ZERO DEFECT

A buzz word or reality?

Fefco Technical Seminar 2013
Wilbert Streefland
Technology Coaching BvbA
There is nothing that is a more certain sign of
insanity than to do the same thing over and over
and expect the results to be different
Albert Einstein
2
Zero Defect
Conclusion
Zero Defect & Innovation
Zero Defect & Quality
Zero Defect & Knowledge
Zero Defect & Culture
Introduction Zero Defect
3
Customer/Supplier & Zero Defect
The customer presented his
requirements
Can the box plant supply accordingly?
The machine suppliers showed what
they have available
Does this help to solve the current issues
between customer and box plant?
ZD & Introduction
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Introduction Zero Defect
How many of you have made mistakes since
waking-up this morning?
If Zero did you do anything?
We all make mistakes every day!
At best we can extend the time between
consecutive mistakes
The best way to achieve a longer time between
consecutive mistakes is to record every mistake
we make and learn how to avoid them
ZD & Introduction
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Zero Defect
Definition
Infinite Time until the
next Defect to occur
ZD & Introduction
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The impact of a defective product?
Use risk engineering:
What will be the impact of a failing product?
Fatal accident or injury
Loss of production or product
Reputation damage
How much do we invest to detect/avoid failing
products?
Analyse the product failing interval. This in time
and number of products produced
Do we provide training?
The biggest risk is: Ignorance
ZD & Introduction
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Zero defect interpretations
1. Focus only on zero defect products send
to the customer
2. Focus on all raw materials converted to
zero defect products at maximum
production speed
Interpretation 1 results in waste!
ZD & Introduction
Customer
All
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The way to Zero Defect:
Process variability at target level
< (smaller)
Customer agreed tolerances
This for all property tolerances agreed
with the customer
ZD & Introduction
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Zero Defect
Custom or Standard product
Process capabilities set the standard for
what can be promised in terms of Zero
Defect targets
The process needs upgrading if it is not
meeting customer requirements
Investment in higher level process!
(Training, machines, retrofits etc.)
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ZD & Introduction
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Zero Defect
Conclusion
Zero Defect & Innovation
Zero Defect & Quality
Zero Defect & Knowledge
Zero Defect & Culture
Infinite Time until the
next Defect to occur
Introduction Zero Defect
11
Zero Defect & Culture
Follow the airline principle:
A pilot is never blamed if a major problem occurs so
he will provide all information freely needed to
investigate the case
The exception is in case of proven negligence, fraud
and or deception
Management need to allow the making of mistakes
else you can't detect and avoid them
No Blame Culture!
ZD & Culture
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Zero Defect
Conclusion
Zero Defect & Innovation
Zero Defect & Quality
Zero Defect & Knowledge
No Blame! Zero Defect & Culture
Infinite Time until the
next Defect to occur
Introduction Zero Defect
13
Believing or Knowing
Why?
..is a box plant supplier allowed to
agree tolerances with a box plant
customer not understanding the box
plant process variability?
..is a box plant customer asking for
Zero Defect products without a list of
parameters and targets for these
parameters?
..are box plants understanding so little
and believing so much?
ZD & Knowledge
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What is knowledge?
Theory
Knowledge
and Insight
Experience
The right
combination of
experience, evidence
and theory allows to
develop knowledge
and insight
ZD & Knowledge
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Long time between
two defects

Short time between
two defects
Relation between Knowledge
and Defects
Knowledge about
what you are doing

Believing that you
know what you are
doing
ZD & Knowledge
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Zero Defect
Conclusion
Zero Defect & Innovation
Zero Defect & Quality
Quantitative tests,
Observations, Training
Zero Defect & Knowledge
No Blame! Zero Defect & Culture
Infinite Time until the
next Defect to occur
Introduction Zero Defect
17
What is current practise?
All box plants have a lab facility with
measuring equipment
For what is the lab facility used?
1. To check the board grade of a
competitor box?
2. When there is a customer complaint?
3. To systematically monitor product
performance?
ZD & Quality
Lets look at the box plant process
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Box Plant Process
All elements need to Pass for Zero defect
Substrate
Corrugating Printing Die Cutting Folding
BCT
Erection
# Boxes
On time delivery
Etc.
Fishtailing
Gap
Glue
Box Dimension
Etc.
