Defects are one of the seven wastes of lean manufacturing or 7 mudas, defects are when products or service deviate from what the customer requires or the specification. When you talk about waste most people think of defects rather than the other wastes such as waiting and transportation.
缺陷浪费，是精益生产的七大浪费（或者七大muda）之一，指的是产品/服务偏离客户的要求或者规范。实际上，在谈到浪费时，绝大多数人会想到缺陷，而不是诸如等待及运输之类的其他形式的浪费。
There has been much written regarding the cost of defectives, the reason being that the cost is not always what we perceive it to be. The cost of rejects and rework are often compared to an iceberg; only a small fraction of the true cost being visible above the water level.
关于缺陷成本，已经有大量文章，原因在于：成本，并不是一直如我们所认为的那样。我们通常将不良件和返工的成本比作冰山，而我们只看到了在水面之上的真实成本的一小部分。
In addition to the obvious cost of the initial scrap item we have a number of other costs that are not always obvious or considered although frequently far in excess of this initial cost. The general rule of thumb is to multiply the cost of the scrap by a factor of ten to arrive at the true cost to your business.
除了最初报废项目的显而易见的成本之外，我们还有许多其他方面的成本，这些成本不会一直那么显而易见或者被我们所考虑，实际上，这些成本通常会远远超出最初的成本。惯例是将报废的成本乘以十倍，以达到企业的真实成本。
There are costs associated with problem solving, materials, rework, rescheduling materials, setups, transport, paperwork, increased lead times, delivery failures and potentially lost customers who will take their custom elsewhere.
还有一些与问题解决、物料、返工、重新安排材料、设置、运输、书面工作、交货时间增加、交付失败，以及潜在的失去客户（这些客户将把会把生意带到别处）的成本相关。
Defects can be caused by many different problems, many that should be avoidable with a little thought when designing your products, processes and equipment.
缺陷，可能是由许多不同的问题所导致，在产品、工艺和设备设计时稍加思考的话，缺陷是可以避免的。
Many defects are caused by incorrect method due to non-standard operations, differences in the way that processes are undertaken by different operators on different shifts.
许多缺陷是由于不规范的操作方法所造成的，不同班组的操作员会采取不同的方法。
We also build the opportunity for errors into our products by failing to think about how items can be assembled when we design them, we have components that can be assembled incorrectly if the operators do not align them correctly and so on.
我们在设计产品时，并没有考在错误地考虑如何在我们设计产品时组装产品的机会。如果操作员没有将组件放到正确的位置，那么装配就可能会错误。
We fail to maintain our equipment, machines and fixtures allowing defects to occur.
我们未能去做维护、机器和工装夹具设备，使得缺陷得以出现。
We don’t have a culture that empowers and makes our operators confident enough to highlight problems and allow them to be solved, they often continue and make the best of a poorly fitting component rather than stopping to have either the fixtures or the components corrected.
我们没有授权并让操作员有足够的自信来重点关注问题并予以解决的文化，他们经常会继续装配，并对不合适的组件进行将就处理，而不是停下来去纠正工装夹具或者部件。
We don’t provide training to our people; we throw them straight in at the deep end and tell them to do the same as the guy stood beside them, often the one that was thrown in there the week before.
我们没有给员工提供培训，我们把他们直接扔到“深水区”，告诉他们要和站在旁边的人做一样的事情，通常旁边的人是前一周被扔在“深水区”的。
We also reward the wrong behaviors, paying for quantity rather than quality, encouraging our employees to work as fast as possible and even penalizing them if they do not make the numbers with little thought to the consequences on the quality of our products or services.
我们还奖励错误的行为，为产量而不是质量买单，我们鼓励员工要尽可能快地工作，甚至还会因为他们没能凑齐数量而去惩罚他们，而很少去考虑对产品或服务质量的影响。
缺陷浪费举例
Scrap produced by poorly maintained fixtures.
工装夹具维护不到位所产生的报废。
Parts assembled with the incorrect orientation.
零件装配方向错误。
Missing screws and other fixing due to lack of controls.
由于缺少管理，螺钉与其他固定装置缺失。
Incorrect components used due to incorrect, or missing instructions.
由于作业指南错误或者丢失，使用了错误的组件。
Poorly made components that continued to be made as the employees wanted to reach their performance bonus.
员工为了达到想要拿到的绩效奖金，不良的组件仍然被继续生产出来。
Parts damaged due to excessive handling.
零件因过度处理而损坏。
Faulty parts that have reached the customer.
到达客户端的错误零件。
There are many techniques out there to help you to identify and eliminate wastes; however within lean manufacturing we wish to prevent them occurring in the first place.
有很多方法可以帮助你去识别和消除浪费；在精益生产中，我们希望一开始就防止浪费产生。
This prevention of defects is achieved by a number of different techniques from autonomation / Jidoka (Machines with “human” intelligence that are able to detect when a non standard event has occurred) through to Pokayoke devices that detect if a product is defective, either preventing the process from running or highlighting the defect for action.
这一缺陷的预防，是通过从由自动化（人工智能的机器能够检测非标准事件发生）多种不同的技术实现的，通过防错装置来检测产品是否有缺陷，要么是阻止流程运行，要么是突出所需要采取行动的缺陷。
We also implement standard operations procedures (SOP) and training to ensure that the correct methods are undertaken and standards achieved.
我们还执行标准操作程序（SOP）和培训，以确保正确的方法和标准的实现。
The most important factor however is the empowerment of teams to solve and prevent their own problems. By harnessing the talents of your employees you are able to quickly and efficiently prevent the occurrence of defects.
然而，最重要的因素是赋予团队解决和防止自身问题的能力。通过利用员工的才能，你能够快速有效地防止缺陷的产生。
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