I have an assy that is a machined version of a part. The assy contains one part, and the features needed for the machined part are done in the assy.

I have different configs of this assy, from .060" thick to .625" thick. When I go choose different configurations, the assy is loosing faces and edges on which features, chams and fillets are created. I can't see any reason why, as I think I've made my machining in a logical order and done my sketches to refer to actual dims and not faces, when practical.

I've attached the assy. The configs are controlled by a design table. Please take a look and let me know what you think. When I go to the thicker configs, it loses the tapped cbored holes on the front face, and loses chams, too.

Please advise if there would be a better way to sequence the machining operations in the future. I did not do part within a part due to the issues I've heard about it. Attached is the assy.

Thanks