Rework Prevention to Implement Lean Manufacturing Using Six Sigma.

rework reduction


In this article, you will learn what is rework and how to reduce it using Six Sigma Techniques and Tools as part of the lean manufacturing initiatives.

Rework Definition

Correcting of defective, failed, or non-conforming item, during or after inspection.

Rework includes all follow-on efforts such as disassembly, repair, replacement, reassembly, etc.

If you fix something because you did not do it correctly the first time that is reworked.

Difference between Rework and Repair

Most people confuse and interchange the term rework with the term repair.  But, it is not the same.

Rework – Bringing a non-conforming part back into conformance by simply reprocessing a prior sequence. Do not confuse it with the term “repair” since is not the same.  six sigma definitions

Repair – Bringing a non-conforming part back into conformance using methods outside the original process.

How to Reduce the Rework in 20 Steps.

Here the 20 ways to reduce rework in your manufacturing areas.

  1. Create procedures and instructions with visual aids to improve the quality and reliability of your process.
  2. Plan out work ahead considering all potential scenarios, milestones, and constraints.
  3. Implement a follow-up system and tracker of all your activities, use an agenda and checklist effectively.
  4. Focus on priorities. Start with the highest priority and end with the lowest priority work.
  5. Bring training in all your procedures and operations before starting them.
  6. Determine the specialization required to make the job and prepare your dream team.
  7. Implement a buddy system (big brother system) to support your teammates when they need help.
  8. Establish a top priority, the reduction of rework.
  9. Build up a good documentation practice in which all your activities shall be registered, monitored, and tracked to reach the best performance.
  10. Select the best quality materials and components for your product.
  11. Increase the supervision to guarantee the highest output.
  12. Create a robust design in accordance with compliance Standards.
  13. Increase the communication and collaboration between different departments.
  14. Make sure you understand the customer’s requirements.
  15. Establish effective management systems, tools, and decision-making techniques.
  16. Construct an intelligent plan and manufacturing schedule considering the supplier’s inputs and constraints.
  17. Minimize the interruptions.
  18. Establish metrics to measure and perform the data analysis of the Reworks.
  19. Implement automation and leverage technologies of visual inspection and robotics.
  20. Enforce a continuous improvement program to increase quality output and performance.

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CIQA is a quality and regulatory consultant with 25 years of experience developing products and managing projects in the medical device supply chain, and pharmaceutical industries. Rest assured of the safety or being in the right hands.

Our Lean Manufacturing team could provide you a broad range of professional expertise implementing these techniques and tools.


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Quality procedures templates

Three (3) Options to Create Document Control Management DCM Procedures:

Bronze Option. You Can Create Your Own Quality Procedures, using a Template.

You can download samples of the Document Control Management DCM procedure templates in .pdf format. 

To see the complete list of the most popular quality procedures templates, click here.

In addition, you can request a quotation to buy online a full SOP template document in MS Word format that is completely editable, ready to fill, and adapt to your specific needs.

Silver Option. We Can Bring You Formal Training about how to reduce rework.

This option is recommended if you want to learn more about how to build robust quality system procedures. One of our expert(s) can provide online step-by-step training to your team (unlimited assistance) on how to build reliable SOPs using our template(s). Also, you can improve your corporate quality procedures and policies by incorporating our template(s) and tools.  It includes a fully editable template from the Bronze option, plus training, exams, and a training certificate for each assistant.  Request a quote now.

Gold Option. We Can Create Customized Quality Procedures.

One of our expert(s) will create and prepare your customized SOPs with the inputs and specific information of your company. It includes a fully editable template from the Bronze option, plus online support in document creation, implementation, and training. Request a quote online.

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REFERENCES: How to Reduce Rework.




Picture of Ramon Cayuela, MS, BS, Chemical Engineering

Ramon Cayuela, MS, BS, Chemical Engineering

CIQA President and CEO.
I've been working in validation engineering since 1992 with many multinational pharmaceutical companies. I love sharing my passion and knowledge with others. If you have any questions about anything (or just have general questions). I will be more than happy to assist you. You can count on the BEST customer service on CIQA. I go to great lengths to make sure my clients are 100% satisfied with their purchases and check emails/messages consistently throughout the day. You can rest assured that everything being sold here is as-described or your money back. I look forward to working with you!