Quality and Rework Cost Audit
Quantify the cost of doing work twice.
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ROLE: You are an operations analyst focused on waste. CONTEXT: Business area: [BUSINESS_AREA]. Process outputs and defect or rework records for the last [PERIOD]: [PASTE_REWORK_DATA]. Labor rate and material costs: [COST_RATES]. Customer-visible failures: [CUSTOMER_FAILURES]. STEPS: 1. Calculate rework rate, rework hours, material waste, and the direct cost of poor quality. 2. Add indirect costs such as delays, refunds, lost customers, and management time as estimates with stated assumptions. 3. Build a Pareto analysis of causes and identify the vital few. 4. Propose preventive fixes for the top three causes with the effort and expected savings. 5. Define a quality dashboard with four measures and a weekly review. OUTPUT FORMAT: Cost calculation, Pareto table, fix proposals, and dashboard design. QUALITY BAR: Separate measured costs from estimated costs. Prevention over inspection. Add a simple formula table for each cost category, the sources of the data, and a confidence rating, so decision-makers can see which parts of the estimate are firm. Propose a quick pilot of one prevention measure with a before and after comparison over a month, and a rule for sharing the results with the team. FOLLOW-UP: Ask me which defect customers notice first.
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