Rework

Rework is the process of correcting a nonconforming part, through an additional operation such as re-machining, refinishing, or other correction, to bring it into compliance with its requirements, as an alternative to scrapping it. It's only viable when the nonconformance is physically correctable and doing so is more cost-effective than remaking the part from scratch.

Why rework is a cost comparison against scrapping and remaking

Rework adds its own operation and time to a part's cost beyond the original routing, so the decision to rework rather than scrap depends on whether that added cost is still less than the cost of scrapping and remaking the part entirely.

Where rework decisions happen

Not on the drawing; rework is a response to a nonconformance identified during or after production, not something anticipated by the part's original requirements.

Common mistakes

Attempting rework on a nonconformance that isn't actually physically correctable, or where the added rework cost exceeds what remaking the part from scratch would have cost.

Is rework always cheaper than scrapping and remaking?

Not necessarily; it depends on how much additional work rework requires versus the cost of a fresh part, and whether the nonconformance is correctable at all.

Can every nonconformance be reworked?

No, some nonconformances (such as a feature machined undersized with no material left to correct it) aren't physically correctable and must be scrapped.

Does rework require a customer's approval?

Often yes, particularly in regulated industries, since the part deviates from its originally planned process even if it ends up meeting requirements.