Non-conformance rework is actually extra works that need to perform to correct a product, process or component. When any product, process or service that does not meet the requirements as per standards, specifications, technical needs or customer expectation, it is require to perform as additional work. In this works need to fixing the defects so that the item became complete, without change its original functions, and design as per standards.
Usually, when a product / process is fails to comply quality and standards requirements. It is considered as nonconformance product. These products require rework to comply the requirements to match up to acceptable level. Hence, the manufacturing unit require to perform the rework tasks, such as:
- Correcting the defect of product or repair the product
- Manage, adjustment dimensions of product
- Reprocessing or repeating production steps
- Re-testing to ensure conformity, and re-inspection processes.
The rework process will be complete when the product corrects at level of acceptance.
Types of Non-conformances
There are basically three types of non-conformances with product that we can define to performing rework.
| Minor Non-Conformance | Major Non-Conformance | Critical Non-Conformance |
| If the dimensional / size or criteria deviation that does not affecting product’s performance, functionality or even safety concern. This type of non-conformance is possible to correct easily. | In case of Major NC, the deviation that impacts on product’s functions, performance, of non-compliance with standards. At this level, rework process should be approved by quality or engineering head. | The critical NC is only raised in case of product failure, safety related hazards, or it is violating regulatory requirements. This is actually highly review require, and require approvals before any action on it. |
How NC Identify?
Testing & Inspection process
It is common that, most of the non-conformances are identify and detect during the incoming inspection process, in-process or final inspection. The quality engineers are conduct the testing and inspection process as per requirements. They are conducting visual checks, instruments, gauges, and functional tests.
Customer Complaints
In some cases, customers are conducting the testing and they are identifying any non-conformance. Some non-conformities are identified during the installation of the product at end application at the customer premises. The defect or non-conformity from customer end rise the rework or replacement.
Internal audit findings
During internal audit, in case any non-conformances identify for the product, process or system. These NCs are requires to be records, and immediately require to correct in line with standards and customer requirements.
Process deviations
It is obvious that during the manufacturing operations, there are possible arising errors due to misconfiguration of machinery parameters, tooling issues, or operator mistakes.
Non-conformance rework report sheet
How to conduct rework process?
At the initial stage of process, evaluation of defect is needs. The Quality assurance, engineers evaluate feasibility of reworks, severity, and the method requires.
In the second step authorize personnel are approve the reworks before it starts.
The thirst step is to documentation and rework instructions. The clear documentations and rework instruction are much important. There will be all associate details such as tools, methods, and AQL include as per standards.
At the next step, the tasks of reworks are required to perform. The execution of reworks is performed by train personnel with authorized and approved methods.
In the final step, all the rework complete at the production lines, needs to be re-inspection and testing. The full quality inspection is required to confirming the conformity as per standards.