I believe zero defects was over and done with when Don Starry was at TRADOC--my recollection of circa 1980 is that it was a thing of the past and an example of how not to do things. At about the same time in Germany I was told that the Bad Tolz NCO academy had a paste-waxed floor that nobody was allowed to walk on.
Edit:
Found the following on the National Archives website under Records of the Army Staff, so the zero defects term has been around for a while.
Records of the Director of Review and Analysis, consisting of records relating to the zero defects program, 1965-74; command analysis reports, 1963- 67; army program reviews and summaries, 1951-68; reports and management control records, 1962-68 ...
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