While optimizing your processes to eliminate rework is a critical goal of operational excellence, in the meantime, it needs to be managed effectively and efficiently. Intraratio's RunCard offers a flexible and powerful way to manage rework scenarios. Check out how, below:
Inline Rework
Inline rework is the most straightforward and commonly used option. It allows users to send units back to any previous step in the same routing without needing to open a new work order. For example, if you discover that a component was installed incorrectly during the assembly step, you can quickly move the unit back to the installation step. This enables the operator to correct the issue without disrupting the flow of the remaining units. Inline rework is ideal for minor corrections that can be handled within the same line and routing.
Reprocess/Retest Work Orders
This option is useful when you need to process units through the entire flow again, but without consuming additional BOM components. A common use case is in RMA (Return Material Authorization) scenarios when returned products need to be retested or to go through certain manufacturing steps again. With this configuration, you can transfer returned items from inventory into a new work order and run them through the process without affecting material cost tracking, or stock levels.
Dedicated Rework Flow
The dedicated rework process is best suited for environments where rework needs to be handled separately, either due to quality protocols, traceability, or the use of specialized equipment. In this model, rework units are transferred to a new work order specifically configured for rework with its own process flow, stations, and tracking, separate from the regular production work order.
RunCard's rework capabilities are built to support real world manufacturing needs, from quick inline fixes to complex RMA and high volume rework management. By giving you the flexibility to choose the right approach for each situation, RunCard ensures you maintain production efficiency while preserving traceability and product quality.