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The 6 Quality Basics - Rework Under Control

This document provides guidelines for organizing an effective rework process in production sites. It outlines that rework should be done off-line in clearly designated rework stations to avoid disrupting the normal production flow. Any non-conforming parts detected on the production line should be immediately removed and sent to a rework station, where qualified personnel will attempt to rework the part according to specified instructions before the end of the shift. Records of reworks, rejects, and defects should be kept at each station to analyze quality issues.

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257 views5 pages

The 6 Quality Basics - Rework Under Control

This document provides guidelines for organizing an effective rework process in production sites. It outlines that rework should be done off-line in clearly designated rework stations to avoid disrupting the normal production flow. Any non-conforming parts detected on the production line should be immediately removed and sent to a rework station, where qualified personnel will attempt to rework the part according to specified instructions before the end of the shift. Records of reworks, rejects, and defects should be kept at each station to analyze quality issues.

Uploaded by

patima_sv4875
Copyright
© Attribution Non-Commercial (BY-NC)
We take content rights seriously. If you suspect this is your content, claim it here.
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Faurecia Excellence System

Group Quality Department

Quality System Efficiency

The 6 Quality Basics -> Rework under control


Purpose: Rework methodology

Scope: all production sites

Verify the validity of the version of this document.

FAU-S-PS-0640 / EN issue 01

Rework flows
The rework process must be organized with as much care as the standard production flow. A rework circuit must not disrupt production flow. In fact, rework is an unpredictable operation we cannot foresee when and where rework will be needed nor how much time will be needed. It is therefore very important that rework be done off-line, on one or more clearly identified workstations set up specifically for this purpose. 1 Pull the products off the production line As soon as a non-conform is detected by an operator, it must be possible for him/her to remove the part from the normal production flow, using a red hook, a red bin, or other standard methods. The operator must clearly identify the part with: a sticker (adhesive dot or arrow) marking the location of the defect A red flag or plate singling out the product as non-conform As these products come off the line, they must be reworked by the GAP leader or a qualified reworker. If a non-conform cannot be readily withdrawn from the production flow, it is removed at the end of the line. On the other hand, if rework time will not disrupt normal production flow (e.g. cutting a thread, quick cleaning), the product can remain on the line. In such case the operator performs the rework at his/her own workstation and records it. 2- Return the parts to the production flow If the part cannot be reworked, the reworker rejects it. After rework, the part is returned to the line at the same spot where it was removed. All tests and inspections at this workstation must be redone.

FAU-S-PS-0640 / EN issue 01

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The rework station

The rework station is a workstation specifically set up for and dedicated to rework. It has its own display and instructions.

All of the equipment required for disassembling and reassembling the product is available at the rework station and must have the same characteristics as those of standard production equipment (e.g. . Automatic screwdriver that counts the number of screws and verifies the angle and torque). Rework must be performed as and when required, and before the end of the shift: by qualified personnel This qualification covers rework operations as well as knowledge of all aspects of quality needed to decide whether or not to reintegrate the reworked part in the flow (e.g. boundary samples and master parts). It is recommended that the GAP leader do the rework when it is done off-line. If there are too many reworks, an additional person can be assigned to this duty. with specific instructions. These instruction must specify: which types of rework are permitted and which forbidden (e.g. no rework on airbag as the black box can not be opened) rework method to be used (e.g. disassembly directions, weld location) means of rework (e.g. grade of sandpaper for a finishing job in Paint).

FAU-S-PS-0640 / EN issue 01

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Record-keeping and an example of a flow


At each workstation, tally the number of non-conforms per defect type At each rework station, record the number of reworks and rejects. These records are used to analyse problems.
Non-conforms
Tally count
IIIIIIIII III IIIIIIIIIIIIIIIIIIIIIIIII I IIIII

Record defects

Workstation

Record

Record reworks
Rework Station

Record rejects
Record

Reworkable Not reworkable


Treatment of non-conforms (rejects and reworks) : example of a U-line

Rework Circuit

Legend : Production flow Red bin Record Flow of conforming reworked parts

Tally count

Flow of non-conforms to rework FINAL INSPECTION

REJECTS

REWORKS

Record rejects Record reworks

FAU-S-PS-0640 / EN issue 01

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General Information

Author : Group QSE Date : 12 January 2004 Aim of the modification: Complete revision of the previous version Cancels and replaces: Associated documents: FAU S PS 0610 FAU S PS 0620 FAU S PS 0630 FAU S PS 0650 FAU S PS 0660

FAU-S-PS-0640 / EN issue 01

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