The process of diagnosis, repair, and rework is essential to ensure that non-conforming products are correctly analyzed, corrected, and returned to the production flow or discarded with traceability.
This process is common in environments of electronic production, automation, embedded systems, medical devices, and technical laboratories, where precision in identifying the root cause and the quality of the repair are fundamental.
Well-done rework starts with precise technical diagnosis and ends with reliable validation.
🧩 Process Steps
| Step | Technical Description |
|---|---|
| Diagnosis | Failure identification via functional test, logs, visual or electrical analysis |
| Repair | Replacement, firmware correction, soldering, component or connector adjustment |
| Revalidation | Repetition of tests, logs, and release with tracked serial number |
⚙️ Typical Tools Used
- Functional test benches with log capture
- Logic analyzers, oscilloscopes, multimeters, inspection cameras
- Diagnostic scripts with detailed error messages
- Traceability software with failure status and rework history
- Rework stations with thermal control, flow, and ESD protection
🏭 Where is Diagnosis and Rework Applied?
The process of diagnosis and repair is not limited to the manufacturing environment. It can be applied both:
- In production lines, during the final test (End of Line), to identify and correct failures before product release,
- As well as in screening and post-sale repair centers, where returned products are screened, analyzed, and revalidated for return to the customer or reintegration into stock.
In both scenarios, standardization of the process, traceability, and well-defined technical criteria are essential to ensure reliability and quality.
🔧 How AJOLLY Testing Supports Diagnosis and Rework
AJOLLY Testing structures diagnosis and rework processes with a focus on precision, traceability, and technical reliability, providing complete tools and systems.
🧠 Automated Technical Diagnosis
- Test sequences with point-to-point verification
- Identification of common symptoms, signal comparison, and automatic measurement
- Integration with dashboards of top failures, Pareto, and statistical analyses
🛠️ Repair and Revalidation Tools
- Rework stations with controlled flows and precision tools
- Revalidation scripts that replicate production testing with stringent criteria
- Visual interface for technicians, with probable cause messages and step-by-step instructions
📁 Traceability and Quality Control
- Recording of serial number, defect, responsible technician, and batch
- Complete history with status “NG”, “REWORK”, “OK”
- Support for CAPA actions and continuous improvement with real failure data
With AJOLLY Testing, rework ceases to be an improvised rework and becomes a controlled, documented, and integrated step in the quality process.