Rework & Repair Order Tracker

The problem this kills

A unit fails inspection. Somebody quietly fixes it. It ships. And nobody ever writes down what went wrong, how long the fix took, or what extra material it burned. Rework becomes invisible - which means your scrap-and-rework cost is a guess, your defect trends are a mystery, and the same failure keeps coming back because nobody can point to a record.

Most teams "track" rework in a notebook, a side spreadsheet, or someone's head. The original work order shows "done." The cost accountant has no idea the job was actually touched three times. The quality engineer can't tell you the top five defects. And there's no approval gate, so a unit can get reworked - or scrapped - with nobody signing off.

This tool makes rework a first-class, on-the-books event: every failure becomes a tracked rework order, linked back to the original work order, with its own steps, its own cost, and its own sign-off.

What you'll build

A small, private web app for your shop floor and quality team:

• Flag a failure against the original work order or unit that failed inspection.
• Open a rework order that captures the defect, a root cause if known, and the rework steps (the routing) you define.
• Capture the real cost - extra labor hours and extra material consumed during the rework.
• Re-inspect the unit and record the result.
• A human approval gate where a supervisor or quality engineer approves opening the rework order, and approves the final disposition (passed re-inspection, or scrap).
• A costed rework log you can export to CSV so cost accounting can finally see rework spend.

It links every rework order back to its original work order and the inspection failure, tallies rework cost separately from production cost, and guards against the same failure being opened twice.

What's inside the Implementation Plan

The plan opens by interviewing you about your shop - your inspection process, how you name work orders and units, your defect codes, your typical rework steps, your labor rates, and the messy exceptions (re-failures, partial scrap, vendor-caused defects). It reads back a short tailored spec and waits for your thumbs-up before building anything. You get a tool shaped around how your plant actually works, not a generic template.

Then it walks you - step by step, with a ready-to-paste prompt at the end of each step - through building the database, the login, the rework-order screens, the approval gate, the cost tally, the re-inspection step, and the CSV export. Every step explains what you're doing in plain language.

The governance it includes (this is the point)

• Login so only your team can open or close rework orders.
• Row-level security so each plant or organization sees only its own rework orders.
• A complete audit trail - who flagged the failure, who approved the rework, who captured the cost, who signed off the disposition, and exactly when.
• A hard human-in-the-loop approval gate - the tool drafts the rework order and the proposed disposition, but nothing is committed to the rework log until a supervisor or quality engineer reviews and approves.
• Duplicate guards - the dedupe key is the original work order plus the rework sequence number, so the same failure can't be opened twice as two competing rework orders.

Who it's for

Quality engineers who need defect and rework data, supervisors who approve and sign off rework, and cost accountants who need the true, separated cost of rework instead of a number hidden inside "production."

You've got this - paste the first prompt and let the interview tailor it to your shop.