By Larry MacAdams • April 30, 2018

Rework and Inspection

Manufacturing Product Rework and Inspection

Product rework is something no one wants to need but every good supply chain must include. There are many reasons that products may need to be corrected during or after inspection:

  • Packaging or label revisions
  • Packaging mistakes
  • Defective product (see Yankee Candle case study below)
  • Missing or skewed lot codes and expiration dates
  • Does not meet client product specifications
  • Conformance or new regulatory guidelines
  • FDA mandated changes
  • Revised marketing strategies
  • Salvage excess product supply

It is very stressful to discover a product defect during inspection when an expected ship date is approaching. Product rework is an effective solution when defects can be fixed in a timely and efficient manner. The rework should recapture the value of the order to an acceptable level for your customer, without causing more quality issues, delays and prohibitive costs.

When considering whether to rework your materials, ask yourself these questions:

  • How severe is the defect? Will customers reject or return the product?
  • What will it cost to rework the item?
  • Do I have the manpower and space?
  • Is there enough time?
  • What are the risks?

A good manufacturing practice is to maintain inspection/testing processes that can identify errors before the product reaches the customer. Carrying out rework before a product is shipped can save you time and money over waiting to address defects after an order is received. Major defects often lead to return of goods and leave the importer with a stock of unsellable product. But trying to send back defective goods to suppliers often leads to importers incurring expensive value-added taxes and custom duties. And, import restrictions may even prevent defective goods from entering the country.

Finding a qualified, secure facility to complete rework and inspection projects can be difficult and time consuming. L.P. MacAdams, located in Bridgeport CT., are custom fulfillment specialists that offer efficient solutions for complex rework and inspection projects.

The case study for Yankee Candle below shows how L.P. MacAdams resolved a defective vent stick product on-time and within budget in their 150,000 square foot facility.

Yankee Candle Vent Stick Rework and Inspection Case Study

Estimated Quantity – 160,000 packages in 16 different vent stick fragrances and heads

The Problem – the head of the vent stick has defective paint coating and is deteriorating within the packaging due to strong fragrance inside.

lpm-yankeeRework Process –

  1. Remove 4 vent sticks out of packaging and take the defective heads off each scented vent stick body.
  2. Mount new heads back on the scented vent stick bodies and repackage with new materials.
  3. Corrected units to be repacked in original inner and master carton.
Outcome – LPM arranged pick up of the defective units in Massachusetts, reworked the packages and sent back the corrected units  within the specified drop-dead dates and budget. During the inspection, 57,582 good units were found, returned to original case and inner box packaging to be staged for return.