Treat rework as a second demand stream
Show rework loops as demand on the value stream rather than as background noise.
Draw the loop. Count the loop. Fix the source. Rework as Demand A returned item is not just a defect. It is another piece of work entering the same capacity pool. Percent Complete and Accurate At each handoff, ask whether the receiver can use the output without correction, clarification, or chasing. Low %C/A predicts downstream waiting. Five Whys Without Blame Ask why the process allowed the defect to move forward and why detection happened late. The goal is a process countermeasure, not a culprit. Future-State Test A good future state removes avoidable repeat demand before it reaches the constraint.
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