Is Zero Rework Possible?

ANY REWORK IS TOO MUCH

I’ll wager that your reaction to rework is similar to mine, but whether it is or not, I think we can agree that the only acceptable level of rework for our in-plants is zero. As long as one has rework—any rework—there’s still work to be done.

But is zero rework really possible? Can we frail and imperfect humans pull off some system or methodology that can make that happen? Regrettably, in my in-plant that answer so far has to be “no.” Also, I’ve corresponded with many in-plant managers about rework; I know of one exceptional manager who has wrung so much rework out of his in-plant that it is now measured in parts per million, but even in his case, the answer is ultimately no.