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Tolerance Design
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EML4550 2007 1
Definitions
Tolerance
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Definitions
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Tolerance Design: Process Flow Diagram
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Tolerances
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Different Approaches to Tolerancing
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Classical Tolerance Design Process
Select Process
Change Process
Collect Statistical Data
Under
N
Control?
Work on process
Y Management Decision
Live with it
Change Specs
Y Process
N Test 100%
Capable?
Stop Production
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Classical Tolerance Design Process (Contd)
Specs
N
Being Met?
Recenter Process
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Tolerances and Quality Engineering
Taguchi:
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Taguchi Approach
Concept of off-line QC
On-line QC
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The three phases in Tolerance Analysis
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Taguchis Approach to Tolerancing
Select the customer tolerance values for the Quality Loss Function:
Ao ($ lost due to off-target value) and Do (measurement of
Off-target performance in engineering terms)
m-Do m m+Do
target
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Customer Tolerance
% of people
complaining
50
L( y) k ( y m ) 2
L is the economic loss to my customer if my product deviates y from its rated value m
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Quality Loss Coefficient
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Customer Loss Functions
L(y)
The nominal-the-best case
Ao
Ao
L( y) 2
y m 2
Do m-Do m m+Do y
L(y)
The smaller-the-better case
Ao
Ao
L( y ) y 2
D o2 y
L(y) Do
The larger-the-better case
D o2
L( y) A o Ao
y2 y
Do
L(y)
Asymmetric cases
L k y m if y m
2
Ao
L k y m if y m
2
y
m-Do m m+Do
EML4550 -- 2007
Taguchi Tolerancing Equations
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Taguchis Loss Function
Do
Di
Losses
Ao
Financial incentive Ai
Since A<Ao
yo yi=m-Di Target (m)
Note:
Do-Di=range of safety
EML4550 -- 2007 Do/Di=safety factor
Safety Factor
Do
Deviation from target
Di2 y m 2
Loss associated with
deviation
Ao
L( y i ) A i Di2
D o2
Ai Ao: manufacturing-allowable loss
should be smaller than the customer loss
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Safety Factor
In general notation:
Ao
S
A
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Safety Factor
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Example
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Example
Ao
L( y) k y m
2
2
y m 2
Do
A o $200
D 0 20V
Ao $200 2
k 2 2 2
0 . 5($ / V )
Do 20 Volts
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Example
A 5
D Do 20 3.16V 3V
Ao 200
The safety factor is: Ao 200
S 6.32
A 5
If the assembly line detects a power supply with voltage
lower than 112V (115-3) or higher than 118V (115+3) it
is economical to pull it off and repair it
The difference between the customer loss and the
manufacturing cost is relatively large (200/5=40)
smaller tolerance is permissible
sqrt(Ao/A)=sqrt(40)=6.32~20/3
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Example (alternative interpretation)
Ao 200
L( y ) k y m 2 y m
2 2
( y m ) 2
Do (20) 2
L( y ) 0.5( y m) 2
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Average Quality Loss
n i 1 n 1 i 1 Ao
Q k ( m)
2 2
when n is large. m-Do m
m+Do y
Q
1
n
L( y1 ) L( y 2 ) L( y n ) k ( y1 m ) 2 ( y 2 m ) 2 ( y n m ) 2
n
k
n
( y 1
2
2my1 m 2 ) ( y 2
2
2my 2 m 2 ) ( y n
2
2my n m 2 )
k n n
k n
n y i2 2m y i nm 2
n
y 2
i 2m ( n ) nm 2
i 1 i 1 i 1
1 n
1 n
k
n
y
i 1
2
i 2 m m 2
k 2 2
n
y
i 1
2
i 2 m m 2
1 n
1 n
k ( m) 2
n
y i 1
2
i 2
k ( m) 2
n i 1
y i2 2 2 2
1 n
1 n
1 n
k ( m) 2
n
y 2
i
n i 1
(2 ) yi
n i 1
2
i 1
1 n
y i2 2 y i 2
n
1
k ( m) 2 k ( m) 2 y
2
i
n i 1 n i 1
n 1 2
k ( m) 2
n
n n
1 1
where
n
i 1
y i and 2
n 1 i 1
( yi ) 2
Q k ( m) 2 2
when n is large.
EML4550 2007
Example
EML4550 -- 2007