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ZDQ is a process to insure 100% defect-free quality at the source – which means, 100% quality management on the process, 100% of the time, as the product is made.
Much more effecting than traditional quality inspection methods, ZDQ has 2 parts and 4 levels of Quality Control:
Level 1 Mistake Proofing = eliminating sources of product defects;
Level 2 Mistake Proofing = preventing defects from being made;
Level 3 Fail Safing = detecting a defect as soon as it’s made (line stop); and,
Level 4 Fail Safing = managing the defect that is made (countermeasures).
Mistake proofing, or its Japanese equivalent poka-yoke (pronounced PO-ka yo-KAY), is the use of any automatic device or method that either makes it impossible for an error to occur or makes the error immediately obvious once it has occurred.
You should use Mistake Proofing:
When a process step has been identified where human error can cause mistakes or defects to occur, especially in processes that rely on the worker’s attention, skill or experience.
In a service process, where the customer can make an error which affects the output.
At a hand-off step in a process, when output or (for service processes) the customer is transferred to another worker.
When a minor error early in the process causes major problems later in the process.
When the consequences of an error are expensive or dangerous.
Benefits to your organization:
CITEC delivers ZDQ as a workshop with implementation at your organization over a period of 3 – 5 days for your employee team. It is also one of the topics covered during CITEC's Lean White Belt certification program.
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