What is the key difference between Repair and Rework?

It is not about being all the same. It’s about respecting differences: Unknown

Introduction

The interpretation of the words changes in the context of the situation where we are using it. The word ‘Sorry’ can be interpreted as ‘feeling sad’ or ‘feeling regret’ depending upon the situation where we are using it. Similarly, the word ‘Thanks’ can be understood as ‘relieved’ or ‘gratitude.’

Objective

Both Repair and Rework are an integral part of any manufacturing facility. Each has its significance and importance in the context of the situation. When these words are understood correctly, they can be effectively communicated and implemented in the organization. Let us understand their meaning, key differences, examples, similarities and present challenges.

Definitions: ISO 9000: 2015

Rework (Cl 3.12.8): Action on a nonconforming product or service to make it conform to the requirement.

Repair (Cl 3.12.9): Action on a nonconforming product or service to make it acceptable for the intended use.

Detailed Information

As per ISO 9001: 2015 and IATF 16949: 2016, both Repair and Rework have their specific meaning and intent.

The objective of these terminologies is to align the IATF Standard with the present scenario in the automotive sector as well as Customer Specific Requirement (CSR) of IATF subscribing OEM. One very common activity which happens in many of the organisation is Repair & Rework. So far, many of us were using both the terminologies interchangeably.

Example of Repair (IATF Clause 8.7.1.5)

1. After the machining process, if the thickness is less than required, we repair it by filling more material by the welding process and then re-machining it to make it acceptable for the intended use (adding material is not the approved process by Customer).
2. After the assembly process, during final inspection, if shade variation is observed on the painted components, the paint can be removed and components can be repainted to fulfil the intended use (although repainting may not be approved by the customer)   

Example of Rework (IATF Clause 8.7.1.4)

1. After the machining process, if the thickness is more than required, we rework it by re-machining it to make it conform to the requirement.
2. After the assembly process, while conducting the inspection, if any sub-assembly is missing, the operator can assemble the missed part and fulfil the specifications.

Key difference between Repair and Rework:

Key Similarities

1. Risk Analysis (FMEA) assessment
2. Documented process (Procedure) for both
3. Work instruction for Repair or Rework including re-inspection and traceability
4. Retention of documented information for disposition of Repair or Rework product

Present Challenges:

1. How often we read the definitions written in ISO 9000: 2015 & IATF 16949: 2016 and try to interpret it?
2. How often the organization is clear about the difference between Repair and Rework?
3. How often the organization take customer approval before Repair?

References:

IATF 16949: 2016

ISO 9000: 2015

Industry Experts

This is the 96^th article of this Quality Management series. Every weekend, you will find useful information that will make your Management System journey Productive. Please share it with your colleagues too.

Your genuine feedback and response are extremely valuable. Please suggest topics for the coming weeks.