Difference between Rework and Repair

What is the Difference between Rework and Repair?

→ Before going to understand the difference between rework vs repair we will discuss the fundamental of those words.

→ As we all know, in IATF 16949:2016 Standard, many new words have been added like Interested Parties, Risk, Context, Product Safety, Corporate Policies, Embedded software, TPM, Temporary Change, Interim action, Error Proofing, Repair, etc.

→ The objective behind adding new terminology is to align the updated standard with the current manufacturing practices in the automotive sector.

→ Also, it will help the industry to match with the customer's expectations as per the Customer Specific Requirement (CSR).

→ Rework and Repair is the most common activity that happens in almost all organizations.

→ So far, many of us were using both terminologies interchangeably.

IATF 16949:2016 Standard has mentioned the control of rework and repair_processes in clause no. 8.7.1.4 and 8.7.1.5 respectively.

→ Many organizations do not have adequate controls over their manufacturing process.

→ It results in the initiation of the Disposition_Process.

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Types of Product Disposition

→ Generally, there are 5 stages of product disposition as mentioned below.

  • Segregation,
  • Rework,
  • Repair,
  • Deviation,
  • Scrap.

Types of Product Disposition

Rework vs Repair | ISO 9000 | IATF 16949

→ Now as per the ISO 9000 Standard, and IATF 16949:2016 Standard we will understand the differences.


Rework Process:

→ Rework is an action on a non-conforming product or service to make it conform to the requirements.

→ In this process, the product matches the specification or drawing.

→ This process has lower risk as compared to the repair process.


Example Rework Process:

→ Problem: After the machining process, if we found the length of the shaft is more than the specifications.

→ Action Taken: So we rework the shaft and by the re-machining process make shaft length within the specification.

→ This is an example of the Rework Process.

→ We will take one more example for a better understanding.

→ Problem: If we found our bike's tire pressure is less than the operational pressure.

→ Action Taken: So we will just inflate the tire by adding the air up to the operational pressure.

→ In these examples, both the product shaft and tire look like all the other good products and there is no visible sign of any changes in physical appearance.


Repair Process:

→ Repair is an action on a non-conforming product or service to make it acceptable for the intended use.

→ In other words, we can say that after repair the product is ready to use functionally but it might not meet the specification or drawings.

→ This_process has a higher risk as compared to the rework process.


Example of Repair Process:

→ Problem: After the machining process, if we found the length of the shaft is lower than the specifications.

→ Action Taken: So we rework the shaft by applying the welding and by the re-machining process to make shaft length within the specification.

→ This is an example of the Repair_Process.

→ Here we are adding extra material for making the product functionally and specification-wise ok.

→ We will take one more example for a better understanding.

→ Problem: If we found our bike's tire got punctured.

→ Action Taken: So we will add one patch on the tire and make it functionally ok. So the tire is ok for the intended use.

→ Here in both examples, the adding material is not the approved process by the Customer.

Rework vs Repair Summary


👉 See Also:

10 Comments

  1. Good explanation. Thank you

    ReplyDelete
  2. You content makes my studies for lean six sigma black belt seamless. It is so simplified and with comprehensive relevant illustrations and examples for ease understanding

    ReplyDelete
    Replies
    1. Thank you for your kind words and in-depth feedback really it motivates us

      Delete
  3. Then what will be the difference between repair and deviation

    ReplyDelete
    Replies
    1. Both terminology is used for the different perspective.
      You can reach us at contact@nikunjbhoraniya.com for more detail.

      Delete
  4. Man, you are awesome....that would be a great help if you could give some lean and six Sigma project demo as well

    ReplyDelete
    Replies
    1. Sure you can reach us at: contact@nikunjbhoraniya.com

      Delete
  5. That chart was the most helpful part, mostly because our company deals with paint and not parts so the line between repair and rework was confusing. Repair isn't really a thing for us since everything is checked 100% before shipping.

    ReplyDelete

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