come up with an action plan, which became the
organizing, motivating, and initiating elements of Zero Defects. The Department of Defense also took notice and in
1964, began to actively encourage its vendors to adopt Zero Defects programs. Interest in the program from outside
firms, including Litton Industries, Thiokol, Westinghouse, and Bendix Corporation, was keen and many made visits
to Martin to learn about it. Their feedback was incorporated and rounded out the program. In particular, General
Electric suggested that error cause removal be included in the program.
Martin claimed a 54% defect reduction in defects in hardware under government audit during the first two years of
the program. General Electric reported a $2 million reduction in rework and scrap costs, RCA reported 75% of its
departments in one division were achieving Zero Defects, and Sperry Corporation reported a 54% defect reduction
over a single year.

During its heyday, it was adopted by General Electric, ITT Corporation, Montgomery Ward, Rolls-Royce Limited,
and the United States Army among other organizations.
While Zero Defects began in the aerospace and defense industry, thirty years later it was regenerated in the
automotive world. During the 1990s, large companies in the automotive industry tried to cut costs by reducing their
quality inspection processes and demanding that their suppliers dramatically improve the quality of their supplies.
This eventually resulted in demands for the "Zero Defects" standard. It is implemented all over the world.

QUALITY TOOLS FOR ZERO DEFECTS

Total quality management(TQM)

Quality specifications and costs
TQM Tools: external benchmarking
ISO 9000
Service quality measurement(SQM)

C. No mistake

Fig. 2
In zero defect technology there must be no mistake in any work field so there will be more amount of outcome and
zero defects.
In this there is no possibly of no mistake but should be reduce the mistake by more than 50 to 60% of it to get more
amount of outcome and also reduce in price. So after 5 years till 2020 there will be a great success in urban areas.

3. Zero waste

Fig. 4
A. Definition:Zero Waste is a philosophy that encourages the redesign of resource life cycles so that all products are reused. No
trash is sent to landfills and incinerators. The process recommended is one similar to the way that resources are
reused in nature. The internationally recognized definition of ZERO WASTE adopted by the Zero Waste
International Alliance is:
"Zero Waste is a goal that is ethical, economical, efficient and visionary, to guide people in changing their lifestyles
and practices to emulate sustainable natural cycles, where all discarded materials are designed to become resources
for others to use.
Zero Waste means designing and managing products and processes to systematically avoid and eliminate the volume
and toxicity of waste and materials, conserve and recover all resources, and not burn or bury them.

B. Three Rs use for zero waste

Fig. 5
Tips
on
reducing
waste
and
conserving
resources.
The three R's - reduce, reuse and recycle - all help to cut down on the amount of waste we throw away. They
conserve natural resources, landfill space and energy.
Plus, the three R's save land and money communities must use to dispose of waste in landfills. Sitting a new landfill
has become difficult and more expensive due to environmental regulations and public opposition.
Missouri has a goal of reducing the amount of waste going into landfills by 40 percent. Everyone can help meet this
goal and save natural resources, energy, and money by following the three R's.
REDUCE

The best way to manage waste is to not produce it. This can be done by shopping carefully and being aware of a few
guidelines:

Buy products in bulk. Larger, economy-size products or ones in concentrated form use less packaging and
usually cost less per ounce.

Avoid over-packaged goods, especially ones packed with several materials such as foil, paper, and plastic.
They are difficult to recycle, plus you pay more for the package.

Avoid disposable goods, such as paper plates, cups, napkins, razors, and lighters. Throwaways contribute to
the problem, and cost more because they must be replaced again and again.

Buy durable goods - ones that are well-built or that carry good warranties. They will last longer, save
money in the long run and save landfill space.

At work, make two-sided copies when ever possible.

Maintain central files rather than using several files for individuals.

Use electronic mail or main bulletin board.

Remove your name from the mailing lists of materials you no longer want to receive: write to Mail
Preference Service, c/o Direct Marketing Assoc., P.O. Box 90008, Farmingdale, NY 11735.

Use cloth napkins instead of paper napkins.

Use a dish cloth instead of paper towels.

REUSE
It makes economic and environmental sense to reuse products. Sometimes it takes creativity:

Reuse products for the same purpose. Save paper and plastic bags, and repair broken appliances, furniture
and toys.

Reuse products in different ways. Use a coffee can to pack a lunch; use plastic microwave dinner trays as
picnic dishes.

Sell old clothes, appliances, toys, and furniture in garage sales or ads, or donate them to charities.

Uses reseal able containers rather than plastic wrap.

Use a ceramic coffee mug instead of paper cups.

Reuse grocery bags or bring your own cloth bags to the store. Do not take a bag from the store unless you
need one.

RECYCLE
Recycling is a series of steps that takes a used material and processes, remanufactures, and sells it as a new product.
Begin recycling at home and at work:

Buy products made from recycled material. Look for the recycling symbol or ask store managers or
salesmen. The recycling symbol means one of two things - either the product is made of recycled material,
or the item can be recycled. For instance, many plastic containers have a recycling symbol with a numbered
code the identifies what type of plastic resin it is made from. However, just because the container has this
code does not mean it can be easily recycled locally.

Check collection centers and curbside pickup services to see what they accept, and begin collecting those
materials. These can include metal cans, newspapers, paper products, glass, plastics and oil.

Consider purchasing recycled materials at work when purchasing material for office supply, office
equipment or manufacturing.

