Rework Control and Traceability Procedure

Standard operating procedure for storing, identifying, tracing, verifying, and reincorporating internal scrap and rework while maintaining same-composition control and full traceability.

Steps

• Quality Inspector identifies nonconforming material
  The Quality Inspector reviews the nonconforming material report, visually inspects the item against the defect criteria, and confirms it meets the threshold for hold or rework. Acceptance criteria: the defect is clearly documented and the material is removed from normal production flow.
• Production Operator segregates and stores the material in the rework hold area
  The Production Operator places the identified material in the designated rework hold area and secures it with the correct hold identification. Acceptance criteria: the material is physically separated from approved inventory and cannot be used in production until disposition is approved.
• Quality Technician records the source lot and quantity
  The Quality Technician records the source lot, quantity, date, and reason for rework in the traceability log and verifies the count or weight against the physical material. Acceptance criteria: the recorded quantity matches the verified quantity and the traceability record is complete.
• Quality Supervisor verifies same-composition eligibility
  The Quality Supervisor compares the material against the approved product specification, bill of materials, and batch record to confirm same-composition eligibility. Acceptance criteria: the material matches the approved specification with no differences in formulation, grade, color, size, or other controlled attributes.
• Quality Supervisor obtains disposition approval
  The Quality Supervisor reviews the non-conformance record and obtains documented approval for rework, scrap, or other disposition from the authorized approver. Acceptance criteria: the disposition is recorded in writing and linked to the affected lot before any reincorporation occurs.
• Production Operator re-identifies the approved rework lot
  The Production Operator applies the approved label or identifier to the rework lot and confirms the label matches the original traceability record. Acceptance criteria: the new identifier is legible, unique, and traceable to the original lot without ambiguity.
• Line Lead reincorporates the rework into production
  The Line Lead adds only the approved quantity of rework into the production batch and records the exact amount used in the batch record. Acceptance criteria: the rework is added under controlled conditions and the recorded quantity matches the amount introduced to production.
• Quality Technician re-verifies the final output and closes the record
  The Quality Technician inspects the final output against the acceptance criteria, confirms the rework did not introduce a new nonconformance, and closes the traceability record. Acceptance criteria: the output is conforming, the record is complete, and all disposition details are documented.