Apple Marks 50 Years, Traces iPhone’s near-Zero Defect System to 1945
Apple’s near-zero defect manufacturing system stems from Homer Sarasohn’s 1945–50 quality-management seminars in post-war Japan, later advanced by Deming’s statistical controls and honoured by the Deming Prize. Apple marks its 50th anniversary while remaining secretive about its supply chain and production processes.
1. Foundational Seminars by Homer Sarasohn
In 1945, engineer Homer Sarasohn led an eight-week course in Osaka teaching mission statements and total-system quality management to Japanese factory managers. His approach emphasized empowering workers, instilling dedication to quality, and orchestrating production processes to approach zero defects.
2. Statistical Controls and the Deming Prize
Sarasohn’s successor, W. Edwards Deming, introduced statistical process controls that formalized defect tracking and process optimization. These methods became globally influential and were institutionalized through the annual Deming Prize, setting benchmarks for electronics and automotive manufacturers.
3. Legacy in Apple’s Production Systems
Apple’s current global assembly of high-end iPhones, achieving vanishingly few defects at scale, reflects this heritage of post-war Japanese management philosophies. As Apple celebrates its 50th anniversary, it continues to guard details of its supply chain and manufacturing processes.