Repair/Reject Muda

The repair or rework of defective parts involves a second attempt at producing a good item.  Rejects involving scrapping of the whole part are a definite waste of resources.  Having rejects on a continuous flow line defeats the purpose of continuous flow.  Line operators and maintenance will be used to correct problems, putting the “takt” time off course.  Repair and rework may require nonconforming product forms to be filled out by suppliers generating muda.

Various design changes can be muda too.  Design changes are rework or a development effort causing additional labor.

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