Evaluating Manufacturing Maturity: A Comprehensive Framework for Industrial Readiness for Zero Defect Manufacturing

Industry 4.0 is reshaping manufacturing, with Zero Defect Manufacturing (ZDM) emerging as a cornerstone for competitiveness and sustainability. This paper introduces a readiness assessment framework that evaluates four critical dimensions—infrastructure, processes, personnel, and company culture—bridging technological capability with quality management. A structured questionnaire operationalises these dimensions and was applied to five European firms in the automotive and semiconductor sectors. Results show that while technological infrastructure is relatively advanced, predictive analytics and workforce data literacy remain underdeveloped, limiting the realisation of ZDM's full potential. The findings highlight the importance of integrating human-centred factors such as training, culture, and risk awareness with advanced digital tools. By providing both a diagnostic baseline and actionable insights, the framework supports companies in benchmarking their progress and guiding strategic investments. Beyond individual firms, it also offers researchers and policymakers a foundation for advancing ZDM adoption as part of a sustainable, defect-free manufacturing ecosystem.