We were having many rejects by a customer on a Ø.37535 ± .00025 ID.
We had been using Class X Gage Pins, which have a total tolerance of .00004. Following the 10:1 Gage tolerance rule; this class of Gage pins is just not accurate enough to catch the tolerance.
I told my calibration tech. to order Class XX pins (total tolerance of .00002). She mistakenly ordered Class XXX GP's (total tolerance of .00001). These GP's have a lead time of 5-6 weeks and the customer is expecting Gage R&R's using the new GP's way before that.
I figured, hey, this isn't ideal because we could be finding good parts to be bad, but at least there's no risk of calling bad parts good (due to the gage being more accurate than necessary).
The customer has concerns about this. They came back with essentially this: "this will increase scrap rates, which will then lead to using wrong measurement techniques to confirms parts which may result in errors."
I understand that it is not ideal, but I am really not concerned about the .00001 difference between the two classes of GP's increasing our scrap rate.
Does anyone have any insight on how you can justify using a slightly more accurate gage than necessary?
We had been using Class X Gage Pins, which have a total tolerance of .00004. Following the 10:1 Gage tolerance rule; this class of Gage pins is just not accurate enough to catch the tolerance.
I told my calibration tech. to order Class XX pins (total tolerance of .00002). She mistakenly ordered Class XXX GP's (total tolerance of .00001). These GP's have a lead time of 5-6 weeks and the customer is expecting Gage R&R's using the new GP's way before that.
I figured, hey, this isn't ideal because we could be finding good parts to be bad, but at least there's no risk of calling bad parts good (due to the gage being more accurate than necessary).
The customer has concerns about this. They came back with essentially this: "this will increase scrap rates, which will then lead to using wrong measurement techniques to confirms parts which may result in errors."
I understand that it is not ideal, but I am really not concerned about the .00001 difference between the two classes of GP's increasing our scrap rate.
Does anyone have any insight on how you can justify using a slightly more accurate gage than necessary?