Where rework comes from
- Scope agreed verbally and remembered differently.
- Measurements taken once and not verified.
- Details captured during sales that never reached the crew.
- Materials ordered against an outdated version of the plan.
- Changes approved by the customer but not recorded anywhere.
Why it stays invisible
Rework rarely gets a line in the accounts. It appears as a longer job, an extra trip, or a margin that came in lower than expected without an obvious reason.
Until it is recorded as its own category, it cannot be managed — only complained about.
A simple reduction loop
Log every return visit with a one-line cause. After a month, the causes cluster into three or four patterns, and those patterns almost always point at a specific handoff.
Fix the handoff, not the individual incident.