Colour
Grade
Moisture
Strength
Delaminating
Etc.
Box
(Customer)
ZD & Quality
All elements need a quantitative
and measurable specification
Board grade
Calliper
ECT
FCT
No Wash Boarding
No Warp
Bond
Etc.
Colour to colour
register
Dot size
Colour target
Colour variation
Bar-code readable
Defects
Edge Sharpness
Etc.
Print to die cut
register
Box Dimension
Scoring depth
Cutting
Cracking
Etc.
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Box Plant Process
All elements need to Pass for Zero defect
Substrate
Corrugating Printing Die Cutting Folding Box
(Customer)
If one element fails then the total box fails!
ZD & Quality
BCT
Erection
# Boxes
On time delivery
Etc.
Fishtailing
Gap
Glue
Box Dimension
Etc.
Colour
Grade
Moisture
Strength
Delaminating
Etc.
Board grade
Calliper
ECT
FCT
No Wash Boarding
No Warp
Bond
Etc.
Colour to colour
register
Dot size
Colour target
Colour variation
Bar-code readable
Defects
Edge Sharpness
Etc.
Print to die cut
register
Box Dimension
Scoring depth
Cutting
Cracking
Etc.
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Zero Defect & Quality
Important about Acceptable Quality!
Quality is a True/False property. Better
than 100% is not possible high quality
is a buzz word!
Measure properties at regular interval
For destructive measurements use a
product that is produced weekly
Do not take one measurement of all products
Take regular many measurements of a few
regularly produced products it will provide
the process quality assurance evidence
needed for zero defect production
ZD & Quality
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A closer look at variability and the
impact reducing it
1. Determine process variability by systematic
measuring e.g. WARP
2. Reduce process variability by implementing
working standards and procedures
(magenta curve). Resulting in:
Increased product level
Variation reduction
3. Lower specification while the product
performance still meets customer demands
(Yellow curve)
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Step 1 Step 2
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ZD & Quality
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It is a must to understand the relation between process
variables and product quality
A feed-forward closed loop is not common available yet!
Extending time between Defects
What is current practise?
Measure properties
Decide if properties are
within customer tolerance
Eject if not!
Next product produced might
need again ejection because
process was not corrected
Waste is produced
What would be better to do?
Agree tolerances
Set control limits (lower than
agreed tolerance)
Measure properties, preferably
in line
Adjust process setting when
outside control limits
Next product is always within
tolerance No waste
ZD & Quality
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Zero Defect
Do and Donts, 2 examples
1. Colour case The wrong solution for a
problem?
2. Folding case Does measuring and
ejecting solve the problem?
ZD & Quality
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1 Colour Case
What has the largest impact on colour?
On an off line printer a spectrophotometer and colour
matching software was used to correct the ink formulation
before starting production due to colour deviations
This only corrects the consequence of a process defect
but not the reason
Downtime evaluation on this off line printer revealed:
33% colour related downtime of the total production
time
The implemented working procedure for correcting colour
on the press is the source for high downtime
Tests showed that the main problem for the start-up colour
deviation was the screen roll specification and
unpredictable status
ZD & Quality
The target:
Print all sheets Zero Defect starting with the first
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Colour case solution
Screen roll related ink transfer problems result in:
Unpredictable colour!
Unpredictable dot gain!
Change the screen roll specification to an ink film
thickness and line count allowing:
Releasing the ink
Being cleanable
Implement strict screen roll cleaning procedures
Check everyday the screen roll on cleanliness
ZD & Quality
Colour related downtime reduced to 0%!
Colour was printed with Zero defect
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2 Folding Case
What is the problem?
Inline data collection
In depth Analysis
Gap fishtailing simulation
ZD & Quality
Lead Edge
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What is the problem?
Gap at the glue flap not under control + Skew + Alignment edge
ZD & Quality
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Folding data of 3,200 boxes
Lead/Trail edge Gap
Le ad Edge
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ZD & Quality
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Fishtailing
Is this approach OK or is it Lottery data?
What happens to the faulty product?
What can be done to reduce variability?
What is really happening?
Fis h Tailing
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ZD & Quality
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Feeding skewed board using trim knife
Skewed 1
Skewed
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ZD & Quality
Skewed 1
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In depth folding analysis
(No trim knife used!)
