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ABSTRACT
Zero Quality Control (ZQC) is a quality control approach for achieving zero defects. ZQC is
based on the principle that defects are prevented by controlling the performance of a process so
that it cannot produce defects, even when a mistake is made by the machine or a human operator.
This is done by combining four basic elements1 : i)source inspection ii) 100 percent inspection
iii) immediate feedback and iv) use of poka-yoke (mistake-proofing) devices. ZQC is widely
gaining popularity in the industry. It is well established in Japan and its practice is catching on in
USA. At the department of mechanical and manufacturing engineering technology at the
University of North Texas, we strongly feel that this important tool needs to be addressed in our
Quality Control class. A plan has been made to cater to this desire, and strategies have been
made to incorporate it in other classes as well.
INTRODUCTION
Shigeo Shingo2 is credited with starting the Zero Quality Control (ZQC) quality system. He was
a leading proponent of statistical process control in Japanese manufacturing in the 1950s, but
became frustrated with the statistical approach as he realized that it would never reduce product
defects to zero. Statistical sampling implies that some products to go untested, with the result
that some rate of defects would always reach the customer. ZQC tries to achieve zero defects in
all products. This helps in maintaining customer satisfaction and loyalty, in reducing the cost
associated with scrap, rework and downtime, and in attaining a companys ability to adopt lean
production methods with smaller inventories.
The majority of the defects that arise inside a factory3 originate in four Ms (Materials,
Machinery, Manpower, Methods) and one I (Information). However most of the defects can be
traced to the people involved in the above sources. Simple mistakes are the most common cause
of defects, and they are the hardest to prevent. Since the goal of ZQC is to prevent all defects,
these simple mistakes must be caught first. ZQC does not point fingers after the mistake has been
made or hassles people to perform better next time. Instead it uses devices to keep errors from
ever turning into defects in the first place. It talks about mistake-proofing the process and not
fool-proofing it. ZQC uses control function that ensures that the necessary conditions are
present to make good products.
The traditional quality improvement cycle1 is Plan, DO, Check (figure 1a).This cycle catches
and corrects defects after they occur, but it cant make sure that work is done according to plan
in the first place. The ZQC approach integrates the Check and Do stages. This gives instant
feedback so problems can be corrected before defects happen.
PLAN
PLAN
CHECK
DOCHECK
DO
POKA-YOKE SYSTEMS
Poka-yoke is Japanese for mistake-proofing. These devices are used either to prevent the special
causes that result in defects, or to inexpensively inspect each item that is produced to determine
whether it is acceptable or defective. A poka-yoke device is any mechanism that either prevents a
mistake from being made or makes the mistake obvious at a
glance. It is used to carry out 100 percent inspection and provides immediate feedback and action
when errors or defects occur. However as Shingo2 himself mentions, these system are a means
and not an end. Simply putting in such devices does not eliminate defects. It has to be supported
by successive checks and self-checks.
Various examples of poka-yoke system can be had from reference 1,2 and 3. Jon Grout4
maintains an elaborate page on this subject matter. Ricard, L.J.5, described an example of a pokayoke device at General Motors (GM). "We have an operation which involves welding nuts into a
sheet metal panel. These weld nuts will be used to attach parts to the car later in the process.
When the operator loads the panel, the weld nuts are fed automatically underneath the panel, the
machine cycles, and the weld nuts are welded to the panel. You must remember these nuts are
fed automatically and out of sight of the operator, so if the equipment jams or misfeeds and there
is no part loaded, the machine will still cycle. Therefore, we have some probability of failure of
the process. An error of this nature is sometimes not detected until we actually have the car
welded together and are about to attach a part where there is not a nut for the bolt to fit into. This
sometimes results in a major repair or rework activity." "To correct this problem, we simply
drilled a hole through the electrode that holds the nut that is attached to the panel in the welding
operation. We put a wire through the hole in the electrode, insulating it away from the electrode
so as it passes throughit will only make contact with the weld nut. Since the weld nut is metal, it
conducts electricity and with the nut present, current will flow through, allowing the machine to
complete its cycle. If a nut is not present, there will be no current flow. We try to control the
process so that the machine will actually remain idle unless there is a nut in place."
Figure 4 shows some examples of poka-yoke devices employed for defect prevention and
detection.
Returns the remaining units when the units being converted do not
represent the same type of physical measurement. For example,
converting "12 joules" (a measure of energy) to "newtons" (a measure
of force) returns "12 meters" (a measure of length).
Other tools are being currently designed keeping in mind the students of mechanical design.
CONCLUSION
ZQC, an important quality tool, is used to achieve zero defects. It combines steps that helps one
to either detect or prevent an error before it becomes a mistake. There are four basic features that
can be attributed to this method. Although it has been used in the manufacturing areas, its use in
a class room setting has not been tested. The mechanical engineering technology program at the
University of North Texas wants the students to be exposed to this powerful tool. They plan to
introduce it in several manufacturing courses and its use in the design courses has just begun. A
software tool to convert units has been completed and has some attractive features. Several such
small tools are being envisioned that would make number retrieval and processing error free. In
turn this would make the design calculation, either by hand or by some other software, less prone
to human error, and which would capture the spirit of ZQC.
REFERENCES
1. Productivity Press; Mistake Proofing for operators; Portland, Oregon.
2. Shingo, Shigeo; Zero Quality Control: Source Inspection and the Poka-Yoke system;
Productivity Press, Portland, Oregon.
3. Hirano, Hiroyuki; Poka-Yoke: Mistake Proofing for Zero Defects, PHP Institute Inc., New
York.
4. Grout, J.R. , Edwin L. Cox School of Business, Southern Methodist University, Dallas, TX .
5. Ricard, L.J., "GM's just-in-time operating philosophy", in: Y.K. Shetty and V.M. Buehler,
(Eds.)., Quality, Productivity and Innovation. Elsevier Science
Publishing, New York.
BIOGRAPHICAL INFORMATION
RATAN KUMAR obtained a BME in Mechanical Engineering from Jadavpur University (India), ME in Nuclear
Engineering from the University of Florida and doctorate in Nuclear/Mechanical Engineering from University of
Florida. He has worked as a Mechanical Engineer for three years and since 1992 has taught at American Technical
Institute and currently at the University of North Texas.
GEORGE W. WATT obtained a BS in Mechanical Engineering from the University of Wyoming, MS From the
Air Force Institute of Technology in Aerospace Engineering, and doctorate in Metallurgical Engineering from Ohio
State University. He spent 23 years in the US Air Force and has taught at Utah State University and currently at the
University of North Texas since leaving the USAF in 1985.