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    The 6 Quality Basics - Rework Under Control

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    patima_sv4875
    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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    The 6 Quality Basics - Rework Under Control

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    patima_sv4875
    113 views5 pages
    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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    Sps0640en Rework

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    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.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    113 views5 pages

    The 6 Quality Basics - Rework Under Control

    Uploaded by

    patima_sv4875
    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.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PDF, TXT or read online from Scribd
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    of 5
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    The key takeaways are that rework needs to be done off-line to not disrupt production flow, non-conforming products should be clearly identified and removed from the line, and there needs to be a dedicated rework station with the proper equipment and instructions.

    Non-conforming products should be removed from the production line as soon as they are detected using standard methods like a red hook or bin. They should be clearly marked with a sticker indicating the defect and taken to be reworked by a qualified person.

    A dedicated rework station is needed that has all the required equipment for disassembling and reassembling the product. It should have specific instructions for the types of reworks allowed and methods to use. All reworks should be done here by qualified personnel.

    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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