Type of Part / Manufacturing Process | Typical Part Function | Typical Defect(s) | Typical Rework Process(es) |
---|---|---|---|
Molded Plastic/Rubber | Multiple & Widely Various | Excess Flash | Trim with knife, razor, nippers, sandpaper, grinder |
Short Shot | Separation by cavity, or none 100% scrap | ||
Dimensional (caliper, scale, or go/no gauge) | Usually none; 100% scrap | ||
Presence/Absence of holes (visual) | Usually none; 100% scrap | ||
Hole size (gauges) | Possible drilling, reaming, or scrap | ||
Appearance | Usually none; 100% scrap | ||
Leak Testing | Usually none; 100% scrap | ||
Contamination | Usually none; 100% scrap | ||
Splay | Usually none; 100% scrap | ||
Warping | Usually none; 100% scrap | ||
Rips/Tears | Usually none; 100% scrap | ||
Stampings, Roll Formed, or Wire Forms | Multiple & Widely Various | Burrs / sharp edges (handling safety) | File, Nip, Sand, or Grind |
Dimensional (caliper or go/no gauge) | Usually none; 100% scrap | ||
Dimensional (caliper, check fixture, or go/no gauge) | Usually none; 100% scrap | ||
Hole size (gauges) | Possible drilling, or scrap | ||
Excess oil or other Surface Contamination | Wipe or Clean with/without solvents | ||
Mis-Hit | Usually none; 100% scrap | ||
Rust / Corrosion | Sand or Grind, with/without solvent, add rust inhibitor | ||
Cracks or Splits | Usually none; 100% scrap | ||
Castings / Forgings | Suspension, Brake or Drivetrain parts | Excess Flash | File or grind excess |
Burrs / sharp edges (handling safety) | File or grind excess | ||
Short Shot | Usually none; 100% scrap | ||
Dimensional (caliper or go/no gauge) | Usually none; 100% scrap | ||
Presence/Absence of holes (visual) | Usually none; 100% scrap | ||
Porosity | Usually none; 100% scrap | ||
Finished Body Panels | Class A Surfaces (Hoods, Trunk Lids, Bumpers) | Visual for any defects | Usually none; 100% scrap |
Plated, Coated, Painted | Appearance Sensitive Applications | Visual for "bubbles", scratches, appearance defects, missing paint or E-coat | Possible "Touch UP" paint or coating, sand/grind & return to plater/coater, clean, polish, or none 100% scrap |
Glass Parts | Windows | Visual for "bubbles", scratches, appearance defects | Polish out small defects, or none; 100% scrap |
Cracks or Chips | Usually none; 100% scrap | ||
Assemblies / Sub-Assemblies | Multiple & Widely Various | Presence/Absence of fasteners, holes (visual) | Manual "bench top" re-assembly |
Dimensional (caliper, check fixture, or go/no gauge) | Usually none; 100% scrap | ||
Missing or malfunctioning component parts | Manual "bench top" re-assembly | ||
Weld-Splatter, Missing Welds, Bad Welds | File, Sand, Grind, or scrap | ||
Bond/Adhesive Failure | Re-Glue/re-Bond, scrap | ||
"Fit" of Mating Components | Replace defective component/s & re-assemble | ||
Textiles / Fabric / Carpet | Multiple & Widely Various | Presence/Absence of fasteners, holes (visual) | Manual "bench top" re-assembly |
Presence of trimmed residue on appearance surface | Remove residue manually | ||
Delamination | Re-Laminate, Glue, Sew, or scrap | ||
Wire Harnesses | Automotive | Presence/Absence of all wires specified (visual) | Manual "bench top" re-assembly, or scrap |
Dimensional - individual wire lengths to spec | Manual "bench top" re-assembly, or scrap |
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Quality/Functionality of components (usually connectors) | Manual "bench top" re-assembly, or scrap |
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Correct orientation/location | Manual "bench top" re-assembly, or scrap |
||
Nuts / Bolts / Weld Studs | Multiple & Widely Various | Dimensional - usually thread functionality related (Thread Gauge, Mating Component) | Manual replacement of rejected component, possible tap or thread, or 100% scrap |
Incorrect Torque | Re-Torque to correct specification | ||
Electronics | Timers, Controls | Function Test / Inspection via electronic test equipment | Re-Flash or scrap |
General / All Part Categories | Multiple & Widely Various | Mixed Parts | Sort & re-package |
Mis-Label | Sort, re-label, re-package | ||
Damage in Transit (spilled or damaged containers) | Sort, re-label, re-package | ||
Dimensional - Oversized | Cut-to-size with knives, scissors, razor | ||
Dimensional - Undersize | Usually none; 100% scrap | ||
Off-Location Clips, clamps, fasteners | Manually relocate or scrap | ||
Contamination | Usually none; 100% scrap | ||
Incorrect packaging | Re-Pack | ||
Questionable/Wrong Counts per Package | Re-Pack with correct counts/quantities | ||
Experience & Capability: Typical Sorts & Inspections

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