Tolerance Analysis for Product Development (MS351)

SynopsisWhen a design is an assembly with multiple parts, the control of all the dimensions becomes very critical. Tolerance analysis (TA) plays a major role in determining how well the product is designed for manufacturability. This course covers the essential concept, role and applications of TA in a product design environment. The critical techniques of tolerance analysis such as 10 steps in performing TA and developing the looping equation for the dimensions of components in an assembly are covered in details. The fundamentals and application of basic statistic will also be presented so the participants are able to appreciate the essential statistical parameters used for analyzing the variation and contribution of the tolerance in each component towards the whole assembly. In addition, process capability study will be taught to ensure a closed-loop understanding of TA in a complete product development cycle which inevitably includes variations in the manufacturing processes.

This 2-day course is intended for Design Engineers or Manufacturing engineers who need to conduct tolerance analyses of their designs and assemblies. The sequence of TA will be walked through with some practical examples and case studies. The course aims to equip the participants with the knowledge of how to correctly define critical dimensions in a design and to perform a tolerance analysis, which covers but not exclusively limited to analyzing dimensional dependency, selecting the correct datum, deriving the looping equations and analyzing the contribution of each parameter. Participants will also be exposed to ways of improving the design by incorporating process variations by means of a process capabilities study.

The instructor will draw on his real life industrial experiences to make the course highly interactive and practical. Upon completion the participants should be able to confidently identify and analyse critical parameters and take process variations into consideration during the dimensioning of engineering drawings, ensuring the production of high quality parts with minimal assembly issues.

What You Will Learn

• Tolerance effect on design
• Relationship of tolerances to the system
• How to select a datum
• How to loop the dimensions
• How to analyze the tolerances by utilizing the essential of Basic Statistic
• Actual product’s process tolerances through Process Capabilities Studies
• Determine the critical dimensions and ways to improvement through design and process

Who Should Attend

• Mechanical design engineers
• Manufacturing engineers
• Designers
• Professionals that handles assembly of different parts

PrerequisiteAlthough the participants are not required to have in-depth knowledge in this field, some prior acquaintance with basic statistics and related experience should be helpful.

Course MethodologyThis course is conducted in a seminar room. Each participant will receive a set of course material.

Course Duration2 days, 9am - 5pm

Course StructureDay 1

Basic Statistics Overview

• Hypothesis Test
• Normality Test
• Independence Test
• Design Phase Concept, Design, Optimise and Verify (C.D.O.V.)

Types of Data Distributions
Introduction to Tolerance Analysis

• Type of Tolerance: Equal Bilateral Tol, Unequal Bilateral Tol, Unilateral Tol, Limit Dimension
• Datum selections: Fixed Datum, Floating Datum
• Dimensions Looping: Building Equations
• Worse Case TA, RSS TA, SRSS (Static Root Sum Square) TA

Why Tolerance Analysis is Needed

• Design Robustness
• Cost Avoidance

When Tolerance Analysis Should be Performed: CDOV
10 Step by Step Tolerance Analysis

Day 2

Introduction to Process Capability Studies

• Variability
• Stability
• Capability

Correlate the Design Tolerances and Process Capability

• Monte Carlo Simulation

Practical Industry Application Examples:

• Opportunities for improvement – Design & Process
• How to regenerate the baseline of design tolerances based on process capabilities