Horror Story
A company I once worked for had product that was receiving a large number of customer complaints in regards to a dimensional characteristic. In response, the engineers and quality people researched what the dimensional spec should beto eliminate this cause of customer dissatisfaction. Inspection gaging was modified to inspect for this new specification. Less than one week after implementing the new gaging, the plant manager and the engineering manager dictated that the old specification be reinstated due to a 30% scrap rate in manufacturing.
It still makes no sense to me that they would change the specification to meet a process instead of changing the process to meet a specification.
This same company would also wait until a gage was machined and inspected to find out what it measured before they would assign nominal dimensions with acceptable tolerances.
