How can I minimise the number of defected and broken items in my production line?

in a simply way :-

1- To follow the preventive maintainance schedule mentioned by the manufacturer and also to reduce the mean time between failures MTBF.

2- Select the right candidae to work on the machine.

3- Set KPI for the worker related to the prodution issue.

There are several ways to reduce defects. You can group these strategies into early stage strategies and late stage strategies. Early stage strategies focus on removing defects before the manufacturing process begins. Late stage strategies generally involve using scientific methods to reduce manufacturing defects during the production process.  Early Stage Strategies for Reducing Defects:1. Sometimes product defects are a result of poor product design. Manufacturing engineers can forecast potential areas of concern in the preliminary stages of development if they are involved in the process.  The everyday manufacturing experience that these manufacturing/production engineers have can be invaluable to the development team and save the company a lot of time and money.  Involving an interdisciplinary team of engineers during the product development process is one way to reduce future manufacturing defects.  2. Building flexibility into the production process can be another way to reduce product defects.  Just like innovation is encouraged during the design of new products, an innovative approach to production can also be helpful.  For example, identifying what parts of production should be outsourced vs. done internally. Sometimes a new manufacturing process is what it takes to uphold product quality and decrease defects.3. Some major manufacturing companies are using computer modeling or simulations to detect product defects and handle them in the early stages of the production process. Using such technology can offer a real life test of real world production runs and identify problems early.Late Stage Strategies for Reducing Defects:

1. Manufacturers can take preventative actions such as replacing obsolete equipment and machines that require excessive repairing.  Also making sure that all operating machinery is serviced regularly.2. Firms should inspect the entire manufacturing process to identify the main cause of defects. They can use ultrasonic technology, particle testing, vibration and resistance testing in order to reduce defects in the production process.3. Sometimes innovation in product design becomes fruitless when the production line is not checked on regularly. Quality control ensures that products are produced following strict rules and procedures at every stage of production. A quality control team can use Six Sigma methodology to reduce product defects and ensure better quality.4.  Regular communication between production employees and other product design staff and engineers is always a good idea and helpful in identifying and solving problems quickly.  This teamwork can help bring about greater efficiency and less defects.

you need to do preventive maintenance to your equipment, Identify areas of defect and do a root cause analysis in order to root out the problem from the source.

Perform regular preventive maintenance activities and conduct regular audit on equipment  assigned to ensure operation efficiency and safety.

train employees in quality control,and practice good housekeeping, and exercise the 5 wastes( shingo'swaste)

1)100% Checking should be done while inspecting on production

2)find out where is actual problem on machine to avoid defects and broken items

3)onces we found or trace problem immidetly stop machine and try to solve the problem

First define the problem,

analyze the same thru scientific approach and 7QC tools, 

see the root cause analysis

implement poka yoka 

train the operators

monitor the same and 

go for further continual improvement

• Institute system-directed cycle counting at warehouses to improve inventory accuracy and get to the root cause of issues.
• Use Six Sigma and Statistical Process Control to reduce process variation that can create waste.
• Communicate with customers and suppliers via electronic data interchange to reduce errors and improve productivity.
• Standardize processes to reduce variations. Instruct all workers to use the best practice method, and create visible reminders to ensure a task is done the same way each time, no matter who performs it.
• Organize your workplace using the 5S method—Sort out, Set in Order, Shine, Standardize, and Sustain—for a clean, safe, efficient, and uncluttered environment.

Applying the statistical quality control methods

First Thing :-

you have to apply TPM, and when i say TPM i mean redical reform for Machines And Employes.

You have to decrease Time Wastes like Over production, waiting and unusing talents.

you need to know the root of problems which cause defects.

To follow the preventive maintainance schedule mentioned by the manufacturer