Rework vs Repair | Difference between Rework and Repair
There is
always confusion about which activity is called Rework and which is known as repair.
After going through this post, it will be very clear in your mind about the
concept of Rework and Repair.
Let us understand
the outcome of any Inspection. When we perform Inspection on any Product, mainly
there will be following outcome.
Either Product
will be:
> Conforming
> Nonconforming
Outcome of Inspection |
In case of
conforming product (OK product), it will be dispatched to customer. But
Nonconforming product cannot be dispatched. We have to Hold it till further
decision.
Now, Nonconforming
Product may be mainly of three types:
> Can be Reworked
> Can be Repaired
> Cannot Rework or Repair (Reject)
Types of Nonconforming Outputs |
We have not considered
here 2nd sale or degrading of Product.
Now, let us
understand the definition of Rework and Repair as per ISO 9000 standard
Rework Definition as per ISO 9000
Action on a non-conforming
product or service to make it to confirm to the requirements.
Explanation:
Any activity
or action taken on the Product or service to make it to conform as per
customers requirement (i.e. as per Drawing, standards, specifications, etc..).
That activity or action is termed as Rework Activity or Rework Action.
Note: After
Rework, Product will be 100% conforming to the requirements of the customer.
Repair Definition as per ISO 9000
Action on a non-conforming
product or service to make it acceptable for the intended use.
Note:
A successful
repair of a non-conforming product or service does not necessarily make the
product or service conform to the requirements.
It can be
that in conjunction with a repair a concession is required.
Explanation:
Any activity
or action taken on the Product or service to make it functionally usable. That
activity or action is termed as Repair Activity or Repair Action.
Before
performing repair activity, customer approval (Concession / Deviation) is
required. After Approval of Concession / Deviation, repair activity can be
started.
Reference of Rework and Repair in IATF 16949 standard.
Reference of Rework
In IATF 16949
: 2016 version, there is a reference of Rework as mentioned below
Clause 8.7.1.4 – Control of Reworked product
The
organisation shall utilise risk analysis (such as FMEA) methodology to assess
risks in the rework process prior to a decision to rework
the product.
Explanation:
Before taking
decision of performing Rework activity on Product, organisation must assess
risks (by risk analysis methodology like FMEA) involved in Rework Process.
Clause 8.7.1.5 – Control of Repaired product
The
organisation shall utilise risk analysis (such as FMEA) methodology to assess
risks in the repair process prior to a decision to repair
the product.
Explanation:
Before taking
decision of performing Repair activity on Product, organisation must assess
risks (by risk analysis methodology like FMEA) involved in Repair Process.
Now let us
understand the same through some Examples
Example of Rework
Required Outer
diameter of a Product as per customer Requirement (mentioned in Customer
Drawing) is 50 ± 0.2mm
During
Inspection, one Product observed with Outer Diameter = 51.20mm (Diameter is
oversize and is not as per customer requirement). This product is termed as
Non-conforming Product and cannot be dispatched to Customer.
Action to be Taken:
As this Diameter
is Oversize and have extra material to remove on OD, it can be re-machined to
make it conform to Drawing requirements and in turn customer requirement.
After Re-machining,
Diameter observed is 50.10mm which is as per Customer requirement.
After re-machining,
the Product now is a conforming Product.
Example of Rework |
Above
activity or action performed on nonconforming Product (Re-machining) is termed
as Rework.
Example of Repair
Let us take
the same Product Data for Repair example also
Required Outer
diameter of a Product as per customer Requirement (mentioned in Customer
Drawing) is 50 ± 0.2mm
During
Inspection, one Product observed with Outer Diameter = 49.60mm (Diameter is undersize
and is not as per customer requirement). This product is termed as
Non-conforming Product and cannot be dispatched to Customer.
Action to be Taken:
As this Diameter
is Undersize and have No extra material to remove on OD, it cannot be re-machined.
We must
approach to customer for Concession / Deviation (welding on OD and then again
re-machining to achieve required OD). If customer approves the same then perform
the activity on the Product.
After welding
and re-machining, the Product now is functionally usable but not as per the
customer requirement as we have carried out Welding.
Example of Repair |
Above
activity or action performed on nonconforming Product (Welding & Re-machining)
is termed as Repair.
Some more Examples of Rework and Repair
Rework:
On a
Rectangular MS Plate 3 Holes of Diameter 24 ± 0.2mm to be drilled. In one
Product, it was observed that Drill Holes were Undersize (23.6mm).
With Re-drilling
of required Size, part can be a conforming Product. This activity is termed as
Rework.
Repair:
On a
Rectangular MS Plate 3 Holes of Diameter 24 ± 0.2mm to be drilled. In one
Product, it was observed that Drill Holes were Oversize (24.6mm).
In above
case we must approach to customer whether we can Plug these holes and Drill new
Holes as per required Size.
If customer
approves this Deviation, we can Plug deviated Holes and Drill fresh Holes. In
this case Product will be functionally usable but it is not as per the customer
requirement.Above activity
is termed as Repair.
Example of Rework and Repair |
General Example of Rework and Repair (For Better Understanding)
If your two-wheeler
tyre is flat and there is no air in the tyre. You approach to Puncture shop.
Rework:
Shop owner checks
the tube and does not find any air leakage. He refills the air and hand over to
you. This activity is termed as rework.
Repair:
Suppose he
finds air leakage and if there is a puncture he will show you puncture in
the tube and with your permission (Deviation) he will seal the puncture, refill
the air and handover to you. This activity is termed as Repair.
Hope you
have understood Rework and Repair with above Examples.
Inspection Outputs
Now let us
summarise Overall activity / Flow of Inspection outputs
Nonconforming Output types and actions |
Now let us
summaries the Difference between Rework and Repair or Rework vs Repair
Rework
> 100%
conform to requirements
> Customer
approval not required. (Exception)
> Documented
Approval not required from Customer
> Low
Risk - It meets requirements.
Repair
> It is good for intended use. (Functional)
> Customer approval required. (Must)
> Doc. Approval reqd. from Customer.
> High Risk - Chances of Field Failures
Common Requirements – Rework & Repair
- Documented Information Mandatory
for How to carry out Rework / Repair.
- Work Instruction Required along
with Re-inspection and Traceability
- Risk Assessment of that defect
to include in FMEA
- Documented Information for
Disposition including Quantity, Disposition & Date of Disposition.
Feel free to
comment below if you wish to know difference between any other term, I will prepare
a separate post on that Topic.
Thanks and
Happy Learning Ahead…….
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