Leak zone
Rework: where it leaks and how to measure it
Quick answer
Rework is effort spent doing the same job twice: callbacks on maintenance that did not hold, product that fails quality and must be reprocessed, and work lost or undone in the handover between shifts and teams.
What it looks like on site
Jobs come back, and shifts redo each other's work.
What we measure
Repeat work orders, quality failures, and handover breakdowns.
Key metrics
- repeat work order rate.
- first-time-fix rate.
- quality reject rate.
- callback rate.
What drives it
- Root causes left unaddressed, so repairs are temporary.
- Weak handovers that drop context between shifts.
- No standard for what good looks like, so quality drifts.
- Pressure to clear the board fast, so jobs are closed before they are finished.
How to fix it
- Track repeat work orders and treat them as defects to eliminate.
- Standardise shift handover so context does not fall through.
- Define and inspect the finished-job standard.
Frequently asked questions
How do you measure the rework leak zone?
By measuring repeat work orders, quality failures, and handover breakdowns. The Diagnostic quantifies it against your own CMMS and downtime data and translates it into annual dollars.
What does rework leak look like on a plant floor?
Jobs come back, and shifts redo each other's work.
See where your plant is leaking profit.
Score your operation across five leak zones in 3 minutes, or book a free 30-minute Fit Call to confirm whether a Diagnostic is the right next step.
15 questions. 3 minutes. Instant grade. No email required.