Context

Sample scenario: A production build resets tolerance tiers to recover cost stability. A tolerance tier reset is how you recover cost stability after an over-specified design.

A tolerance tier reset is a production move: keep critical features tight and relax non-critical ones to reduce CMM load and stabilize cost.

The Trap

The trap is keeping prototype-level tolerances in production. That drives inspection load and scrap long after the risk has passed.

The Geppetto Take

We reset tiers after pilot runs. Critical interfaces stay tight, but support and cosmetic features loosen to keep yield stable.

Evidence / Data

  • Over-tolerancing is a leading cause of late scrap in production.
  • Tier resets reduce inspection time without harming performance.

Control Actions

  • Review pilot data to identify stable features.
  • Reassign features to A/B/C tiers.
  • Update inspection plan to match tier reset.
  • Lock revised tiers in the drawing revision.

Checklist

  • Pilot data reviewed and archived.
  • Tier map updated and approved.
  • Inspection plan adjusted for new tiers.
  • Suppliers notified of revision change.

What to Send

Send pilot yield data and the list of features you want to relax.

FAQ

When should we reset tiers?

After pilot runs demonstrate stable performance.

Does this reduce quality?

No. It removes over-control, not critical control.

How do we document the change?

Through a controlled drawing revision and updated inspection plan.

CTA

Send a screenshot for a chaos-check.