Thanks for the reply Tagin
For point #1, the manufacturing process has been well designed (e.g. poka yoke) that the likelihood of misassembly and/or error is low. So essentially the test station is a detective control to mitigate failure from design -- as far as I know PFMEA should only include controls to mitigate failure from process, so I am not sure if this is something to be included inside PFMEA.
On the 2% reject, I might say it is a mixture of design/fabrication tolerance. E.g. imagine 5 parts to be fitted together, but due to respective tolerances in dimension, at worst case scenario the gap could be too big and cause excessive leakage along the path, thereby reducing the flowrate. It is quite costly to control all these tolerances to a tighter spec as compared to implementing the test station, so several parts of "the right spec" which are "assembled correctly", could still be failing the total flowrate requirement due to the said tolerance.
For point #1, the manufacturing process has been well designed (e.g. poka yoke) that the likelihood of misassembly and/or error is low. So essentially the test station is a detective control to mitigate failure from design -- as far as I know PFMEA should only include controls to mitigate failure from process, so I am not sure if this is something to be included inside PFMEA.
On the 2% reject, I might say it is a mixture of design/fabrication tolerance. E.g. imagine 5 parts to be fitted together, but due to respective tolerances in dimension, at worst case scenario the gap could be too big and cause excessive leakage along the path, thereby reducing the flowrate. It is quite costly to control all these tolerances to a tighter spec as compared to implementing the test station, so several parts of "the right spec" which are "assembled correctly", could still be failing the total flowrate requirement due to the said tolerance.