Worst-Case Tolerance Analysis

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Definition and importance of Tolerance Analysis

Tolerance analysis is the term given to a number of processes used to calculate the overall variation and effect of variation on products stemming (i.e. arisen) from imperfections in manufactured parts.

Tolerance analysis is performed by product design engineers as they prepare to components for manufacturing. This is done to ensure according to end users’ demand as well as guarantee so that all manufactured components are fitted together within an assembly.

The Definition of Tolerance Analysis

Tolerance analysis is defined as the general term for activities related to the subject of potential collected variation in mechanical parts and assemblies. Its methods may be implemented on other types of systems subject to collected variation, such as mechanical and electrical systems.

Why It is Important?

Improve Quality -

Improve visual as well as mechanical quality of the product.

Determine Gap and Flush -

Determine optimum Gap and Flush conditions depended on our manufacturing processes.

Optimize Processes -

Simulate our manufacturing and assembly processes to calculate optimum methods and order.

Reduce Variation -

Minimize overall variation about compensating for it in design.

Control Rework and Scrap -

Through robust design, minimize the need for scrap and rework.

The Benefits


The high demand for quick turnaround and the ability to manufacture on demand has made this step crucial to eliminate errors. The process is to check consistency of parts for obtaining quality assurance, which is an important factor of product engineering today.

Who Can Conduct Tolerance Analysis?

While there are many tools and programs that can assist in conducting analysis, many companies prefer to outsource professionals for performing product design and tolerance analysis.

Updated on 02-Jan-2020 06:29:34