A Combined Function-Structure-Behaviour and Return on Investment Framework for Improved Decision-Making in Zero-Defect Manufacturing

Zero-Defect Manufacturing (ZDM) is a complex challenge that requires not only advanced technologies but also sound decision-making tools to ensure successful implementation. This paper proposes a novel approach that combines Function-Structure-Behaviour (FSB) analysis with Return on Investment (ROI) calculations to support more accurate and holistic investment decisions in ZDM. The combined framework aims to reduce the reliance on gut feelings and subjective judgement, making ZDM investment decisions more transparent, rational, and ultimately more successful. It allows decision-makers to explore trade-offs, validate strategy performance, and implement ZDM in a scalable, digitally supported way. Simulation results demonstrate the feasibility and practical value of the proposed approach, and a critical analysis reveals that the two strategies embody fundamentally different philosophies of quality management and carry distinct implications for scalability, human factors, and operational robustness.