Is Zero Rework Possible?

THE PARETO DIAGRAM

1| Identify and record the cause of every rework as it happens. (If you’re not already doing this, you should begin even if you have no intention of doing Pareto Analysis. Anything that is measured improves; no ifs, ands or buts).

2|Estimate the cost of each rework.

3| Note other factors of urgency that may give a cause of rework more weight than its dollar amount alone would indicate. One example of this would be a cause of rework that is usually caught by the customer only when the project is in his/her hands vs. a cause of rework that is usually caught and corrected by in-plant personnel before the project leaves the shop.