In response to the second of your two questions, are there clear definitions for the terms repair and rework?

Yes, IPC-7711/7721 Rev B section 1.4 Terms and Definitions provides clear distinction between Rework and Repair as follows:

REWORK is the act of reprocessing noncomplying articles, through the use of original or equivalent processing, in a manner that assures full compliance of the article with applicable drawings or specifications.

Whereas a REPAIR is the act of restoring the functional capability of a defective article in a manner that does not assure compliance of the article with applicable drawings or specifications.

Now in response to your first question, we would define this process a Rework. We perform this rework on a regular basis.

We are able to replate the gold fingers using an "equivalent processing" and we can measure the plating deposition thickness to "assures full compliance of the article with applicable drawings or specifications" as detailed in the IPC definition.

Gold edge contact re-plating is considered to be a Repair, not a Rework, and is detailed as such in IPC 7711/7721 section 4.6.3 of the Repair section.

The distinctions between "Repair" and "Rework" and "Modification" are also defined in IPC 7711/7721 section 1.4:

1. Modification
   The revision of the functional capability of a product in order to satisfy new acceptance criteria. Modifications are usually required to incorporate design changes which can be controlled by drawings, change orders, etc. Modifications should only be performed when specifically authorized and described in detail on controlled documentation.
2. Rework
   The act of reprocessing non-complying articles, through the use of original or equivalent processing, in a manner that assures full compliance of the article with applicable drawings or specifications.
3. Repair
   The act of restoring the functional capability of a defective article in a manner that precludes compliance of the article with applicable drawings or specifications.

October 2003 IPC-7711A/7721A

Because you are replating using chemicals and methods not originally on the CCA BOM, you are not returning the CCA to full print compliance, so it is considered to be a Repair. It may be fully functional, but just does not comply with the original process and/or materials. Performance of Rework is generally considered to be acceptable without customer permission, but performance of Repair methods is usually more strictly controlled and the customer may allow them outright if as done per IPC 7711/7721, or may require pre-authorization by the customer, or may not allow them.

It is important that this is defined clearly ahead of time within the contract, as agreed between User and Supplier (AABUS). Modifications are pre-approved changes documented by the customer and flowed down to the Supplier (usually) in the form of Engineering Change Notices (ECN).

You should always discuss the ground rules with your customer or supplier as the case may be, and document it as part of the Contract.

It is all a question of definition.

We define these activities as follows:

REWORK -- an operation that is carried out to rectify a manufacturing fault or error such as a soldering defect, a missing, incorrect or malfunctioning component. It is performed on the shop floor and usually follows the Inspection and Test procedures which reveal a defect.

REPAIR -- An operation carried out on an assembly that has passed all Inspection and QC tests, has been shipped and has subsequently failed "in the field". It is returned to the factory or a Repair Site where the repair is carried out. The actual procedures may be the same as Rework -- depending on the diagnosis of the fault -- but may also cover physical damage such as cracked PCB, broken traces, etc.

As far as the Solder Splash is concerned -- take your pick!

According to IPC-7711B/7721B Rework, Modification and Repair of Electronic Assemblies, the removal of solder from a gold contact finger constitutes a repair.

The definitions of the 2 classifications are as such:

Rework: The act of reprocessing non-complying articles, through the use of original or equivalent processing, in a manner that assures full compliance of the article with applicable drawings or specifications.

Repair: The act of restoring functional capability of defective article in a manner that does not assure compliance of the article with drawings or specifications.

My thoughts are:

Solder splash on contacts are caused by poor process control/design and therefore should be defined as rework as with any other defect associated with process control/design. Repair should be used for defects that have been caused by defective parts.