Advancing human-centric zero defect manufacturing: a theoretical framework and practical insights

The Industry 5.0 revolution emphasises human-centric (HC) approaches, balancing automation with human expertise and creativity. This paradigm shift is especially relevant in the luxury fashion industry, where quality is both a technical requirement and a brand identity marker. Despite the critical importance of Human-Centric Zero Defect Manufacturing (HZDM) in ensuring defect-free production while preserving artisanal craftsmanship, the concept remains underexplored in literature and practice. Existing research predominantly focuses on traditional Zero Defect Manufacturing (ZDM), which prioritises standardisation and automation, neglecting the role of human input in managing complex, high-stakes production scenarios. Addressing this gap, this study introduces the DMI2CI framework, an evolution of the DMAPA cycle to explicitly integrate the human element into ZDM processes. To answer two key research questions, the study develops comprehensive guidelines for implementing HZDM (RQ1) and demonstrates its practical application through a case study in the luxury fashion industry (RQ2). The findings contribute theoretically by advancing ZDM literature and demonstrating the value of HC approaches. Managerially, the DMI2CI framework offers actionable insights for HZDM implementation in industrial contexts. Future research should explore the framework’s scalability through multiple-case studies across industries to evaluate its adaptability and sector-specific relevance.