"In the U.S.A., about a third of what we do consists of redoing work previously done." — J.M. Juran
Nearly
every business has some level of ongoing rework. Most product-based businesses
have some form of rework when they don’t satisfy the customer with their first
effort. It may be that you can’t supply the complete order in one lot, or the
quality of the product does not meet the customers’ needs. In service
businesses, rework can occur when the customer is not happy with the service and
some form of corrective work or follow up is required by the management team.
Scrap
and rework costs are a manufacturing reality impacting organizations across all
industries and product lines. No matter why scrap and rework occurs, its impact
on an organization is always the same—wasted time and money. Activities that
reduce the quality or efficiency of a manufacturing operation or business
process, but are not initially known to managers or others seeking to improve
the process are referred to as “The Hidden Factory.” Most organizations have
some form of a Hidden Factory.
Instead
of trying to fix the rework process (which is Muda), determine the root causes
of needing rework/repair and fix those. If priority is given to evaluating and
improving your manufacturing processes, it becomes much easier to reduce the
amount of scrap and rework in your organization. Remember, Lean is about zero
defects.
To
maintain a competitive edge, manufacturers must constantly find ways to cut
costs and improve efficiency. Correcting your systems by finding and
eliminating the root causes of rework will result in a much smoother workflow.
This will translate directly to bottom line improvements.
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