--- title: Best Practices to Achieve Zero Defects description: The following checks and balances ensure that a complex electronics build can be completed on time, on budget and with zero defects. Each practice in the process allows for corrections to occur real time, instead of discovering them at the end. image: https://info.zentech.com/hubfs/DSC03284.jpg --- - [Contact Us](https://www.zentech.com/contact) (443) 348-4500 - [Customer Login](http://207.87.225.180/portal/) - [Blog](https://info.zentech.com/blog) - [News](https://www.zentech.com/news/) - [Facebook](https://www.facebook.com/ZentechManufacturing/) - [Twitter](https://twitter.com/zentechman) MENU [![Zentech Manufacturing, Inc](https://info.zentech.com/hubfs/Zentech_May2018/images/zentech-logo.png)](https://www.zentech.com) X - [Blog](https://info.zentech.com/blog) - [News](https://www.zentech.com/news/) - [Facebook](https://www.facebook.com/ZentechManufacturing/) - [Twitter](https://twitter.com/zentechman) - [Contact Us](https://www.zentech.com/contact) (443) 348-4500 - [Customer Login](http://207.87.225.180/portal/) ![Banner Image](https://info.zentech.com/hs-fs/hubfs/Zentech_May2018/images/top-page-banner.jpg?width=2000&height=176&name=top-page-banner.jpg) # Best Practices to Achieve Zero Defects Posted by [Stephanie Weaver](https://info.zentech.com/blog/author/stephanie-weaver) on Tue, Jul 17, 2018 @ 11:40 AM - [Tweet](https://twitter.com/share) ![DSC03284](https://info.zentech.com/hs-fs/hubfs/DSC03284.jpg?width=300&name=DSC03284.jpg)The following checks and balances ensure that a complex electronics build can be completed on time, on budget and with zero defects. Each practice in this process allows for adjustments or corrections to occur real time, instead of discovering them at the end of the build or worse, when it's already arrived at the end user.   1. **New Product Introduction** To make your product a success, you need to ensure reliability and optimum functionality of the final product. If your company simply takes the data provided and immediately fabricates the product with no [careful study](https://info.zentech.com/blog/new-product-introduction-contract-manufacturing-is-a-partnership) of the data, materials or process, it will most likely result in faulty products and leaves you with unhappy customers. Careful review of the data before the manufacturing begins is extremely important. 1. **Planning and Scheduling** The following [planning and scheduling](https://info.zentech.com/blog/best-practices-for-task-order-execution) processes are essential: - Assembly Instructions (AI): actual detailed instructions used to assemble the product. These are generated during the New Product Introduction process. - Production Lot Traveler (PLT): This process is like a road map, containing the consecutive operations required to fabricate/assemble/inspect/test each item. - Master Schedule: The process flow is outlined in the Master Schedule for each assembly. There should be a standard production flow from Kit Pull through End Item Delivery. Each item must be defined through company work instructions, standard operating procedures, and other command media. 1. **Multiple Inspections, Testing & Reporting** Inspections and testing should be multiple and strategically placed throughout the manufacturing process. Inspections that should be considered: - Incoming component inspections - FAI – First Article Inspection - AOI – Automated Optical Inspection - 4D Flying Probe - Other Testing such as ICT (In Circuit Test), functional and environmental testing - During the assembly process, problems resulting from in process and final inspections must be recorded on Inspection Defect Reports. Production reports showing yield rates, types of defects, and number of defects should also be generated. 1. **QMS System** All quality functions should be controlled under a Quality Management System (QMS) which is certified to ISO 9001-2015, ISO 13485 or AS9100 Standards. These systems should also be audited by outside auditors two times each year to ensure that all manufacturing processes meet the latest ISO requirements. 