Here is some boundary sample info "benchmarked" from an OEM:
PURPOSE: Boundary samples are used as a supplement to the part inspection standard (e.g. visual or sensory) when the characteristics are difficult to define or communicate by any other method.
TIMING: From the production preparation through the life of the part.
REQUIREMENTS:
1. Boundary samples must be prepared for all items noted on the Inspection Standard as “per boundary sample”.
2. Preliminary boundary samples should be discussed prior to tooling and process development to determine quality expectations and process capability.
3. Boundary samples may also be created to define problems discovered in both production preparation and mass production stages.
4. Proposed boundary samples must be representative of confirmed process capability and be consistently achieved.
5. Boundary sample approval is based on internal quality standards, consumer acceptance impact, part design characteristics, and supplier process capability.
PURPOSE: Boundary samples are used as a supplement to the part inspection standard (e.g. visual or sensory) when the characteristics are difficult to define or communicate by any other method.
TIMING: From the production preparation through the life of the part.
REQUIREMENTS:
1. Boundary samples must be prepared for all items noted on the Inspection Standard as “per boundary sample”.
2. Preliminary boundary samples should be discussed prior to tooling and process development to determine quality expectations and process capability.
3. Boundary samples may also be created to define problems discovered in both production preparation and mass production stages.
4. Proposed boundary samples must be representative of confirmed process capability and be consistently achieved.
5. Boundary sample approval is based on internal quality standards, consumer acceptance impact, part design characteristics, and supplier process capability.
