In a fairy tale factory, every machine is flawless, and work is done on schedule with equipment that never breaks down. However, in the real world, mistakes are made during assembly or at the component level due to problems with production machinery.
Rework involves repairing a product that does not meet the minimum quality requirements for a product. After repair, the product can be sold, allowing the company or business organization to recoup some of the cost of the product that would otherwise have been thrown away.
Rework can involve several processes, such as disassembling a finished product, replacing missing parts, reassembling and repackaging. It can be costly to bring a product into compliance with a company’s requirements. Therefore, Rework ends up creating a smaller profit.
No one wants products to have to be reworked, but a healthy supply chain always includes this. That is because rework processes are only necessary when something has gone wrong, and a manufacturing problem needs to be fixed before a product can go into production. Rework, and repair processes are important parts of manufacturing logistics because mistakes can and do happen. They are also part of Lean Supply Solutions’ strategy to increase operational efficiency.
Rework Rate And How To Calculate Rework Rate
Rework rate refers to the percentage of time spent on rework processes. It is calculated by dividing the number of hours spent on rework by the number of hours spent on productive activities or by dividing the total number of reworked (repaired) goods by the total number of products manufactured. The rework rate is an outcome measure to identify operational jobs requiring initial quality improvements.
Rework rate (%) = (rework hours ÷ productive labor hours) × 100%.
(Total quantity of reworked (repaired) products ÷ Total quantity produced) × 100%.
Rework hours are the time required to recycle, classify, and repair waste-producing components. Repair, repackaging, re-sorting, and further inspection are some of the tasks that may be performed during rework hours. Activities may be performed internally or externally during rework time.
Productive Labour Hours
This refers to the total number of hours worked by direct production personnel.