Rework orders from rejects or from stock
Pieces rejected for rework go through the extra steps you choose, on the same production order, so the time lands on its cost. A lot found bad later is reworked by its own order. Either way you record how many came good again and how many were scrapped.
PLANSFrom Growth
The problem it solves
- Rework is done in a corner with no record, and the order's cost looks better than it was.
- Reworked pieces are added back to stock by guess.
- A bad lot found in the store is fixed without anyone knowing what it cost.
- Nobody can say how much of last month's output was reworked.
How it works
- At the terminal, rejects are marked Rework with their reason. In Manufacturing > Shop Floor > Production Log, select them and choose Make Rework Order. You get one per production order, with the pieces and the stations they came from.
- Or open Manufacturing > Operations > Rework Orders > New, choose In Production or From Stock, the item, pieces, lot, where it is and why.
- Add the steps: what to do, the machine or station, and the minutes (10 to start with). Press Start Rework.
- In production, the steps are added as jobs on the same order; operators count them on the terminal as pieces good again. From stock, a production order is made that uses the bad pieces (lot kept) and makes them again.
- Press Done with Good Again and Scrapped. Good pieces go back into what the order makes; scrapped ones use up their share of the material. A rework from stock closes when its production order is done.
Everything it does
The rework order
- Numbered RW/2026/0001 and on
- Kind: In Production (to start with) or From Stock
- Production Order (open ones), Item, Pieces to Rework, Lot / Serial, Where It Is, Why (reject reason)
- Tabs: Steps, Rework Jobs, Instructions
- Good Again and Scrapped; Rework Production Order for rework from stock
- States: Draft, In Rework, Done, Cancelled
Rules
- Start needs steps and pieces to rework
- In Production needs an open order; otherwise rework from stock
- Serial items are reworked one at a time
- Good Again and Scrapped cannot add up to more than the pieces sent to rework
- A finished rework cannot be cancelled
- Make Rework Order takes only rejects marked Rework that have no rework order yet
From quality
- A non-conformance decided as Rework makes a rework order from stock for the item, lot and quantity, where the lot is. It opens to add the steps
Who uses it
SupervisorMakes rework orders from the production log, adds steps, starts and finishes them.
OperatorCounts rework jobs on the terminal.
Quality ManagerDecides a non-conformance as Rework, which makes the rework order.
Production ManagerReads what rework cost each order.
Where you use it
- Web: Manufacturing > Operations > Rework Orders; Make Rework Order in Shop Floor > Production Log
- The shop floor terminal: rework jobs in the station's queue
- Not in the SmartMy Manufacturing app as its own screen; rework jobs show among the jobs
What you control
Settings
- Minutes per rework step: 10 to start with
- Rejects Use Up Material: on to start with
Questions
Does rework time go on the order's cost?
Yes, for rework in production: the steps are jobs on the same order, so their machine time is in its cost. Rework from stock has its own production order and cost.Can we rework goods already in the store?
Yes. Choose From Stock: a production order uses the bad pieces, keeps the lot, and makes them again through your steps.What happens to pieces that cannot be saved?
Enter them as Scrapped when you finish. They use up their share of the material, so the loss shows.Can quality send a lot for rework?
Yes. When a non-conformance is decided as Rework and carried out, a rework order from stock is made for that lot.Related features
SHOP FLOORThe shop floor terminal: a tablet at each machineA tablet at each machine or station shows its jobs in big tiles. Operators sign in with a PIN or badge, and start and pause jobs. They count good and rejected pieces with a reason, and stop the machine with a reason. Every count goes straight into the order.PLANNING, QUALITY AND COSTQuality checks with sampling (AQL), held lots and non-conformanceCheck material as it comes in, each step on the floor, the finished product and goods going out. Each check has a sheet and a sample worked out from the lot. A failed check holds the lot, raises a non-conformance whose decision is approved, and a Rework decision makes the rework order.SHOP FLOORWork in progress value and the cost of rejectsEach open production order shows what is tied up in it. That is components picked so far at cost, and machine and labour time booked at the machines' cost per hour. The WIP list adds them up for the month end, and each order shows the value lost in rejects and scrap.PLANNING, QUALITY AND COSTProduction reports: plan against actual, material against BOM, scrap by reasonThree ready reports for the production manager. What was planned and what was made, by item and month. The material planned and used on orders. What was scrapped, by reason. Each opens as a pivot you can turn, filter and export.PRODUCTION AND JOB WORKOutsourced steps with a challan and a service orderSome steps are done outside, such as plating, heat treatment or painting. For these, the production order makes the challan and the vendor's service order by itself. Send the pieces, receive them back, and the step finishes with the pieces that returned.
See your shop floor on it.
Tell us what you make, how many machines and people you run, and how production is recorded today. We will set up a line with you and run a job on the terminal.