Why Even 3% Rework is Too Much in Precision Manufacturing
In high-volume precision component manufacturing, rework is never “just 3%.”
It’s a signal that somewhere, the process isn’t seeing clearly enough.
When parts move from machine to rework table every day, you’re not fixing quality.
You’re firefighting with a blindfold on.
What That Extra Shift Is Really Costing You
Take this example:
- 1,000 parts/day
- 3% rework = 30 parts
- Avg. time per rework: 12 minutes
That’s 6 hours of skilled labor every day just spent rechecking, re-machining, re-hoping.
In a month? That’s over 130 hours lost to problems that could’ve been prevented upstream.
And that’s not counting:
- Energy, air, coolant used twice
- Delays in dispatch
- Internal trust deficits
- And the one part that still slips through and hits the customer
In precision environments, even one missed micron can lead to a gear not meshing properly, a shaft vibrating, an automated assembly line completely stopping or a bearing seat failing.
Why It Happens And Why It Keeps Happening
Most plants still rely on standard room inspection removed from the floor, removed from the process.
By the time the QC room flags a problem, production has already pushed through 40 more parts.
Your inspection system is doing its job just too late to help.
Real-Time Inspection is Now a Necessity
If your line is running parts with tolerances in microns, your feedback loop needs to work in real-time.
That’s where CalibroMeasure fits in.
We build systems engineered to bring standard room inspection accuracy onto your shop floor without the delays, disconnections, or dependencies.
our solutions enable:
- Inline/nearline absolute measurement (no master required)
- Instantaneous temperature compensation in measurement
- Submicron-level accuracy in rugged shopfloor conditions
- Instant feedback to operators and machines
- Faster process corrections to prevent error multiplication
- Coverage of critical features like runout, roundness, concentricity, PCD, and profile
In short, fewer surprises, faster fixes, and measurable control.
You’re in Precision Manufacturing, Not Guesswork
If you’re planning for rework, you’re building failure into your system.
And no amount of quality room investment will change that unless your inspection process moves closer to where the part is made.
It’s not about chasing zero rejection as a dream.
It’s about designing for it and that starts by killing the rework shift.
