Management rework

Pressure to continuously improve ESH performance and stop taking continuous corrective action by correcting the underlying systematic failure. Another aspect of this is the tendency to continuously rework the same issues over and over again. Well-designed management systems should prevent this. 

Management s responsibility includes providing staff robust tools and processes necessary to accomplish their jobs efficiently. Complex, missing, or fragmented processes do not allow for easy operational execution, the ability to leave work at reasonable times, and may result in poor-quality output or rework. This type of environment quickly becomes dissatisfying to employees and results in poor morale, low efficiency, and ultimately lack of interest and loss of staff. 

It works best when everyone in the company is involved. Six Sigma is a management philosophy focused on eliminating mistakes, waste, and rework. It establishes a measurable status to achieve and embodies a strategic problemsolving method to increase customer satisfaction and dramatically enhance the bottom line. 

Other possible risk management measures range from control of recipes and specifications, awareness of the reuse of intermediate products in production (rework), and, in the case of carry over through the production line, discarding the first amount of product. 

As previously stated in Chapter 10, testing should be designed to detect errors in the developed computer system. If the testing process itself is not robust, that, too, will induce errors and rework. The testing conducted on 85 computer systems used across primary and secondary pharmaceutical manufacturing in several companies is analyzed here to examine test failures and how they were managed to closure. 

Transfer of software modules, configuration, graphics, data, and other software objects needs to be managed and controlled formally when building the validation and live environment. Control is also required over the development environment to avoid rework and inefficient software development. 

In an API facility, the construction manager is tasked with coordinating the overall construction and installation of the equipment within the process facility. The installation of the interconnecting components must be installed in a quality manner. Rework takes time and delays the entire process. 

Scrap and rework management planning for management of the disposition of parts for scrap and rework... 

One approach to analyze the performance of a process is to compare measures to an established standard, set of specifications, or customer requirements. The outcomes of the process can then be classified as acceptable or unacceptable. The unacceptable product is then scrapped, reworked, repaired, blended, or sold at a lower price. An unacceptable service usually requires rework, as well as management of an unhappy customer. This approach to the analysis of a process is an application of inspection. Inspection is useful to sort the good product or service from the bad, but without further analysis of the data, it provides no help in determining what should be done to improve the performance of the process. 

Going a step further, the cost standards only measured operating performance with no regard for quality or overall yield. A manager could push a lot of material through a process and look good from a cost basis even though the product was substandard and/or required rework. This could easily happen in intermediate process steps where the material is passed on to another process. 

As discussed in The Inventory Chapter, 5 of the Toxic Substances Control Act (TSCA) requires that all chemicals manufactured, processed, or used in the United States must be on a comprehensive list of chemicals maintained by the United States Environmental Protection Agency pursuant to 8(b) of TSCA, called the TSCA Inventory. When commercial product is not manufactured according to specifications, that nonconforming product could be, or could contain, a chemical substance not on the TSCA Inventory, which would limit the ability to sell the product as is or to rework it. This procedure deals with how to assess the TSCA implications of the management of manufactured nonconforming commercial product. 

The lifetime of most furnaces extends through a variety of sizes and types of loads, through a number of managers and operators, and through a number of reworks with... 

The second reason management should consider a rework of their safety program is for financial reasons. A lack of safety and the resulting injuries are costly. To protect businesses against costly litigation, when injuries occur, they carry state-mandated worker s compensation insurance. Worker s compensation insurance costs may be equal to 2.5 percent of the average employee s wages. ... 

When the intended aim is to change a formula, reduce costs or duplicate a formula, an evaluation is sought. Holistic tests (with same-different or triangular tests) can be used in the context of a similarity-based approach (beta risk). In practice, these tests can certainly be implemented, but at project team level they are impossible to manage because of insufficient participants. Rework of products is also difficult, because these tests do not provide any information on how products differ. We have therefore formalized an approach that can evaluate proximity between tests and a reference product. 

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