ReworkRate

ReworkRate is a quality metric used in manufacturing, software development, and service delivery to quantify the share of output that must be reworked after initial completion to meet requirements. It reflects inefficiencies caused by defects, miscommunication, or process deficiencies and is typically expressed as a percentage of total units or tasks processed.

Calculation is straightforward: Rework rate = (number of units or tasks requiring rework / total units or tasks processed) × 100. For example, if 500 units are produced and 40 require rework, the rework rate is 8%.

Rework Rate is related to, but distinct from, other quality metrics. It differs from defect rate (defects found per unit), first-pass yield (the percentage passing without rework), and scrap rate (units that are discarded rather than repaired). In practice, rework may include repairs, revisions, or retesting required to bring output up to standards. Applications include monitoring process quality, guiding improvement initiatives, assessing supplier quality, and evaluating software teams' post-release changes.

Data used to compute rework rate typically come from quality control logs, nonconformance reports, repair tickets, or issue tracking systems. Limitations include dependence on how rework is defined and detected, potential timing effects, and the possibility of underreporting or overreporting. It should be interpreted alongside root cause analysis and other performance metrics, such as Pareto analyses or Six Sigma tools, to identify where processes can be redesigned to reduce rework and improve overall efficiency.