Zero defect manufacturing in 2024: a holistic literature review for bridging the gaps and forward outlook

Abstract

This study conducts a comprehensive review and analysis of zero defect manufacturing (ZDM), a strategic and imperative approach in manufacturing, aiming at eliminating defects to enhance product quality and sustainability. It bridges theoretical concepts with practical applications, identifying gaps in current ZDM strategies and advocating for the integration of predictive, preventive, and production scheduling approaches. Despite existing individual strategies, a need for cohesive frameworks emerges to fully leverage ZDM's potential. Accordingly, we propose an integrated ZDM framework representing a significant advancement beyond current fragmented solutions. This framework emphasises the synergy between ZDM strategies and critical manufacturing processes, offering a comprehensive pathway to ZDM objectives. We stress the economic benefits, effective risk management, and the imperative of workforce training for ZDM success. Advocating for standardised methodologies, enhanced risk protocols, and comprehensive training, our study demonstrates their feasibility and effectiveness. We call for global collaboration and interdisciplinary research to overcome identified challenges, propelling ZDM towards manufacturing excellence with zero defects. This approach not only promises to elevate product quality and operational efficiency but also establishes new benchmarks for sustainability and economic viability. By addressing research gaps and offering actionable solutions, our study advances ZDM discourse, promoting broader adoption and implementation across industries.