Deutsch: Nacharbeit / Español: Retrabajo / Português: Retrabalho / Français: Retouche / Italiano: Rilavorazione
Rework in the quality management context refers to the process of correcting or modifying a product or component that does not meet predefined quality standards or specifications. The goal of rework is to bring the non-conforming item into compliance without compromising its functionality, performance, or safety.
Description
Rework is an integral aspect of quality management systems, particularly in manufacturing, construction, and service industries. It occurs when a product or process fails to meet quality requirements and must be adjusted, repaired, or reprocessed. This could include tasks such as repairing defects, replacing faulty components, or adjusting the product to align with design specifications.
While rework ensures that a product meets acceptable standards, it also highlights gaps in the initial production or service processes. Excessive rework is often seen as a sign of inefficiency and can negatively impact timelines, costs, and customer satisfaction. Consequently, effective quality management aims to minimise the need for rework through root cause analysis, process improvement, and robust quality assurance measures.
Rework is often documented as part of the quality management process to track non-conformities, evaluate their causes, and implement preventive actions. Tools like Pareto analysis and fishbone diagrams are commonly used to identify and address the factors leading to rework.
Application Areas
- Manufacturing: Repairing or adjusting defective items to meet quality standards, such as fixing welding imperfections or repainting products.
- Construction: Rectifying deviations from building plans, such as correcting plumbing installations or redoing concrete work.
- Software Development: Debugging or rewriting code to resolve errors or meet client requirements.
- Healthcare: Adjusting medical devices or equipment to comply with safety standards.
- Automotive Industry: Fixing assembly defects or replacing faulty components in vehicles.
Well-Known Examples
- Electronics: Reworking circuit boards with defective solder joints.
- Textile Industry: Fixing stitching errors in garments to meet quality requirements.
- Aerospace: Adjusting aircraft components during maintenance to meet strict safety and performance standards.
- Food Industry: Repackaging or relabelling products with incorrect information.
Risks and Challenges
- Increased Costs: Rework involves additional labour, materials, and time, driving up production expenses.
- Reduced Productivity: Resources allocated for rework could otherwise be used for new production, affecting efficiency.
- Risk of Damage: Excessive handling during rework may lead to further damage or reduced durability.
- Customer Dissatisfaction: Rework delays can impact delivery timelines, potentially frustrating customers.
- Root Cause Overlooked: Addressing symptoms of non-conformance without identifying underlying causes may lead to recurring issues.
Similar Terms
- Repair: Restoring a damaged or defective product to operational condition.
- Scrap: Discarding defective items that cannot be reworked or repaired.
- Remanufacturing: A comprehensive process of rebuilding a product to meet original specifications.
Weblinks
- industrie-lexikon.de: 'Nacharbeit' in the industrie-lexikon.de (German)
Summary
Rework is a corrective process aimed at bringing non-conforming products or processes in line with quality standards. While it helps recover value and maintain compliance, rework also highlights inefficiencies and can lead to increased costs and delays if not managed effectively. Minimising rework through robust quality assurance and continuous improvement is essential for optimising production and maintaining customer trust.
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