Rework & Rejection Analysis: Turning Quality Data Into Actionable Insight

Rework Analysis — When It Can Be Fixed

Rework happens when items fail their first inspection but can be corrected and put back into production. Left untracked, rework quietly drains resources and hides underlying process problems.

How the Flow Works

• Inspection data is recorded: Inspected Qty, Accepted Qty, Rework Qty
• If Inspected Qty > Accepted Qty, the difference triggers rework
• Defective items are sent back for correction and re-inspected after
• The system calculates Rework %, COPQ (Cost of Poor Quality), and PPM

What the Numbers Tell You

A Rework % of 20% isn't just a statistic — it's a signal. It means one in five items needed extra work, extra time, and extra cost. Tracking this by machine, operator, or product line helps you pinpoint exactly where the process is breaking down.

Rejection Analysis — When It Can't Be Saved

Rejection is the harder story: items that fail inspection with no path to correction. They become scrap, and every rejected unit represents lost material, lost labour, and lost time.

How the Flow Works

• Inspection data includes Inspected Qty, Accepted Qty, and Rejected Qty
• Rejected items are categorised: scrap, material defect, process defect, supplier issue
• The system calculates Rejection %, COPQ, and PPM
• High-rejection items are flagged for root cause investigation

Reading the Results

When you see a high COPQ alongside a rising rejection rate for a specific component, that's your cue to dig deeper. Is it a supplier quality issue? A worn tool? A process that needs updating? The data gives you the starting point.

The Quality Flow in Plain Terms

• Production runs → Inspection happens → Decision made
• Accepted items move forward in the process
• Rework items go back for correction, then re-inspection
• Rejected items are scrapped and logged
• Both dashboards feed into root cause analysis and process improvement

Tracking COPQ across both rework and rejection gives leadership a clear picture of what poor quality is actually costing the business — making the case for investment in improvement much easier to justify.

The Business Case

• Reduce waste and scrap costs
• Improve product quality and customer satisfaction
• Make data-driven decisions instead of educated guesses
• Build a continuous improvement culture grounded in real numbers

Quality data is only as valuable as what you do with it. Zentroo's analysis modules make sure your team always knows where quality stands — and what to do about it.