The intelligent repair station is the essential component that either enables or disables effective quality management, both within the factory and out in the market. This paper looks at the key elements that make up an intelligent repair station, looking specifically at those elements that bring optimum value to the repair operation and overall quality strategy. It also covers an in depth at the contribution that the repair station makes to a world class quality control strategy, while asking the question, “Can zero defects ever really be achieved?”.