Automation ROI and payback: a business case operations can verify
Separate installed cost, cash savings, released capacity and recurring expenses, then test a conservative scenario before approving automation.
Rework
Additional processing of a unit to bring it into the required condition after an initial failure.
Rework can recover final good output while consuming labor, material and constraint capacity. Preserve the original unit identity and first-attempt result so repeat attempts do not inflate production counts. Compare first pass and rolled throughput yield when a high final yield hides a costly rework path.
See also: First-pass yield (FPY) · Nonconformance
Use the concept: Downtime log template · SMED changeover observation template · Takt time calculator
In depth
First pass yield vs rolled throughput yield: expose the rework path
Calculate stage yield and cumulative first-time success, keep rework visible, and avoid averaging percentages across incompatible populations.
MES software selection: requirements that survive go-live
Select manufacturing execution software that lasts — shop-floor requirements, integration ownership, vendor evaluation, and pilot criteria that predict success.