Speak to store managers and ask for products and packaging that help cut down on waste, such as recycled
products and products that are not over packaged.

Buy products made from material that is collected for recycling in your community.

Use recycled paper for letterhead, copier paper and newsletters.

C. Benefits of zero waste

Saving money. Since waste is a sign of inefficiency, the reduction of waste can reduce costs.

Faster Progress. A zero waste strategy improves upon production processes and improving environmental
prevention strategies which can lead to take larger, more innovative steps.

Supports sustainability. A zero waste strategy supports all three of the generally accepted goals of
sustainability - economic well-being, environmental protection, and social well-being.

Improved material flows. A zero waste strategy would use far fewer new raw materials and send no waste
materials to landfills. Any material waste would either return as reusable or recycled materials or would be
suitable for use as compost.

D. Role of society

Central government must take the leadership role and develop legislation to support zero waste targets.
Funding to communities and local governments will be necessary to support the development, innovation, and
implementation of national policies.

Regional governments have a major planning role in zero waste. Vision is required to see what the future
may hold or need and provide the necessary facilities to handle material flows. Skills in coordination and
diplomacy will be required to address the concerns of many players from all sectors of the economy.

Local governments must be responsible in implementing legislation and devising measures which favor
material and resource recovery, over disposal. Local authorities need to be responsible for everything pertaining
to zero waste, from recovery facilities, to recycling bin stickers and school programs.

Industrial Designers have a key part to play in zero waste. Products need to be designed that are durable,
repairable and easily disassembled for recycling and incorporated back into nature or the industrial system.

Manufacturers have to invest in new design technologies. The creation of products with minimal waste,
reduced packaging, and being responsible for a products whole life-cycle is significant in the production phase.

Retailers must stock products that are recyclable and repairable, and promote products that are
environmentally sustainable.

Secondary Material Handlers need to provide high quality services that outperform disposal services.
Recyclers have to form partnerships with communities and local government to recycle all waste streams.

Universities and schools need to teach zero waste principles and have recycling systems in institutions to
ensure students gain first-hand experience through participation.

Households need to adopt waste reduction and recycling schemes in the home. As consumers of products
and services, knowledge and informed decisions are essential in order to divert unnecessary waste into landfill.

5. Conclusion
At the end the conclusion is to read, understand and put it in our live activities so we get a good result and it must be
helpful to urban areas in developing them till 2020 in India a make our nation at a next level by making it free from
defects and waste!!!!

Introduction
This paper presents an approach for the industries to produce zero defect
products i.e. products with zero non-conformance/zero non-compliance and zero
waste. It is also essential that during production industries should ensure that they
cause zero waste to the environment i.e. zero air pollution/liquid discharge/ solid
waste and zero wastage of natural resources.
Zero defects
Categories in zero defects
1. Definition of zero defects.
2. History of zero defects.
3. Quality tools for zero defects.
4. No mistake criteria in zero defects.
Definition of Zero Defects
Zero Defects is a management tool aimed at the reduction of defects through
prevention. It is directed at motivating people to prevent mistakes by developing a
constant, conscious desire to do their job right the first time. Zero Defects: A New
Dimension in Quality Assurance
History of zero defects
The development of Zero Defects is credited to Philip B. Crosby, a quality
control department manager on the Pershing missile program at the Martin
Company, though at least one contemporary reference credits a small, unnamed
group of Martin employees.
Quality tools for zero defects
Total quality management (TQM)

Quality specifications and costs

TQM Tools: external benchmarking
ISO 9000
Service quality measurement (SQM)
No mistake criteria in zero defects
In zero defect technology there must be no mistake criteria in any work field so
there will be more amount of outcome and zero defects.
In this there is no possibly of doing no mistake but should be reduce the mistake by
more than 60 to 70% of it to get more amount of outcome and also reduce in price.
So after 5 years till 2020 there will be a great success in urban areas.
Zero waste
Categories in zero waste.
1. Definition of zero waste
2. Three Rs use for zero waste
3. Benefits of zero waste
4. Role of society in zero waste
Definition of zero waste
Zero Waste means designing and managing products and processes to
systematically avoid and eliminate the volume and toxicity of waste and materials,
conserve and recover all resources, and not burn or bury them.
Three Rs use for zero waste
1. Reduce :The best way to manage waste is to not produce it. This can be done by shopping
carefully.

2. Reuse :It makes economic and environmental sense to reuse products.

3. Recycle :Recycling is a series of steps that takes a used material and processes,
remanufactures, and sells it as a new product.
Benefits of zero waste
Saving money. Since waste is a sign of inefficiency, the reduction of waste can
reduce costs.
Faster Progress. A zero waste strategy improves upon production processes and
improving environmental prevention strategies which can lead to take larger, more
innovative steps.
Supports sustainability. A zero waste strategy supports all three of the generally
accepted goals of sustainability - economic well-being, environmental protection,
and social well-being
Role of society in zero waste
Industrial Designers have a key part to play in zero waste. Products need to be
designed that are durable, repairable and easily disassembled for recycling and
incorporated back into nature or the industrial system.
Manufacturers have to invest in new design technologies. The creation of products
with minimal waste, reduced packaging, and being responsible for a products
whole life-cycle is significant in the production phase.
Conclusion
At the end the conclusion is to read, understand and put it in our live activities so
we get a good result and it must be helpful to urban areas in developing them till
2020 in India a make our nation at a next level by making it free from defects and
waste!!!!