Rework KPI challenge

[Mohammed tawili 2]

Hi all ,

it is my pleasure to start hit the topic of rework KPI .Currently , it quite uncommon to see the rework KPI impact due to misunderstanding the knowledge about it.

Also Due to limited capability in CMMS that able to compare work orders based on the same failure codes for identifying reworks and is fully dependent on planner’s knowledge to whether flag it as rework or not , then there could be a trouble of wrongly flagging a rework or not recognizing it or simply not reporting it.
 

How would you verify the rework at your respective plants.

 

Edited March 19 by Mohammed tawili

[Raul Martins 36]

Hi @Mohammed tawili,

Great topic!

Honestly, this is something that I always had problems with. Pretty much the same situation: companies relying on planners to flag the work order as a rework, which ends up not happening.

One thing that in my view influences this "not flagging" situation is culture.  If someone works at a place that failing is something unacceptable, people might be afraid of admitting something as a rework.

However, from a process perspective, I have no much experience about how to tackle it. I will try to see if I can find more information in regards to this and let's see if someone else has another perspective about this.

Regards,

Raul Martins

[Raul Martins 36]

Hi @Mohammed tawili,

I have been thinking about this topic and it reminded me of one of the 4 steps of THE ROAD TO RELIABILITY™ e-book: Defect Elimination.

By implementing a defect elimination process, you will be able to analyse the failures that have occurred on your site and identify the root cause of the failures, such as poor workmanship or improper procedures.

Relying only on planners without having such process implemented or without training them, will result in a KPI that does not display the reality of you rework percentage, stopping you from improving your results.

What are your thoughts about it?

Regards,
Raul Martins

[Mohammed tawili 2]

@Raul Martins I could not agree with you more! It is defect elimination process where it should be looked from system aspect ( Asset Management ) and assure such gap is fully governed ... I already rolled it out within the Quality Assurance program I currently led and hope to see great results. as matter of fact , I would pull out the data with histories from CMMS and try to figure out on qualitative approach according to failure mode, description and histories if the particular work order should have been ticked as rework or not. End of the day , I will show compliance graph during QA monthly report  along the violators so I can have faster paced culture change and TOP leadership support on such issue. At same time, conduct multiple awareness session. 

how this sounds to you?

[Raul Martins 36]

Hi @Mohammed tawili,

It seems to be a good idea. Once you have such data, you will probably classify by failure mode, equipment family, criticality and then create an action plan to improve such numbers, correct?

By the way, just make sure that flagging as a rework is a step mentioned on your Defect Elimination procedure, so that you can ensure everyone will have the same approach as you.

Regards,

Raul martins 

[Mohammed tawili 2]

@Raul Martinsthanks indeed!