An inspection report comes back with a reject quantity, and the next message asks a commercial question disguised as a technical one: can the batch be reworked? The answer depends on the defect, not on the schedule, and the decision rules should exist before the batch is built.
This guide is part of our Charger Quality & Inspection. Read the full topic guide for the decisions that come before and after this step.
Not all defects are reworkable
Rework is justified when the intervention restores the unit to the approved specification without compromising safety, reliability or appearance. It is not justified when the process itself damages the part – a solder joint reworked twice, a housing opened after final assembly, a connector reseated beyond its rated cycles – or when the defect touches a safety-critical parameter. The first step is classifying the defect, not scheduling the repair.
Category A: cosmetic touch-up
Cosmetic defects on the enclosure – a light scuff, a small print blemish, a dust inclusion in a matte finish – can often be reworked by replacing the affected part rather than repairing it. Because the electrical assembly is unaffected, the risk is low and the re-inspection can be limited to appearance against the approved reference. The commercial question is whether the cost of the replacement part is lower than scrapping the fully assembled unit.
Category B: component-level rework
Component rework includes replacing a connector, correcting a solder joint, or reflowing a specific component. This category carries real risk: heat exposure, flux residue, mechanical stress on the board and the possibility of a latent defect that passes the functional test today and fails in the field. It should be governed by a written instruction with a temperature profile, an approved tool, a maximum rework count per board, and mandatory re-inspection at the affected gate.
Category C: scrap-only failures
Some defects end the unit’s life: a damaged transformer, contamination inside a sealed assembly, a cracked PCB, or any failure that would require opening a unit that is not designed to be opened. Scrapping is the correct decision, and a factory that proposes rework for this category is a warning sign about how it treats risk. The scrap should be recorded and, where the customer requires it, witnessed or documented before disposal.
| Category | Example | Decision rule |
|---|---|---|
| A – Cosmetic | Print blemish, light scuff, part replacement | Low risk; re-inspect appearance only |
| B – Component | Connector replacement, solder correction | Written instruction, rework limit, gate re-inspection |
| C – Scrap | Cracked board, contamination, sealed damage | Scrap; document and dispose |
Why rework has a boundary and who sets it
The boundary is set by the product’s reliability requirement and the process capability, and it should be agreed before the first shipment. A practical rule is that any rework affecting the electrical assembly must be authorised in writing, must have a maximum count, and must be recorded against the unit’s traceability code. Uncontrolled rework is one of the most common sources of field failures that cannot be explained from records.
Re-inspection scope after rework
Re-inspection must cover the parameter the rework could have affected, not only the original defect. A connector replacement requires an electrical test and, where relevant, a pull or seating check. A housing replacement requires an appearance check and a functional test after reassembly. Where the rework changes the thermal path, an aging or load test is appropriate. The scope should be written into the rework instruction rather than decided by the operator.
Traceability of reworked units
Reworked units should carry a distinguishable traceability mark so that a later claim can be linked to the intervention. This does not mean marking the product visibly to the end customer; it means the internal record links the date code to a rework event. Without that link, a field failure in six months cannot be attributed, and the investigation stalls.
What the buyer receives as proof
- Rework quantity by defect category, with the instruction referenced
- Re-inspection results for the affected parameter
- Scrap quantity for the non-reworkable category
- Traceability record linking reworked units to the batch
- Statement of the final disposition for the whole lot
Commercial terms: who pays for rework
Rework caused by the factory’s process is normally at the factory’s cost, including the second inspection and the delay. Where the defect arises from a customer-approved design or a customer-supplied component, the cost allocation changes. The point to settle in advance is not the principle but the mechanism: who authorises the work, who records the hours, and how the cost appears on the invoice or the credit note.
Rework approval checklist
- Defect classified as A, B or C
- Written rework instruction with tool, profile and limit
- Re-inspection scope defined for the affected parameter
- Traceability updated for every reworked unit
- Scrap recorded and disposed of under the agreed procedure
- Corrective action raised for the root cause, not only the units
FAQs
Can a rejected charger batch be repaired and shipped?
Only where the defect is reworkable without compromising safety or reliability, and only with a written instruction, a bounded rework count and re-inspection. Cosmetic rework is usually straightforward; electrical rework needs stronger controls.
Does reworked stock need new traceability codes?
The batch code can stay, but the rework event must be recorded against the affected units so that a later claim can be linked to the intervention.
Who pays for rework and re-inspection?
Typically the party responsible for the defect. Process-caused defects are usually at the factory’s cost; customer-approved design issues may be shared. The mechanism should be agreed before the first shipment.
Next step
Wecent Group controls rework through written instructions and re-inspection at the affected gate, with batch records retained for traceability. Send your quality and disposition requirements to the contact page. Related reading: inspection gates, 8D defect handling, quality control and batch traceability. External references: AIAG, ISO 9001, ISO 2859-1 sampling, IEC standards, GS1 standards and UL.
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