For performance reasons, Pro/ENGINEER uses Relative Accuracy by default (.0012). Absolute accuracy is calculated by multiplying relative accuracy by the lenght of the bounding box diagonal for the part. That means absolute accuracy changes as the model size changes.The bounding box diagonal lenght can be determined by selecting info > model size. Here is an indeptharticle about Pro/ENGINEER accuracy:
http://www.eern.com/proe/tips/accuracy/index.htm
You can also set your accuracy to absolute. It will take a little longer to regenerate depending on how tight you set your accuracy, but it should eliminate the accuracy related failures.
Set the following config.pro options:
<UL>
<LI>enable_absolute_accuracy yes</LI>
<LI>enable_assembly_accuracy yes</LI>
<LI>accuracy_lower_bound should be at leastone decimal point tighter than your tightest tolerance (i.e. tol=.125, acc=.0001).</LI>
<LI>default_absolute_accuracyshould be tighter than your tightest tolerance (i.e. tol=.125, acc=.001).</LI>[/list]
If you set this for existing components, you might get geometry failures due to rounding discrepencies. Definitely set absolute accuracy for your template parts and assemblies for future use.
Good Luck