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Faurecia Excellence System

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Group Quality Department

Quality System Efficiency

The 6 Quality Basics->Rework under control

Purpose: Rework methodology

Scope: all production sites

FAU-S-PS-0640 / EN issue 01


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Rework flowsThe 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 unpredictableoperation we cannot foresee when and where rework will be needed nor how much timewill 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 toremove the part from the normal production flow, using a red hook, a red bin, or otherstandard methods.

The operator must clearly identify the part with:

9 a sticker (adhesive dot or arrow) marking the location of the defect

9 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 aqualifiedreworker.

If a non-conform cannot be readily withdrawn from the production flow, it is removed atthe end of the line. On the other hand, if rework time will not disrupt normal productionflow (e.g. cutting a thread, quick cleaning), the product can remain on the line. In such casethe 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, thereworker rejects it.

After rework, the part is returned to the line at the same spot where it was removed. Alltests and inspections at this workstation must be redone.


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The rework station

The rework station is a workstation specifically set up for and dedicated to rework. It hasits own display and instructions.

All of the equipment required for disassembling and reassembling the product is availableat the rework station and must have the same characteristics as those of standardproduction equipment (e.g. . Automatic screwdriver that counts the number of screws andverifies the angle and torque).

Rework must be performed as and when required, and before the end of the shift:

byqualified personnelThis qualification covers rework operations as well as knowledge of all aspects of qualityneeded to decide whether or not to reintegrate the reworked part in the flow (e.g. boundarysamples and master parts). It is recommended that the GAP leader do the rework when itis done off-line. If there are too many reworks, an additional person can beassigned to thisduty.

with specific instructions.

These instruction must specify:

9 which types of rework are permitted and which forbidden (e.g. no rework on airbagas the black box can not be opened)

9 rework method to be used (e.g. disassembly directions, weld location)

9 means of rework (e.g. grade of sandpaper for a finishing job in Paint).


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Record-keeping and an example of a flowAt 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.

Treatment of non-conforms (rejects and reworks) : example of a U-line

Tally countIIIIIIIIIIII

IIIIIIIIIIIIIIIIIIIIIIIIII

IIIIIWorkstation

Record defects

Non-conforms

ReworkStationReworkable

Record reworks

Not reworkable

Record

Record rejectsRecord

FINALINSPECTION

REWORKS

Tally count

ReworkCircuit

Legend:

Production flow

Red bin

Record

Flow of conforming

reworked parts

Flow of non-conforms

to rework

Record rejects

Record reworks

REJECTS


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General Information

Author :

GroupQSE

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

sps0640en rework

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