Is Zero Rework Possible?

Since we’re all printers here, the advantage of a using a Pareto Diagram instead of a ranked list should be obvious to us: a picture is worth a thousand words. Take a look at Exhibit A (right), which has both a ranked list and a diagram, and compare for yourself.

Exhibit A is last year’s Pareto Diagram from my in-plant showing $30,718 worth of rework spread out over some pretty typical rework causes. You probably see many of the same ones in your in-plant. All rework must be shown in your Pareto Diagram, as well as a cumulative percentage that quickly shows how big a problem it really is.