Dimensional Variation Management (or Tolerance Stack-up Analysis) has variety of applications. Virtually any assembly consisting of multiple parts and requirements are to evaluate fitment, clearances, gaps or interferences, overall dimensions and worst case as well as statistical scenarios of these objectives.
Dimensional Variation Management is of very high importance in case of automobiles (passenger cars), air crafts, where designer, manufacturer, process planning has meet dimensional goals of the entire product, thus meeting dimensional quality of product close to industry benchmark figures. The non-compliance to dimensional goals may lead to poor part/assembly function, misalignments, interferences, uneven and wide/close gaps, vibrations, noise, reduced product life, robustness, warranty claims and customers overall perception of product quality affecting market share.
Application Areas
Critical for passenger cars where dimensional quality directly impacts assembly function, alignments, gaps, and overall product quality.
Essential in aircraft design and manufacturing where precise dimensional control is crucial for safety and performance.
Analysis of dimensional variations in sheet metal parts and assemblies to ensure proper fit and function.
Precision control of machined parts to meet tight tolerances and functional requirements.
Management of dimensional variations in plastic components and assemblies.
Optimization of assembly processes to ensure consistent quality and reduced variation.
Key Impacts on Product Quality
Part/assembly function and performance
Component alignments and fit
Interference prevention
Gap and flush control
Overall product dimensions
Manufacturing process optimization
Quality control and warranty claims reduction
Customer satisfaction improvement