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Rework Production

Rework may be necessary when production problems arise. You can often rework or repair defective assemblies to make them usable. Work in Process provides several options for handling rework. The method you choose depends on the product you are building, your manufacturing process, and the nature of the problem.

The options available are as follows:

Reject Intraoperation Step

When it is possible to rework defective assemblies at their present routing operation, they can be moved into the Reject intraoperation step of that operation. This isolates them from known 'good' assemblies at that operation.

The system views assemblies moved into the Reject intraoperation step from the Queue or Run intraoperation step of the same operation as complete at that operation and updates operation completion information, backflushes pull components, and charges resource costs and overheads accordingly.

You can now perform the rework. When rework is complete you can move the repaired assemblies to the Queue, Run, or To move intraoperation step of the next operation.

If you do not want to rework defective assemblies at their present operation, you can alternatively move them to the Reject intraoperation step of a prior operation. This avoids recreating an operation completion (Queue or Run to Reject and Queue, Run, or To Move to the next operation) at the current operation.

If necessary, you can move irreparable assemblies into the Scrap intraoperation step of the current operation. Moves from the Reject to the Scrap intraoperation step, do not complete assemblies since rejected assemblies are already considered complete. See: Intraoperation Steps.

Rework Operations

When you regularly rework certain assemblies, you may find it convenient to add 'rework' operations to the primary routings of these assemblies. You can then move assemblies that need rework into these operations. Good assemblies bypass these operations.

Rework operations should be set to count point off/autocharge off so that when good assemblies bypass them, the system does not automatically transact operation completions for these operations. In other words, you only need to move assemblies into these operations if they require rework.

Non-Standard Discrete Jobs

You can also use non-standard jobs to perform rework activities. Before defining non-standard jobs for rework, you must first complete the defective assemblies by receiving them into a non-nettable rework subinventory. This subinventory helps you to isolate these assemblies from the known good assemblies.

Once you determine the proper rework steps for these assemblies, you can define a non-standard discrete and add the operations and components required for the rework. You can also create a rework routing that specifically addresses this type of rework. See: Rework Assemblies.

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