Spearheading Project Zero Defects

For decades the idea of reaching absolute zero defects in manufacturing has eluded many. Thought by some to be simply a fantasy, and by many others, not worth the extensive time, resource and cost to achieve it. At The Spearhead Group, we are not easily persuaded that things are impossible, and so we are putting our time and resources towards the goal of reaching zero defects into everything that we do.

Typically, random inspections are employed at production sites, most commonly Final Random Inspections (FRI). These inspections analyze goods after they are produced and ready to leave a factory site. FRI’s use a pre-determined sampling size, supported by statistical calculations. Inspection pass or fail grades are based on the threshold of a particular number of defects in the sample batch – the Acceptable Quality Level(AQL). This means there is predetermined a number of defects a customer must accept before production even begins. This is simply the reality of how inspections have been conducted.

This is why Spearhead is launching Project Zero Defects, an ongoing quality R&D program targeting the goal of zero defects in production. To help us in this quest we will be enlisting and collaborating with some of the best experts in the field of quality control, production management, and engineering automation – to name a few.

Project Zero Defects will have many phases in its journey towards zero defects; we recognize the magnitude and significance of what Spearhead is attempting here and we know it will not be an easy task. What we can say, however, is that our goal is to not tell our clients that “some defects are inevitable and must be accepted”. Allowing “Acceptable Quality Levels” (AQLs) of defects to pass through production and into customers hands is an old standard and we want to lead the charge on updating it.” – Robert Catalano, Co-Founder and President of The Spearhead Group

Project Zero Defects is a bold step towards theoretical perfection. As a quality assurance and compliance expert for over 20 years, I know the challenges faced here will require a massive effort to achieve Zero Defects in production, and I am happy to take the lead on this project for Spearhead. I believe this is yet another example of Spearhead taking on innovation in more than just new product design applications, but also into taking on the serious ongoing challenges of quality control and customer satisfaction. I am looking forward to the challenge.” – Tom Harney, QA & Compliance, Advisory Board Member, Project Zero Defects, The Spearhead Group


About Tom Harney:

Tom Harney has more than 30 years of experience in the consumer products industry with a focus on creating new client relationships and growing the existing business. His technical knowledge allows him to guide customers in making better business distribution decisions to ensuring compliance with global partners.

As a certified ASQ/CQA, CMI, CQT, and ISO 9000 Lead Assessor, Tom is also proficient in ASTM, CFR, AATCC, ANSI, CHPA, FDA, ANSI/ASQ Z1.4, BIFMA, and ISTA standards.


About Spearhead:

With more than 45 years of collective experience designing and delivering memorable Physical Brand Enhancements that make a lasting impact, we understand the importance of a customer’s connection to a particular brand.

Companies choose The Spearhead Group because they know we are invested in all aspects of the process. We bring a unique and personable approach to each and every brand we represent and work towards ensuring ROI on PBE activities.