Advancing zero defect manufacturing: A state-of-the-art perspective and future research directions

Abstract

Zero Defect Manufacturing is a disruptive concept that has the potential to entirely reshape the manufacturing ideology. Building on the same quality management philosophy that underpins both lean production and Six Sigma, the Zero Defect Manufacturing paradigm has in recent years developed significantly, given the onset of Industry 4.0 and the increasing maturity of its digital technologies. In this paper, we review contemporary advances in Zero Defect Manufacturing using structured literature review. We explore emergent themes and present important directions for future development in this continuously emerging field of research and practice. We highlight two specific Zero Defect Manufacturing strategy types: defect prevention, and defect compensation; as well as identify two important themes for future ZDM research, namely advancing ZDM research (particularly with a view to progressing from zero-defect processes to zero-waste value chain strategies) and overcoming the global application challenges of ZDM (with emphasis on cyber-security and the extension of defect prevention and compensation strategies to less explored manufacturing processes).