Quality & Operational Excellence

Rework and Defect Reduction Strategies

Rework and defects consume capacity, raise costs and frustrate customers. This course provides practical strategies to reduce defects: measuring the cost of rework, defect data collection, prioritisation, root cause analysis, error-proofing, process controls, supplier quality and sustaining improvement.

5 days Classroom or live online English

Smart Horizon Certified - Global Leadership Consultants

Take the course details with you.

Download the full standard outline: why attend, methodology, objectives, audience, competencies, the daily outline and current plans.

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Why attend

From knowledge to real-world impact.

Every defect prevented saves cost and time. You will learn systematic ways to cut rework.

Workplace challenges

Professional Problems This Course Is Designed to Solve

The programme explores practical approaches to the following challenges. Results depend on how the learning is applied in your organisation.

Difficulty translating subject knowledge into practical workplace decisions.
Inconsistent approaches to the activities covered in the course outline.
Lack of a structured plan for applying and reviewing new skills.

Course methodology

How you will learn.

Defect data exercises, root cause workshops, error-proofing design and case studies.

Course objectives

What you'll take away.

By the end of this course, participants will be able to:

Quantify the cost of rework and defects
Collect and categorise defect data
Prioritise defect reduction efforts
Identify root causes of defects
Apply error-proofing and process controls
Sustain lower defect rates

Target audience

Who should attend.

This course is suitable for:

Quality engineers and managers
Production supervisors
Process engineers
Service managers
Continuous improvement staff

Target competencies

Capabilities you will build.

Participants will develop competencies in:

Cost analysis
Defect data management
Root cause analysis
Error-proofing
Process control

Course outline

Your learning journey.

A focused, practical outline with time to explore, apply and reflect.

Day 1Cost of Defects

09:00–10:08Rework costs
10:08–11:00Hidden factory
11:00–11:30Coffee break
11:30–11:45Hidden factory (continued)
11:45–12:53Measurement
12:53–14:00Exercise

Day 2Defect Data

09:00–10:08Defect categories
10:08–11:00Data collection
11:00–11:30Coffee break
11:30–11:45Data collection (continued)
11:45–12:53Pareto
12:53–14:00Workshop

Day 3Root Causes

09:00–10:08Analysis tools
10:08–11:00Process and design causes
11:00–11:30Coffee break
11:30–11:45Process and design causes (continued)
11:45–12:53Verification
12:53–14:00Exercise

Day 4Prevention

09:00–10:08Error-proofing
10:08–11:00Process controls
11:00–11:30Coffee break
11:30–11:45Process controls (continued)
11:45–12:53Supplier quality
12:53–14:00Case study

Day 5Sustaining

09:00–10:08Monitoring
10:08–11:00Standard work
11:00–11:30Coffee break
11:30–11:45Standard work (continued)
11:45–12:53Recognition
12:53–14:00Action plan

The timings provided are estimates and may vary depending on the number of participants and the discussions taking place during the sessions. They are indicative only and do not constitute a binding commitment.

Dates & venues

Find a session that works for you.

Confirmed dates accept registration requests. Tentative dates are enquiry only.

Good to know

A few things to know.

How is the course delivered?

Our classroom programmes combine facilitated discussion, case studies, exercises and reflection. The precise format will be confirmed before enrolment.

Can you deliver this programme for our team?

Yes, you can enquire about a tailored programme. Share your goals, group size and preferred dates with our learning team.

Will I receive a certificate?

Participants who complete the programme receive a Smart Horizon certificate of attendance. Smart Horizon programmes are not externally accredited and do not award a professional qualification, licence or designation. Where a course title or outline refers to a professional certification (for example, AACE International's Certified Cost Professional), the programme supports learning and preparation only; the credential itself is awarded solely by the relevant professional body under its own application and examination requirements.

What should I confirm before booking travel?

Please confirm the session, exact venue, accessibility arrangements, fees and any visa requirements with the team before arranging travel. Tentative dates are not confirmed sessions.

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