Max 3.10 Max 2.00
Min -3.11 Min -5.00
Avg 0.00 Avg -1.90
Avg GP -2.14 Std 3.09
Avg GL 2.14
Std 2.23
Skew/m -3.51
Raw data
Cor. Data Cor. CPD,
PD Slot
Max 6.78 Max 1.92 Max 0.96 Max 1.47 Max 1.26 Max 0.57
Min -0.07 Correction Min -0.28 Correction Min -1.18 Correction Min -0.40 Correction Min -0.32 Correction Min -4.30
Avg 3.28 3.28 Avg 0.56 0.56 Avg 0.00 0.00 Avg 0.45 0.45 Avg 0.50 0.50 Avg -2.76 -2.76 2.32
Avg 1357 1.56 1.56 Avg Pos 3 0.20 0.20 Avg Pos 5 0.00 0.00 Avg Pos 7 0.64 0.64 Avg 1357 0.33 0.33 Prediction: -6.71
Avg 2468 5.00 5.00 Avg Pos 4 0.93 0.93 Avg Pos 6 0.00 0.00 Avg Pos 8 0.27 0.27 Avg 2468 0.67 0.67
Std 2.02 Std 0.49 Std 0.40 Std 0.38 Std 0.38 Std 1.03 1.03 1.06
Skew/m -4.52 Skew/m -0.96 Skew/m 0.00 Skew/m 0.49 Skew/m -0.45
Raw Data
CPD feed
corrected
PD feed
corrected
Cor. Data Cor. CPD,
PD Slot
Glue Lash A Avg -0.25 -0.17 0.16 0.24 0.19
Std 0.12 0.10 0.12 0.10 0.12
Glue Panel B Avg -0.21 -0.24 0.19 0.16 0.18
STD 0.07 0.08 0.08 0.08 0.08 Prediction Raw data
Cor. Data Cor. CPD,
PD Slot
Edge 1, 3, 5, 7: Max 1.81
Min -7.52
Edge 2, 4, 6, 8: Max 0.60
Min -5.77
Avg ALL: 2.56 -2.65
Avg Edge 1, 3, 5, 7: 3.08 -3.15 -4.72 -5.27
Delta Glue panel: Delta short panel: Delta long panel Delta glue Lash Std Edge 1, 3, 5, 7: 2.46 2.11 2.30
ALL: -2.72 ALL: -0.56 ALL: 0.45 ALL: 0.05 Avg Edge 2, 4, 6, 8: 2.03 -2.15 -7.14 -5.15
Edge 1, 3, 5, 7: -1.36 Edge 1, 3, 5, 7: -0.20 Edge 1, 3, 5, 7: 0.64 Edge 1, 3, 5, 7: -0.31 Std Edge 2, 4, 6, 8: 1.73 1.36 1.69
-4.07 -0.93 Edge 2, 4, 6, 8: 0.27 Edge 2, 4, 6, 8: 0.41 Edge 2, 4, 6, 8: Edge 2, 4, 6, 8:
Panel Angel Results
Gap results
Drive Side Edge Pos 1b (Glue Panel)
-5 -4 -3 -2 -1 0 1 2 3 4 5
Error in mm
Drive Side Edge Pos 2b (Glue Panel)
-5 -4 -3 -2 -1 0 1 2 3 4 5
Error in mm
Slot 1, Pos 3, CPD Variation
-5 -4 -3 -2 -1 0 1 2 3 4 5
Error in mm
Slot 1, Pos 4, CPD Variation
-5 -4 -3 -2 -1 0 1 2 3 4 5
Error in mm
Slot 2, Pos 5, CPD Variation
-5 -4 -3 -2 -1 0 1 2 3 4 5
Error in mm
Slot 2, Pos 6, CPD Variation
-5 -4 -3 -2 -1 0 1 2 3 4 5
Error in mm
Slot 3, Pos 7, CPD Variation
-5 -4 -3 -2 -1 0 1 2 3 4 5
Error in mm
Slot 3, Pos 8, CPD Variation
-5 -4 -3 -2 -1 0 1 2 3 4 5
Error in mm
OS, Pos 1a (Glue Lash)
-5 -4 -3 -2 -1 0 1 2 3 4 5
Error in mm
OS, Pos 2a (Glue Lash)
-5 -4 -3 -2 -1 0 1 2 3 4 5
Error in mm
Edge to first colour PD, Glue Panel
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Edge 1357
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Edge to first colour PD, Glue Lash
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Edge 1357
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Gap, Pos 1
-12 -9 -6 -3 0 3 6 9 12
Error in mm
Gap, Pos 2
-12 -9 -6 -3 0 3 6 9 12
Error in mm
Fishtailing
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Slot Var., PD, Edge, Pos.: 6
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ZD & Quality
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Correcting the fishtailing for
the feeding error
h values
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h Skew Corrected
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ZD & Quality
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Folding Case
Data collected inline will show if there is a
problem but not the problem source
Detailed testing of production equipment is
needed to find the problem source
Ejecting bundles will avoid problems at the
customer Is that the best option for Zero
Defect product?
