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Quest for Defect Elimination:
is a full color, graphic novel that provides the basics of defect elimination and shows the quest to achieve fewer defects. I-n the manufacturing world, fewer defects mean better quality, better yield, higher energy efficiency, and fewer machine breakdowns.
In the world of equipment maintenance, fewer defects lead to fewer breakdowns and higher reliability. Almost all the programs to improve production and reliability in the last 40 years have one thing in common. They eliminated defects. Eliminating defects is a quest that will test your grit and strength.
Once on the journey, you will find friends to help you and enemies that will fight you tooth and nail passively and actively. “Quest for Defect Elimination” will prepare you for your unique journey. The key to effective defect elimination is to maintain a steady diet of small projects so that gradually the number of defects entering your process is lower than the number of defects getting removed.
What others say about The Quest for Defect Elimination
Bruce R. Collins, Maintenance Planner / Scheduler, U.S. Army Corps of Engineers: I have been involved in Maintenance Management since the 1970’s and have collected numerous reference books, including several by Mr. Levitt. So when I received my copy of “The Quest for Defect Elimination” I was somewhat surprised by the format. Maintenance Management and Graphic Novels don’t often come together. In this case it works! It is obvious that Mr. Levitt has made this Quest himself, probably multiple times. He accurately describes the many pitfalls along the way, as well as ways around them. All the while reminding us to stick with small, continuous, steps. Defect Elimination is not a “One and Done” it is a process, maybe a lifestyle, and Mr. Levitt reiterates this throughout the book. It is an amusing book with a solid premise. If you are serious about Defect Elimination, following Jenny and Sean will get you there, and if you read it before you start your quest it will save you much pain and frustration. I wish I had read it 40 years ago.
So those are my thoughts. When I first flipped though it I was a little skeptical, but it contained a lot of good information. And, as patronizing as this sounds, it’s in a format the younger people will read. My oldest son is 28 and Mechanical Engineer, he’s a big fan of graphic novels.
William H. Closser, Jr., President, NSGI (Consultancy)
Joel, I read your book. It was an easy read. It also presented some very good principle that are foundational to reliability. When you get right do to it defect elimination is what most practitioners on reliability are trying to achieve.
Product details
- ASIN : B086XG33D9
- Publisher : Springfield Resources; 1st edition (April 8, 2020)
- Language : English
- File size : 29.7 MB
- Print length : Print Replica
- Simultaneous device usage : Unlimited
Innovative way to teach the principles of defect elimination (DE)
Reviewed in the United States on May 25, 2020
This is a very interesting way to present the concept of DE by one of the great authorities in maintenance management. Using a comic book approach, the author presented the journey of two young leaders through the challenges and successes in eliminating defects through low cost, simple, quick and yet long-lasting projects, until they became experts and mentors for the next generation of DE warriors. While easy to read, it provides important lessons and tips useful for a wide range of reliability professionals, ranging from newcomers to seasoned leaders. Highly recommended to all those interested in improving value, increasing productivity, reducing negative impacts on health, safety and environment, and eliminating waste. Bravo!
The Quest for Defect Elimination
Joel Levitt’s “The Quest for Defect Elimination” is a comprehensive guide to improving reliability and productivity in manufacturing and maintenance environments. The book outlines strategies to systematically identify and eliminate defects, thereby reducing breakdowns, improving safety, and enhancing organizational efficiency.
Key Themes and Concepts:
Defining Defects: Defects are anything that erodes value, reduces productivity, compromises safety, or creates waste.
Principles of Defect Elimination: Reliability cannot be achieved solely through preventive maintenance, technology, or investment; it requires reducing defects faster than they are introduced. Prioritize small, actionable improvements with high success probability and minimal resource investment.
The 1% Rule: Devoting 1% of resources to defect elimination can reduce defects by 54% in three years and 73% in six years while avoiding burnout and resource overload.
Process of Defect Elimination: Focus Areas: Address careless work habits, contamination, waste, and the root causes of defects.
Precision Practices: Emphasize precision in installation, alignment, lubrication, and maintenance.
The Defect Elimination Journey: The book narrates a metaphorical journey where characters tackle defects as part of a reliability team. They confront challenges reflecting real-world obstacles in implementing change.
Key Strategies: Start with “low-hanging fruit” defects. Create projects that are simple, affordable, and achievable within 90 days. Focus on small wins to build momentum and foster a culture of continuous improvement.
Impact and Benefits: Reducing defects leads to fewer breakdowns, increased yield, improved product quality, and safer workplaces. Sustained defect elimination transforms organizational culture, builds leadership, and fosters innovation.
The book combines practical advice, motivational insights, and engaging storytelling to inspire reliability professionals and teams to embark on the journey of defect elimination. It emphasizes that progress comes from persistence, precision, and a collaborative culture.
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The Quest for Defect Elimination
is part of a series of books called Elements of Great Maintenance Management
Elements of Great Maintenance Management book series of full-color, fun, humorous graphic novels that demonstrate the basics of Maintenance.
You can see from the covers that these books are unique
There are 8 in the series so far. And by the way, we are writing new ones all the time. Contact me, Joel by email JDL@Maintrainer.com for any questions