March 7, 2025 Aerospace, Uncategorized What is the industry adopted ‘Zero Defects’ buzz and how does it benefit your business? Adopting a zero defects mentality and approach is essential for the long-term survival of the civil aerospace sector. The ‘Zero defects’ approach is a mindset that is underpinned by tools and techniques employed throughout the Design and Manufacture of Aerospace product. When considering creating a structured process to support Zero Defects then Aerospace Standard AS9145 defines Aerospace requirements for Advanced Product Quality Planning (APQP) and Production Part Approval (PPAP). This standard provides a more comprehensive approach for planning for product quality with the benefit that it embeds the key elements of the Zero defects approach. The message from Rolls-Royce seems to be clear. They are enjoying the benefits of Zero defects gained by implementing Advanced Product Quality Planning and they are promoting its use by the supply chain. APQP benefits the supply chain, it benefits Rolls-Royce, and it benefits the customers of Rolls-Royce. “Zero Defects” is a quality management philosophy that was embraced by Rolls-Royce to ensure the highest level of precision and quality in its products, particularly in the manufacturing of aircraft engines. The concept originates from the idea of striving for perfection by minimising errors and defects to the point of complete elimination. In the context of Rolls-Royce, “Zero Defects” means: Aiming for perfection: Every part, process, and product must meet the most stringent standards, with no tolerance for defects, whether in design, manufacturing, or assembly. Continuous improvement: The philosophy encourages a culture of continuous improvement where employees are empowered to suggest improvements and are involved in identifying and solving problems to prevent defects. Prevention over inspection: Instead of relying solely on inspection to catch defects after they occur, Rolls-Royce emphasises designing processes and systems that prevent defects from happening in the first place. Customer satisfaction: Zero defects translates to delivering products with no flaws, thus ensuring customer satisfaction and safety, which is critical in the aviation industry, where even the smallest error can have serious consequences. By adopting this mindset, Rolls-Royce aims to maintain its reputation for producing high-quality, reliable, and safe engines that meet the exacting standards of the aerospace industry. Industry Forum can support your organisations drive towards Zero defects with training courses covering Design/Process FMEA & Control Plan, MSA, Process Control and Problem Solving. We also offer training and consultancy for AS9145.
