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Rework#

Estimated time to read: 7 minutes

Rework is the process of routing Material through a temporary repair Flow due to a detected defect or failure. After the repair is completed, the Material returns to a specified Return Flow Path position, referred to as the Return Point. This ensures defective Materials are reprocessed in a controlled manner, maintaining process integrity and traceability, while reducing waste and improving production efficiency throughout the workflow.

Overview#

In this tutorial, we will explore the following key sections:

  • Overview
    Introduction to the Rework operation — its application and value in manufacturing workflows.

  • Rework Configuration Scenarios
    Key configuration elements required to enable and manage Rework operations:

    • Setup
    • Reasons
    • Go To and Return Flow Paths
    • On Rework Rules
    • Applicable States

  • Rework Limits
    Managing Rework Limits and Resetting Counters.

  • Final Considerations
    Supplementary information.

Rework Configuration Scenarios#

This section details the configuration required to enable and manage Rework within a Flow, covering all necessary elements to guide you through setting up Rework Paths effectively.

Tip

To follow along with this tutorial, use this Master Data file, which contains all necessary data to replicate the examples.

Setup#

Before starting, ensure the Master Data is loaded in your MES, and select the Flow you wish to work with.

For this tutorial, consider the Assemble Child Flow illustrated below, which contains essential Steps involved in semiconductor assembly operations and will be used to demonstrate the configuration of Rework Paths.

Screenshot showing a manufacturing process step, specifically die attach, as part of the rework assemble process.

To begin, select Edit on the toolbar and choose the Step where Rework will be configured. Then, open the Step Configuration panel by selecting the icon on the right side of the Step section.

Use the and icons to add or remove Rework Paths for that Step, and for each Rework Path, specify:

Reasons must be of type Off-Flow. They are configured at the Step level, and when assigning a Reason to a Step, it must be applied specifically for Rework. For more information, see Manage Reasons.

You must associate one or more Reasons, and if multiple Reasons are defined for a given Step, you must select one when performing the operation.

Screenshot showing setup options with "Reasons" and "Step" fields.

  • Go To Flow Path: Specifies the Flow Path where the Material will be routed for Rework.

  • Return Flow Path: Defines the Flow Path where the Material will re-enter after completing Rework. This Return Point can be the same Step from which Rework was initiated or a different one, depending on your process.

Screenshot showing a setup configuration for rework, highlighting the return flow path selection.

Security Feature

The Material.ReworkOverride security feature allows authorized users to override specific steps within the rework process. Access to this feature should be restricted to specific roles to ensure traceability and process control.

The On Rework Rule defines a specific Rule (linked to DEE Actions) of scope Material Tracking, that is triggered when a Material is routed through a Rework Path.

This Rule enables automated actions when entering or exiting a specific Step, such as sending notifications or opening a quality protocol.

Screenshot showing a setup for overriding rework rules, with focus on Material.ReworkOverride security feature.

  • Applicable to Queued - Enables the Rework Path when the Material is in a Queued state.
  • Applicable to Processed - Enables the Rework Path when the Material has already been Processed.

If the Material is not in the configured state, the system will prevent Rework.

Screenshot showing a setup for enabling the Rework Path in a manufacturing process.

The following video presents a general walkthrough of the Rework Path setup:

Note

For more information, see Rework Material.

Rework Limits#

Excessive or uncontrolled Rework can compromise product quality, traceability, and overall efficiency. To prevent this, limits can be configured at the Product, Step, or Reason level, applied individually or in combination, based on your process needs.

This section explains how to set up Rework Limits, track Rework counts, and how to reset counters when needed.

To begin, use the Rework Limits section under the General Data section of the Create Product wizard, as demonstrated below.

This limit sets the maximum number of times a Product can be reworked.

Select whether to Apply Global Rework Limits (defaults to false).

When enabled, define a Global Rework Limit greater than or equal to 0. If set to 0, the system will prevent Rework for this Product.

Screenshot showing the Global Rework Limit configuration settings.

To learn how to Apply Global Rework Limits, watch the following video:

This limit controls how many times a Material can be reworked at a specific Step.

Select whether to Apply Step Rework Limits (defaults to false).

These limits are defined in the Step Rework Limits Context Smart Table, where each Step can be assigned a Rework Limit.

Screenshot showing a checkbox selection option for applying rework limits.

To learn how to Apply Step Rework Limits, watch the following video:

This limit controls how many times a Material can be reworked for a specific Reason.

Select whether to Apply Reason Rework Limits (defaults to false).

These limits are defined in the Reason Rework Limits Context Smart Table, where each Reason can be assigned a Rework Limit.

Screenshot showing a dialog box with options related to applying rework limits, specifically for selecting whether to apply reason rework limits.

To learn how to Apply Reason Rework Limits, watch the following video:

Note

For more information on how to configure Rework Limits on Products, see Create Product.

Information about the Rework status is displayed in the Holds/Off-Flows/Rework section of the Material, under the Reworks & Off-Flows tab:

Screenshot showing a graph or chart related to rework limits on a production track.

Reset Counters#

The system tracks the number of times a Material has undergone Rework. If a Material has reached its configured Rework Limit but additional Rework is considered necessary, the Material.ResetMaterialReworkCounters security feature allows authorized users to perform a reset of the counters. For more information, see Reset Material Rework Counters.

Screenshot showing a rework reset counter interface.

Security Feature

Access to the Material.ResetMaterialReworkCounters security feature should be restricted to specific roles to ensure traceability and process control.

Final Considerations#

Return Point#

  • Prior to version 11.0: the Return Point for a Rework Path was required to be within the same Child Flow.
  • Since version 11.1: the Return Point can be set to to any Step within the Main Flow, making the configuration more flexible and practical.

Rework Path Inheritance#

Flows inherit Rework Paths from their Child Flows. Therefore, Rework Paths configured within Child Flows are automatically available for Materials processed in the Parent Flow. For more information on this inheritance behavior, see Rework Flow Paths.