Do we know what folding tolerances are
acceptable?
ZD & Quality
What about a folding error simulation?
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What folding tolerances are machine
suppliers promising and what is delivered?
Check during machine commissioning if the
supplier delivers what is promised?
The next slide will show a mathematical
simulation on how gap and fishtailing are
affected by:
Feed variation
Skew (Due to a feed skew)
Slot position
Glue lash position
Glue panel position
ZD & Quality
35
Folding Error Simulation

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ZD & Quality
36
Specification
Quantitative
Based on facts and figures
Represent the objectives to achieve
Realistic tolerance based on the capabilities of:
Process
Equipment
Raw materials
Measurable Measuring equipment that has
sufficient resolution to detect if the property is
inside or outside the set tolerance
Measuring is done systematically and not only when there is a complaint!
ZD & Quality
37
Always agree SMART targets
S Specific
M Measurable
A Achievable
R Realistic
T Timed
ZD & Quality

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38
Zero Defect
Conclusion
Zero Defect & Innovation
SMART Target Zero Defect & Quality
Quantitative tests,
Observations, Training
Zero Defect & Knowledge
No Blame! Zero Defect & Culture
Infinite Time until the
next Defect to occur
Introduction Zero Defect
39
Zero defect & Innovation
The paradox
Innovation is based on the evolution of
correcting mistakes
Would avoiding defects stop Innovation?
According Murphys law it is likely that
(unknown) defects will continue to occur
At best we can extend the time between
the events!
ZD & Innovation
AndNew technology might be needed to improve
40
Zero defect & Innovation
What can be used now and in 2025
How to produce Zero Defect if testing
damages the product?
Is it possible to investigate paper and
board non destructive?
We know CT scanning for medical
use
Inside Matters, a University Gent
spinoff company, make CT scans of
any material and/or object
CT scanning of paper and board
will provide new ways for
detecting defects!
ZD & Innovation
41
CT scan of wood
ZD & Innovation
42
CT scans paper
3D image 2D cross section
Ink
ZD & Innovation
43
CT scans corrugated board
3D image 2D cross section
ZD & Innovation
44
Zero Defect
Conclusion
New technology will
support improvement
Zero Defect & Innovation
SMART Target Zero Defect & Quality
Quantitative tests,
Observations, Training
Zero Defect & Knowledge
No Blame! Zero Defect & Culture
Infinite Time until the
next Defect to occur
Introduction Zero Defect
45
# of defects
C
o
s
t
Production
Cost
Sales cost
Conclusion
Zero Defect might be a ghost objective at
best the time between two detectable
defects can be extended
Minimizing defects will reduce cost for all up
to a certain level after that the customer and
supplier have to understand the economics
It requires:
Open fact based mind set
Specifications that confirm quality targets
No blame mentality
Responsibility for what you claim
Accepting the need for changes
New technology
Training and education
ZD & Conclusion
There are no shortcuts to Zero Defect
only detours
0
46
Zero Defect
There are no shortcuts
to Zero Defect only
detours
Conclusion
New technology will
support improvement
Zero Defect & Innovation
SMART Target Zero Defect & Quality
Quantitative tests,
Observations, Training
Zero Defect & Knowledge
No Blame! Zero Defect & Culture
Infinite Time until the
next Defect to occur
Introduction Zero Defect
Thank you for your attention
Wilbert Streefland
Technology Coaching BvbA
www.tcbvba.be