AMIT BALLAL
Super Moderator
Why not add the production test as a detection control for earlier station(s) instead of adding as an additional operation?
The most common control for an inspection process [with a sensor] would be a calibration program. Others might include an R&R study, red rabbit testing, etc.
It is the case with us, all test items are always mentioned as Detection Actions.
We only add them also as Process Step when the test itself can physically harm/damage the product.
If I didn't understand your process incorrectly, "Failure mode caused by Leak tester" should come under detection- it being a monitoring/measuring equipment used to detect the failure mode. And if there are leakage failures occurring, occurrence rating should reflect the same. You can collect data of defects on a monthly basis (my suggestion, do what is best for your organization) to review whether defects are occurring in order to review occurrence rating.During our latest IATF 16949 audit we were cited a NC for improper occurence ratings. The auditor used our leak test as an example. He witnessed three leak test failures in a row and said that we should have them represented on the pfmea. We have leal test items on the pfmea but only for failure mode caused by the leak tester. Can you cited the AIAG standard to support your comment above? It will really help us out.