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KPI Library – Rework Level

Rework Level


To ensure design, calibration, production and in process checks deliver a product/service which meets the intended specification first time, every time. This should avoid the requirement for onerous final quality control checks and the associated requirement to return sub-standard issues for costly rectification. The quantity of product/service which fails to meet with the required specification but is capable of receiving an amendment to meet compliance is termed the “Rework level”. The Rework level may be considered as a measure of the organizations’ effectiveness of meeting customer expectations first time without the requirement for correction or alteration.


Usually expressed as a percentage relating to a production “run” or period of service and based on a frequency appropriate for the business. Identification of the number of products from a production run/service period which require rework (and are subsequently passed as compliant with the original specification).


1000 gear shafts are inspected to identify any which fall outside tolerance; 2 of the shafts are identified as oversize. 2 of the shaft are reworked and subsequently passed as within specified tolerance. 2 divided by 1000 = 0.002 0.002 x 100 = 0.2% Rework level.