Does inspection of product constitute rework when the purpose is to segregate good product from bad product?

See this discussion thread: Rework - Definition (http://elsmar.com/Forums/showthread.php?t=12639)

Other Elsmar Cove Rework discussion threads (http://Elsmar.com/Forums/search.php?do=process&titleonly=1&query=rework).
Post details about your specific situation and we can better answer with respect to your situation.

check in the definitions section of the forums and see if the information there gives you the information you need. That is a really good place to check and you probably will either find what you want. good luck!


great minds think alike, Marc? you beat me to it.

Does inspection of product constitute rework when the purpose is to segregate good product from bad product?

Some examples: I would call this "sorting", then fixing the bad parts to conform to requirements is "rework" (such as grinding, cutting, punching missing holes, triming, shaot blasting, re-drilling undersize holes, etc). If you can't fix the parts then in some markets they can be sold at a discount as seconds, or distressed products. If that is not an option, then "scrap". If plastics, then may be rturned into regrind and reused as rework back into the process at a controlled rate.

Thanks for the definition. I have not investigated this site enough to know there actually was a 'definitions' section.

Based on the definition, it sounds like inspection is not rework.

Here is an example that prompted the question.

Parts fail the AQL at QA final inspection due to discoloration that can not be removed. Manufacturing 100% inspects lot to weed out those parts that contain this discoloration. Remaining parts are reissued to QA final inspection and accepted. Only process that was done to the conforming parts is repackaging. Nonconforming parts are scrapped by manufacturing.

Was the 100% inspection considered rework? If not, how would you define it as it was prompted by a final QA inspection, not in process or manufacturing.

Was the 100% inspection considered rework? If not, how would you define it as it was prompted by a final QA inspection, not in process or manufacturing.

"Rework" is usually defined as work done outside of the normal manufacturing process in order to bring nonconforming product into conformance. Inspection doesn't actually fix anything. You would define 100% inspection prompted by discovery of defects as "sorting." If you were to take the defectives found by sorting and fix them, that would be rework.

Jim is right. Apples and oranges - Inspection is checking something against something else (inspection sheet, boundary sample, dimension on print, etc). Rework is physically changing something on the part / assembly.

Thanks for the definition. I have not investigated this site enough to know there actually was a 'definitions' section.

Based on the definition, it sounds like inspection is not rework.

Here is an example that prompted the question.

Parts fail the AQL at QA final inspection due to discoloration that can not be removed. Manufacturing 100% inspects lot to weed out those parts that contain this discoloration. Remaining parts are reissued to QA final inspection and accepted. Only process that was done to the conforming parts is repackaging. Nonconforming parts are scrapped by manufacturing.

Was the 100% inspection considered rework? If not, how would you define it as it was prompted by a final QA inspection, not in process or manufacturing.


As I understand what you are saying, it would not be considered "Rework" unless you sent the parts that were discolored back through the process that would bring them back to Specification. The 100% Inspection is exactly what it states only 100% Inspection.

Now could you explain a little more and specific on what process caused the discoloration, because if it was a finish (Anodize, Hard Coat, Black Oxide, etc) then sometimes the Specification allows variations in color. Maybe the need to scrap the parts might have been a little too drastic, but without further information that could not be the conclusion. If your company wanted to scrap the parts then that is their choice of course, but why scrap something that can be brought back to specification?


Coury Ferguson

I realize there is a 'technical' definition, but I know some companies used 'rework' as the term for all reprocessing. So it's 'rework' per the 'rework' instruction, but in some cases that instruction is 'sort out cavity X.'

I realize there is a 'technical' definition, but I know some companies used 'rework' as the term for all reprocessing. So it's 'rework' per the 'rework' instruction, but in some cases that instruction is 'sort out cavity X.'

You're right, Laura. In fact sometimes there are "rework" accounting "buckets" set up to capture any kind of costs outside of the normal manufacturing process, including sorting costs. I think that what's good for accounting and what's good for general QMS purposes might be different, however, and I do think it's generally a good idea in production to distinguish sorting (or other nonstandard inspection) from rework.

Now could you explain a little more and specific on what process caused the discoloration, because if it was a finish (Anodize, Hard Coat, Black Oxide, etc) then sometimes the Specification allows variations in color. Maybe the need to scrap the parts might have been a little too drastic, but without further information that could not be the conclusion. If your company wanted to scrap the parts then that is their choice of course, but why scrap something that can be brought back to specification?
You might want to start a new thread and ask this question in the Manufacturing and Related Processes forum (http://elsmar.com/Forums/forumdisplay.php?f=111) so this thread doesn't deviate and so others can find it through a thread title search.

You might want to start a new thread and ask this question in the Manufacturing and Related Processes forum (http://elsmar.com/Forums/forumdisplay.php?f=111) so this thread doesn't deviate and so others can find it through a thread title search.


Marc,

You are right, if I wanted to start the thread I would have, but I was only asking if he could be a little more specific. Just adding to my original comments. I will be more careful next time.


Coury Ferguson:D

Was the 100% inspection considered rework? If not, how would you define it as it was prompted by a final QA inspection, not in process or manufacturing.No, but it is Reinspection.

Thank you all very much for your replies. Do not know why the word sorting never entered our minds. That is exactly what we are doing.
This forum was very helpful as always.

I'd probably call what you're doing as either sorting or reinspection.

I'm more concerned that it should somehow be captured in the cost of poor quality, evaluated, determine a root cause for why parts were produced off-color, and possibly priortize the reinspection for reduction/elimination.

I wouldn't expect the path described to be a standard production practice, so there are probably some extra costs involved that could hopefully beeither minimized or eliminated.

Inspection , Repair and Rework

Inspection can be random or 100% of products depending on requirement.

Repair :- If a hole of 1 mm is required and if it is missing in the product then it is sent for repair.

Rework :- If a hole of 1mm is required and if a hole of 2mm is drilled, then it is sent for re-work.

Inspection , Repair and Rework

Inspection can be random or 100% of products depending on requirement.

Repair :- If a hole of 1 mm is required and if it is missing in the product then it is sent for repair.

Rework :- If a hole of 1mm is required and if a hole of 2mm is drilled, then it is sent for re-work.I think you have it reversed. For a discussion on this look at the thread, Repair - Definition (http://elsmar.com/Forums/showthread.php?t=12638&highlight=rework)

Repair :- If a hole of 1 mm is required and if it is missing in the product then it is sent for repair.
You would probably pass it through that process step again, but maybe a jig and manually put in the hole (say in a line with multiple processes that can't be separated for individual operations). I tend to think of this as Rework.

Rework :- If a hole of 1mm is required and if a hole of 2mm is drilled, then it is sent for re-work.
Hle would have to be filled with something and then reprocessed (as in the above). I tend to think of this as Repair.

But I could be wrong.

Thanks for pointing out the error in my earlier posting.(I did the posting from my memory;apparantly memory failed). I checked up my notes and found:-

Rework: If a worker forgets to drill the 0.25-in. hole that the specifications say should be in the middle of that steel plate, the mistake is rectified by rework.

Repair: If, the worker accidentally drilled a hole in the steel plate where none should be, the mistake is rectified by repair.

Thanks for pointing out the error in my earlier posting.(I did the posting from my memory;apparantly memory failed). I checked up my notes and found:-

Rework: If a worker forgets to drill the 0.25-in. hole that the specifications say should be in the middle of that steel plate, the mistake is rectified by rework.

Repair: If, the worker accidentally drilled a hole in the steel plate where none should be, the mistake is rectified by repair.That is better.