Rework keeps repeating
Connect production and quality records to find the recurring cause.
01 · What is usually happening?
A part fails inspection, someone reworks it, and it goes ahead. The fix is quick and so nobody asks why it failed. Tomorrow the same part fails the same way.
Rework becomes a hidden second production line that eats hours and never appears on a report.
The question people usually ask“How much rework do we have?”
The more useful question“Which defects come back, where do they start, and how do we stop them there?”
02 · Common causes
- 01Rework is not recorded, so it is not seen
- 02The cause is fixed on the part, not at the source
- 03Operators are not told what went wrong
- 04Drawings, settings or tools are unclear
- 05Inspection happens at the end only
- 06No one owns the top three repeat defects
03 · What to check now0 of 6 checked
04 · What good looks like
- 01Every rework is logged with the defect and the operation.
- 02The top three repeat defects have owners.
- 03Operators hear about their defects the same day.
- 04Inspection happens early, not only at the end.
- 05Rework hours are reported monthly.
05 · Where this connects
This rarely stays in one department
What it can lead to: The same defect is paid for again and again.
Start from a problem
Work flows left to right, top to bottomKEYMost important for manufacturing
These support every part of the business
Problem
Rework keeps repeating
Usually connected to
How it spreads
- Production
What it can lead to: The same defect is paid for again and again.
lamplamp could record rework from a supervisor's voice note.
Related guidesWhat a production supervisor needs at shift handover
08 · lamp
lamp could keep this moving
lamp is not available yet. These are things it is being built to do.
- lamp could record rework from a supervisor's voice note.
- lamp could group repeat defects by operation and machine.
- lamp could remind an owner when a repeat defect is still open.
- lamp could report rework hours and cost each month.
Does your business handle this differently?Tell us what we have missed: a cause, a check, or a better way of handling it.
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