Rework is not simply sending a defective item back to a workstation. If you cannot identify why quantity was segregated, its source work order, added work and consumption, and the result of reinspection, the product history and cost impact are lost.
Rework requires reinspection and a new decision
When rework is approved for a nonconformity, the product must remain traceable through its source work order or lot, segregated quantity, added consumption and reinspection result. Completing the work alone does not make the item conforming, saleable or ready to ship.
What is rework, and how does it differ from scrap and conditional acceptance?
Work intended to return an item to a defined acceptance criterion
The work is defined by the characteristic it aims to correct and the inspection to be applied afterwards. The item is not released until the outcome is verified.
Closure of quantity that is not technically or economically suitable
A scrap decision is not made automatically just because a rework attempt failed. The authorised decision, quantity and inventory/cost movement are recorded separately.
An exceptional decision for limited use
Conditional acceptance must not be used as a substitute for “conforming” status without a defined use limit, technical or customer approval and affected quantity.
Work that may result in a condition different from the original acceptance criteria
Terms may vary by industry, customer requirement and quality system. Define your company terminology and decision authorities in writing.
How do you track defective products through rework?
01Separate the product and scope
When a defect is reported, identify not only the visible item but also the related lot, work order, operation and affected quantity. Until a decision is made, do not show the quantity as available for stock, the next operation or shipment.
02Authorise the disposition decision
The basis and owner for rework, scrap, supplier return, conditional acceptance or hold decisions must be visible. An operator separating an item does not by itself authorise rework or acceptance.
03Open the rework record
Link the record to the source work order, item/lot or serial, segregated quantity, reason, planned operation and owner. Preserve the original production record and track the new work as a separate traceable movement.
04Record added consumption and time
If extra material, labour, machine time, outsourced work or waiting occurs, link it to the source item and rework record. Costs caused by rework should not be mixed with the original production result.
05Inspect again
Completing the work does not automatically mean the product is accepted. Record the acceptance criterion for the original defect, inspection result, inspected quantity and decision owner again.
06Close or keep under observation
Quantity found acceptable returns to the relevant flow with an authorised release. A new decision is needed for quantity that fails inspection. If evidence or checks are incomplete, keep the record under observation with an open action and owner rather than closing it.
Example quantity trail: a 120-unit nonconforming lot
This scenario illustrates the method; it is not a specific product, quality standard or customer case. The decision, rework and result quantities for 120 units segregated at first inspection remain visible in the same record trail.
Items segregated because of a dimensional deviation
Quantity released for approved rework
Quantity accepted and released
Quantity awaiting a new assessment or scrap decision
If 84 of 90 reworked units are accepted, only that quantity returns to the conforming flow with an authorised release. The remaining 6 units need a new assessment, further rework or a scrap decision. The original 120 units, source work order and each decision must remain linked.
Why should added material and labour be visible separately?
Rework can create unplanned material, labour, machine time or outsourced-service use. If these movements are only added to total production output, you cannot see which product, defect type or operation is creating the rework load. Linking quantity and consumption to the same record lets quality, production and cost reviews examine the same event.
Common record mistakes
Overwriting the original production record
Deleting the prior quantity or result removes the trace of the defect and repeated work. Keep the new movement as a separate record linked to its source.
Automatically accepting the item because the work is complete
The result of rework alone does not prove that the original nonconformity has been removed. Inspection and authorised release are separate steps.
Losing added consumption in general overhead
Leaving added material and time unrelated to the event hides where rework cost is occurring.
Ignoring quantity that remains open
If quantity remains pending after partial acceptance, inventory, planning and shipment must see it. Marking the total as closed can lead to incorrect decisions.
Related guides and record scope
For physical segregation, blocking and release flow that prevents nonconforming items from entering shipments, read our nonconforming product tracking guide. For where to catch defects in production, see the article on quality control points, and for the cost effect of added consumption and loss, see the scrap tracking guide.
Review the scope in which work orders, operations, quantities and records can be tracked in your business on the Korgün Cloud ERP production tracking programme page. This link does not mean that rework decisions or quality acceptance are made automatically by software.
Frequently asked questions
Can a reworked product be shipped directly?
No. After the work is completed, reinspection against the defined acceptance criterion and authorised release are required. Do not treat the item as shippable until it meets the business and customer requirements.
Should rework quantity be recorded as scrap?
No. Quantity approved for rework and quantity designated as scrap are not the same. The outcome is confirmed through reinspection and an authorised decision; each quantity must be tracked with its own status and movement.
Can the same product be reworked a second time?
This must be assessed by authorised people according to the product, technical specification, customer requirement, safety and cost conditions. Do not start another operation without linking the previous work, result and new decision in the record.
Does closing the record also end root-cause analysis?
No. Closing an item disposition and analysing the cause to prevent recurrence are different activities. For recurring events, corrective action and root-cause review should be tracked separately.