2. **Certifications & Compliance** [Certifications](https://info.zentech.com/blog/in-electronics-manufacturing-highly-certified-matters) demonstrate the commitment to excellence of a contract manufacturer. Certifications provide a level of (objective) accountability and ensure that the contract manufacturer remains compliant with current industry standards, regulations, and best-practices which directly impact the quality and reliability of the products and services that the electronics contract manufacturer provides. The following is a list of key certifications and compliance standards that allow your company to stand out from the others. - [NIST 800-171 compliance](https://info.zentech.com/blog/zentechs-matt-turpin-interviewed-on-nist-800-171) - [AS5553 Counterfeit Mitigation Compliant](https://info.zentech.com/blog/best-practices-to-protect-your-company-from-counterfeit-electronic-components) - ITAR registered - AS9100 - [IPC-A-610 Qualified Manufacturers Listing](https://info.zentech.com/blog/zentech-first-to-recertify-for-ipc-qualified-manufacturers-listing) - IPC-J-STD-001 Space Addendum - ISO 13485 - ISO 9001 **About Zentech**: Zentech Manufacturing, Inc. is a privately held, [engineering-driven](http://et1.getsidekick.com/e1t/c/5/f18dQhb0S7lC8dDMPbW2n0x6l2B9nMJW7t5XX48p-Yr-W8rBslF2zhL3CW8qlQyH56dF9cf3hBFNv02?t=&si=4782377452830720&pi=d3a6f877-6386-491f-8866-073fe25c1e10) contract manufacturer specializing in the design and manufacture of highly-complex electronic and RF circuit cards and assemblies. The company is headquartered in its purpose-built facility located in Baltimore, MD, and in Fredericksburg, VA, and maintains several [key certifications, ](https://info.zentech.com/blog/in-electronics-manufacturing-highly-certified-matters)including ISO 9001:2008, ITAR (US State Dept.), AS9100 (aerospace), and ISO 13485 (medical). In addition, Zentech is a certified IPC Trusted Source supplier for Class 3 mission-critical electronics, and the company is IPC J-STD-001 Space Addendum QML certified and is now [NIST 800-171 compliant](https://info.zentech.com/blog/zentechs-matt-turpin-interviewed-on-nist-800-171). Zentech Fredericksburg operations is also a Mid-Atlantic leader in the [fabrication](https://info.zentech.com/blog/beyond-just-pcbs-zentechs-wide-range-of-manufacturing-solutions) of wire harnesses and over-molded cables for harsh environments. [![Zentech Baltimore Video Tour](https://no-cache.hubspot.com/cta/default/165279/9037aa1e-8b86-4102-966f-f87ef13af1ba.png)](https://cta-redirect.hubspot.com/cta/redirect/165279/9037aa1e-8b86-4102-966f-f87ef13af1ba)  [![Zentech Fredericksburg Video Tour](https://no-cache.hubspot.com/cta/default/165279/9520910a-b642-4882-a2fb-bd691f15e260.png)](https://cta-redirect.hubspot.com/cta/redirect/165279/9520910a-b642-4882-a2fb-bd691f15e260) ### Archives - [February 2024 (1)](https://info.zentech.com/blog/archive/2024/02) - [January 2024 (1)](https://info.zentech.com/blog/archive/2024/01) - [December 2023 (1)](https://info.zentech.com/blog/archive/2023/12) - [November 2023 (2)](https://info.zentech.com/blog/archive/2023/11) - [August 2023 (2)](https://info.zentech.com/blog/archive/2023/08) - [July 2023 (1)](https://info.zentech.com/blog/archive/2023/07) - [June 2023 (2)](https://info.zentech.com/blog/archive/2023/06) - [May 2023 (4)](https://info.zentech.com/blog/archive/2023/05) - [May 2021 (1)](https://info.zentech.com/blog/archive/2021/05) - [January 2021 (1)](https://info.zentech.com/blog/archive/2021/01) - [August 2020 (2)](https://info.zentech.com/blog/archive/2020/08) - [March 2020 (1)](https://info.zentech.com/blog/archive/2020/03) - [February 2020 (3)](https://info.zentech.com/blog/archive/2020/02) - [January 2020 (2)](https://info.zentech.com/blog/archive/2020/01) - [November 2019 (1)](https://info.zentech.com/blog/archive/2019/11) - [September 2019 (2)](https://info.zentech.com/blog/archive/2019/09) - [August 2019 (3)](https://info.zentech.com/blog/archive/2019/08) - [July 2019 (1)](https://info.zentech.com/blog/archive/2019/07) - [June 2019 (1)](https://info.zentech.com/blog/archive/2019/06) - [May 2019 (4)](https://info.zentech.com/blog/archive/2019/05) - [March 2019 (1)](https://info.zentech.com/blog/archive/2019/03) - [February 2019 (4)](https://info.zentech.com/blog/archive/2019/02) - [January 2019 (1)](https://info.zentech.com/blog/archive/2019/01) - [December 2018 (2)](https://info.zentech.com/blog/archive/2018/12) - [November 2018 (1)](https://info.zentech.com/blog/archive/2018/11) - [October 2018 (1)](https://info.zentech.com/blog/archive/2018/10) - [September 2018 (3)](https://info.zentech.com/blog/archive/2018/09) - [August 2018 (1)](https://info.zentech.com/blog/archive/2018/08) - [July 2018 (2)](https://info.zentech.com/blog/archive/2018/07) - [June 2018 (2)](https://info.zentech.com/blog/archive/2018/06) - [May 2018 (3)](https://info.zentech.com/blog/archive/2018/05) - [April 