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Zero defect manufacturing: state-of-the-art review, shortcomings and future directions in research

Author

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  • Foivos Psarommatis
  • Gökan May
  • Paul-Arthur Dreyfus
  • Dimitris Kiritsis

Abstract

This paper provides a literature review on zero defect manufacturing based on the content analysis performed for 280 research articles published from 1987 to 2018 in a variety of academic journals and conference proceedings. The review summarises the state-of-the-art, highlights shortcomings and further directions in research. Accordingly, we investigated how zero defect manufacturing was implemented and evaluated the main research patterns in the sample by analysing key factors. Based on the extensive review of the zero defect manufacturing literature, we identified and highlighted four distinctive strategies based on overarching themes for zero defect manufacturing, i.e. detection, repair, prediction, and prevention. Evaluation of current research and descriptive analysis highlighted six major shortcomings of current research in zero defect manufacturing: (i) focus on a single strategy instead of a holistic approach for global optima; (ii) certain industries are under-researched; (iii) full potential of industry-academia collaboration is not achieved; (iv) not enough focus on the beginning of manufacturing lifecycle; (v) cost–benefit comparative analysis is not evident; (vi) standard and clear definition of terms are missing. Finally, we presented four further directions in which an advance of the topic would stimulate scholarly and practical needs: (i) shift from local to global solutions; (ii) investigate pros and cons; (iii) role of people and human activities in manufacturing; (iv) new business models for zero defect manufacturing.

Suggested Citation

  • Foivos Psarommatis & Gökan May & Paul-Arthur Dreyfus & Dimitris Kiritsis, 2020. "Zero defect manufacturing: state-of-the-art review, shortcomings and future directions in research," International Journal of Production Research, Taylor & Francis Journals, vol. 58(1), pages 1-17, January.
  • Handle: RePEc:taf:tprsxx:v:58:y:2020:i:1:p:1-17
    DOI: 10.1080/00207543.2019.1605228
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    Citations

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    Cited by:

    1. Daria Kovalevskaya & Ann-Charlott Pedersen & Elsebeth Holmen & Aristidis Kaloudis & Geir Ringen, 2024. "Triads in Lean Management: Analyzing Buyer–Supplier-Supplier and Buyer–Supplier-Supplier’s Supplier Relationships for Zero-Defect Manufacturing," Journal of the Knowledge Economy, Springer;Portland International Center for Management of Engineering and Technology (PICMET), vol. 15(1), pages 616-660, March.
    2. Eirini Katsidoniotaki & Foivos Psarommatis & Malin Göteman, 2022. "Digital Twin for the Prediction of Extreme Loads on a Wave Energy Conversion System," Energies, MDPI, vol. 15(15), pages 1-24, July.
    3. Chang-Ho Lee & Dong-Hee Lee & Young-Mok Bae & Seung-Hyun Choi & Ki-Hun Kim & Kwang-Jae Kim, 2022. "Approach to derive golden paths based on machine sequence patterns in multistage manufacturing process," Journal of Intelligent Manufacturing, Springer, vol. 33(1), pages 167-183, January.
    4. Mochammad Tutuk, 2023. "Mental Workload Analysis of Workers Using the Swedish Occupational Fatigue Index (SOFI) Method at A Job Shop, Sheet Metal, And Pipe Metal Manufacturing Company in Surabaya," Technium, Technium Science, vol. 16(1), pages 411-416.
    5. Rosmaini Ahmad & Rabiatul Fakhira Mohd Amin & Shaliza Azreen Mustafa, 2022. "Value stream mapping with lean thinking model for effective non-value added identification, evaluation and solution processes," Operations Management Research, Springer, vol. 15(3), pages 1490-1509, December.
    6. Metzker Soares, Paula & Thevenin, Simon & Adulyasak, Yossiri & Dolgui, Alexandre, 2024. "Adaptive robust optimization for lot-sizing under yield uncertainty," European Journal of Operational Research, Elsevier, vol. 313(2), pages 513-526.
    7. Laurentiu Rece & Sorin Vlase & Daniel Ciuiu & Giorgian Neculoiu & Stefan Mocanu & Arina Modrea, 2022. "Queueing Theory-Based Mathematical Models Applied to Enterprise Organization and Industrial Production Optimization," Mathematics, MDPI, vol. 10(14), pages 1-32, July.
    8. Gokan May & Foivos Psarommatis, 2023. "Maximizing Energy Efficiency in Additive Manufacturing: A Review and Framework for Future Research," Energies, MDPI, vol. 16(10), pages 1-28, May.

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