The limitations of Zero
defects are:-
1. Cost – Zero
Defects is known to be extremely costly, in meeting the standards. As the need
and pursuit for perfection is on the extreme, more and more personnel are after
each process which makes the cost to be on the higher side.
2. Employee
perception – Employees might not be ready to cope up with increased
“strictness†levels, which is one of the pre requisite for Zero Defects implementation.
Also employees tend to demoralised due to the excessive pressure the Zero
Defects applies to them.
3. Zero Defects is alleged
to be a non – achievable goal by many experts. Realistically having zero per
cent of defect is somewhat ridiculous, as according to some experts.
4. If Zero Defects is
implemented without sufficient preparations and plans, it can even cause defects
because of the extra stages of increasingly rigorous and expensive inspection and
handling of the products.
5. One of the
pioneers of lean manufacturing, Deming’s 14 points theory is against Zero
Defects. It is said that the 10th point ie. “Eliminate slogans, exhortations, and
target for work force asking for zero defects and new levels of productivity†is
clearly aiming at Zero Defect.
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