2018 (2)](https://info.zentech.com/blog/archive/2018/04) - [March 2018 (4)](https://info.zentech.com/blog/archive/2018/03) - [February 2018 (5)](https://info.zentech.com/blog/archive/2018/02) - [January 2018 (4)](https://info.zentech.com/blog/archive/2018/01) - [November 2017 (2)](https://info.zentech.com/blog/archive/2017/11) - [October 2017 (2)](https://info.zentech.com/blog/archive/2017/10) - [September 2017 (2)](https://info.zentech.com/blog/archive/2017/09) - [August 2017 (9)](https://info.zentech.com/blog/archive/2017/08) - [July 2017 (5)](https://info.zentech.com/blog/archive/2017/07) - [June 2017 (5)](https://info.zentech.com/blog/archive/2017/06) - [May 2017 (3)](https://info.zentech.com/blog/archive/2017/05) - [April 2017 (5)](https://info.zentech.com/blog/archive/2017/04) - [March 2017 (7)](https://info.zentech.com/blog/archive/2017/03) - [February 2017 (6)](https://info.zentech.com/blog/archive/2017/02) - [January 2017 (2)](https://info.zentech.com/blog/archive/2017/01) - [January 2016 (1)](https://info.zentech.com/blog/archive/2016/01) - [December 2015 (1)](https://info.zentech.com/blog/archive/2015/12) - [November 2015 (5)](https://info.zentech.com/blog/archive/2015/11) - [August 2015 (7)](https://info.zentech.com/blog/archive/2015/08) - [July 2015 (7)](https://info.zentech.com/blog/archive/2015/07) - [June 2015 (9)](https://info.zentech.com/blog/archive/2015/06) - [May 2015 (7)](https://info.zentech.com/blog/archive/2015/05) - [April 2015 (7)](https://info.zentech.com/blog/archive/2015/04) - [March 2015 (9)](https://info.zentech.com/blog/archive/2015/03) - [February 2015 (12)](https://info.zentech.com/blog/archive/2015/02) - [January 2015 (7)](https://info.zentech.com/blog/archive/2015/01) - [December 2014 (7)](https://info.zentech.com/blog/archive/2014/12) - [November 2014 (1)](https://info.zentech.com/blog/archive/2014/11) - [October 2014 (2)](https://info.zentech.com/blog/archive/2014/10) - [September 2014 (5)](https://info.zentech.com/blog/archive/2014/09) - [August 2014 (5)](https://info.zentech.com/blog/archive/2014/08) - [July 2014 (8)](https://info.zentech.com/blog/archive/2014/07) - [June 2014 (7)](https://info.zentech.com/blog/archive/2014/06) - [May 2014 (8)](https://info.zentech.com/blog/archive/2014/05) - [April 2014 (5)](https://info.zentech.com/blog/archive/2014/04) - [March 2014 (5)](https://info.zentech.com/blog/archive/2014/03) - [February 2014 (6)](https://info.zentech.com/blog/archive/2014/02) - [January 2014 (2)](https://info.zentech.com/blog/archive/2014/01) - [December 2013 (4)](https://info.zentech.com/blog/archive/2013/12) - [November 2013 (8)](https://info.zentech.com/blog/archive/2013/11) - [September 2013 (1)](https://info.zentech.com/blog/archive/2013/09) - [August 2013 (8)](https://info.zentech.com/blog/archive/2013/08) - [July 2013 (10)](https://info.zentech.com/blog/archive/2013/07) - [June 2013 (7)](https://info.zentech.com/blog/archive/2013/06) - [May 2013 (11)](https://info.zentech.com/blog/archive/2013/05) - [April 2013 (9)](https://info.zentech.com/blog/archive/2013/04) - [March 2013 (8)](https://info.zentech.com/blog/archive/2013/03) [![Zentech Manufacturing](https://info.zentech.com/hubfs/Zentech_May2018/images/zentech-footer-logo.png)](https://www.zentech.com) (443) 348-4500 [sales@zentech.com](mailto:sales@zentech.com) 6800 Tudsbury Road Baltimore, MD 21244 - ### Zentech Baltimore [![Zentech North](https://info.zentech.com/hubfs/Zentech_May2018/images/zentech-north.jpg)](https://maps.google.com/maps?ll=39.334434,-76.754229&z=13&t=h&hl=en-US&gl=US&mapclient=embed&q=6980%20Tudsbury%20Rd%20Windsor%20Mill%2C%20MD%2021244) ### Zentech Baltimore 6800 Tudsbury Road Baltimore, MD 21244 (443) 348-4500 [Tour our Baltimore facility.](https://info.zentech.com/hubfs/Zentech_May2018/images/ZENTECH-Manufacturing-Facility.mp4) - ### Zentech Fredericksburg [![Zentech Central](https://info.zentech.com/hubfs/Zentech_May2018/images/zentech-central.jpg)](https://www.google.com/maps/place/3361+Shannon+Airport+Cir,+Fredericksburg,+VA+22408/@38.2695318,-77.4502427,780m/data=!3m2!1e3!4b1!4m5!3m4!1s0x89b6c3cab010f5b1:0x769b9203a80ef188!8m2!3d38.2695276!4d-77.4480487?hl=en-US) ### Zentech Fredericksburg 3361 Shannon Airport Circle Fredericksburg, VA 22408 (540) 372-6500 [Tour our Fredericksburg facility.](https://info.zentech.com/hubfs/Zentech_May2018/images/Fredricksburg.mp4) ### Contact Us © 2018 Zentech Manufacturing, Inc. All rights reserved. [Privacy Policy.](https://www.zentech.com/privacy-policy)