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Lean Definition: Rework

Rework is the act of correcting a defect. Rework is obviously waste, and can be avoided by eliminating the root cause of the problem.

The further downstream rework is done from where the error originally occurred, the more the problem costs to correct.

Rework is most commonly initiated after an inspection identifies the issue.

Repetitive rework should be a red flag to permanently fix a problem, often with a poka yoke device. Even if the rework takes little time, the risk of missing a defect is a numbers game. More defects mean more chance for one to escape to a customer.

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