Control of rework repair| Procedure, Steps, Guide with example

In the manufacturing world, the major costs will be spend on defect / non-conformity management. Such a cost is a complete waste and the customer will not pay for the same. In this article, we will be discussing the detailed concept, of control of rework repair in manufacturing.

So, rework and repair is one of the method of non-conformity management and a mandatory requirement of standard.

Very few people can understand the concept of rework and repair.

Let’s dive in…

rework repair

What does mean by rework?

According to the rework definition provided by ISO 9000 2015 standard;

Rework :- Action on a non-conforming product or service to make it conform to the requirements.

When manufacturing process is producing defective product, we need to correct the defect.

Therefore rework refers to the process of correcting or improving a product / parts that are not meet specification and requirement, is defective, or requires changes or modifications.

What does mean by repair?

According to the repair definition provided by ISO 9000 2015 standard;

Repair :- Action on a non-conforming product or service to make it Acceptable for the intended use.

So, repair refers to the process of fixing or restoring a product/parts, that are not meeting specification and requirement or is damage / defective.

The repair product is not 100% fulfilling the requirement. Those parts will be conditionally accepted for the intended use.

Example of rework product

Example: If we are manufacturing a gear using a machining process. After measurement of the parts, the internal diameter is undersized.

Then we do the rework by re-machining the part and making it conforms to specification and requirement.

Example rework

Example of repair product

Example: If we are manufacturing a gear using a machining process. After measurement of the parts, the internal diameter is oversize.

Then we do repair by filling the material inside using the welding process. Do the machining again to make it acceptable.

Example repair

Here, the addition of material using the welding process is not the correct process from the customer’s point of view. Therefore it is not 100% conform to the requirement but makes it for the intended use.

Difference between rework and repair | Rework vs Repair

ReworkRepair
No prior approval require, if rework is approved process by customer.

After rework if required by customer, prior approval is required.
Organization must need the approval from the customer to do the repair.

Approval is mandatory for the repair.
Reworked part is 100% conform to its specification and requirementRepaired part is not 100% meet the requirement but it is fit for intended use.
Low-risk factor – It is 100% compliance with requirements.High-risk factor – as it will lead to warranty and reliability failure in the field.

The major difference in the IATF 16949 standard is the requirement mention in clause
(8.7.1.4 -Control of reworked Products)
(8.7.1.5 -Control of repaired product)

The requirement difference is, for rework (if required by the customer the approval is mandatory), and for repair (The organization shall obtain approval from the customer before commencing repair)

In summary, we do rework to correct defects or improve the quality of a product. While doing the repair is to restore a product to its original condition or improve its functionality.

Rework Repair Procedure in detail

Refer to the below procedure for control of rework repair in the manufacturing process,

rework procedure / repair procedure
Rework Repair Procedure

Frequently Ask Question

What is rework and repair in manufacturing?

Rework refers to the process of correcting or improving a product/parts that are not meet specification and requirement, is defective, or require changes or modifications.
Repair refers to the process of fixing or restoring a product/parts that are not meet specification and requirement or is damaged/ defective.

Rework definition

Action on a non-conforming product or service to make it conform to the requirements.

Repair definition

Action on a non-conforming product or service to make it Acceptable for the intended use.

Repair vs Rework

Rework part is 100% conform to its specification and requirement
Repair part is not 100% meet the requirement but it is fit for the intended use.

How do you track rework in manufacturing?

Monitoring of rework repair is important in the control of rework repair,
Rework part is inspected and record in rework/repair inspection and re-inspection record.

Cost of rework and repair

Repair can be more costly than repair, as it may require more labor, materials, and equipment.
Rework, on the other hand, may be less costly, as it typically involves fewer changes to the product.