i work in an automotive production facility. there is a particular part that we machine completely, but are producing "flyers" with regard to a balance spec of .25 ounce/inch. the current rate is about 1.5%-2%. it is a round flange, splined, and has 8 tapped holes, and 2 location holes. we are currently dynamically checking the balance 100% due to an external audit non-comformance for this issue, and it's severely hampering production. there are no provisions for introducing an actual corrective balance to the part. furthermore, one would be inclined to think that since all subject parts pass all gaging and are within blueprint limits, that an out of balance condition would be eliminated by complete machining. such is not the case. Any suggestions? Repeatability of the balancer is a known concern.
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