Rework is the term used for corrections made to a finished part due to the finished product being out of specification. Rework is usually done usually for mechanical specifications. It may either be done manually or using machines.
In manufacturing, rework would denote an event that is unfavourable to quality, cost and delivery (QCD). An occurrence of this phenomenon is the indicator that the machines used for production need servicing/tuning.
- Quality – Since the processes used in rework deviate from the processes required to produce parts, quality might be affected. Rework might include removing a component part and mounting a new component part, filing of a certain region etc all of which has the possibility of not achieving the quality of the ‘first work’.
- Cost – The extra labour and machine time to be out into rework activity costs money
- Delivery – Since rework takes time, there are instances where delivery of parts cannot be made to the customer within the requested time.
Due to the above reasons, it is best to do a QRQC followed by PDCA approach to find the reason behind the deviations as soon as the necessity for rework arises.
To rework or to not rework?
This question is usually approached with the same Delivery, Quality and Cost in that order. Take a look at the following chart for more clarity.