Executing and Validating Rework

Objective

After completing this lesson, you will be able to perform targeted rework and validation.

Execution of the Rework Process

Note

Rework cannot be performed at the Component Workcenter POD. Instead, the worker opens the Component Manufacturing Rework POD either from the launchpad or via a bookmark:

To access the rework POD, the worker chooses the respective tile on the application launchpad.

The operator responsible for rework discovers the SFC in their worklist. They start the SFC at this operation by choosing the button Start which again triggers the visual guidance system.

To start the rework operation, the worker selects the SFC in the Work List and chooses Start.

The system guides the worker to address the missing screw, ensuring that the correct position screw is selected, and the operation is performed accurately.

The image shows an example of work instructions that are projected on the worker table: It visually indicates where rework must be performed (→ which of the three screws is missing) and what to do (→ tighten right screw).

In the background, SAP Digital Manufacturing reads the SFCs data collection and passes that information to the visual guidance system which again projects the position where rework is required to the device. Again, SAP Digital Manufacturing records production-relevant data, such as the torque.

The following business benefits are shown in this process step:

Improved Accuracy: The visual guidance system ensures that the operator selects the correct position screw, minimizing errors in the rework process.
Consistency in Operations: The visual guidance system standardizes rework operations, leading to consistent quality and reduced variance in product assembly.
Integrated Workflow: The seamless integration between the operator's actions and the SAP system ensures smooth workflow and real-time data updates.
Real-time Feedback: The system provides immediate guidance to the operator, decreasing the likelihood of repeated errors and accelerating the learning curve for new operators.
Informed Decision-Making: Access to accurate and precise data allows management to make better-informed decisions regarding production and resource allocation.
Reduced Waste and Costs: Accurate rework processes minimize the need for further corrections, helping reduce material waste and associated costs.

Validation of Rework

To ensure that rework was correctly done, the supervisor must crosscheck and validate the rework process to ensure compliance with quality standards. They open the rework validation function by choosing the respective button in the POD and log successful rework.

The screenshot shows the POD for rework. After rework was performed, the supervisor selects the SFC and chooses Rework Validation to document that they verified that rework was successfully executed.

They then open the data collection

To collect rework data in a data collection, the supervisor chooses the button collect.

and collect that rework was done successfully:

To document that the rework check was successful, they choose Done.

Finally, they move back to the main screen

To close data collection and move to the main screen, the supervisor selects Main.

and complete this operation.

To move the SFC to the next operation, the supervisor marks the SFC as completed by choosing the button Complete.

In the background, the SAP Digital Manufacturing system updates the data collection and evaluates the rework routing. The latter contains a return step which routes the SFC back to the operation where the rework step was initiated from. In our case, this is visual inspection.

The following business benefits are shown in this process step:

Quality Assurance: Ensures that rework is performed correctly and meets quality standards, reducing the chances of defective products reaching customers.
Process Compliance: Ensures compliance with established operational processes and quality standards through systematic validation.

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