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2012 Quality Tips

METHODS OF TOLERANCE STACK-UP ANALYSIS

Methods of Tolerance Stack-up


Stack-up Analysis Method Worst Case Analysis(WCM) Explanation In the WCM we verify that the parts will perform its intended function 100 % of the time. (within the tolerance band) This result in very conservative approach. This method sometimes refer to Method of Extreme The simplest and the most conservative In this approach, the tolerance at the interface is the SUM of individual part tolerances See WCM Flow chart In the statistical Modeling, we assume that the manufactured parts are CENTERED on the MEAN Dimension. (not necessary true!) This therefore Result in LESS Conservative than W-C Model but it offers several benefit. There are two the traditional statistical methods: The Root Sum of Squares (RSS) Model Modified Root Sum of Squares (MRSS) Model RSS Method If the designed CANNOT ACHIEVE producible piece-part tolerance for a given requirement, they can take advantage of PROBABILITY THEORY to increase them. The theory is called Root-sum of square (RSS) Model. Based on premise that most likely the parts will be manufactured near the center of tolerance range (nominal ) rather than at the end. Experience in manufacturing SMALL ERRORS are more FREQUENT THAN LARGE error The deviation are bunched around the Mean and fewer further from the mean dimension (normal Distribution) The manufactured pieces with large deviation from the mean, positive or negative, may approach zero as the deviation from the mean increase (normal distribution) This model assume that it is unlikely that parts in an assembly will be randomly chosen in such as way that the W-CM condition will occur. See RSS Method Flow Chart In reality the probability of a W-C assembly is very low In the RSS model on the other hand does not accurately predict what is manufactured because some (or all) of the RSS assumptions are NOT Valid. Therefore the option is to use is RSS with correction factor. (CF)

Statistical Method

MRSS Method

See comparison of stack-up methods. 1 QBASE ENGINEERING SDN BHD | Advanced Quality Engineering Series

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