What is the tolerance analysis?

Checking assembly variation satisfy th

e quality requirement by adding design
ed tolerance.

10± 0.2 20± 0.3 15± 0.2

45± ??
Is your tolerance design OK? / NG?

제품을 설계기준대로 가공을 했지만 조립 시에

조립성능(품질)이 적정 수준에 미치지 못한다…
왜 일까? 어떻게 무엇을 조정해야 하지?

If the parts which vary within toleranc

e are assembled, does the requiremen
t of assembly quality is satisfied…?
the procedure of tolerance analysis (1)
[Worst Case]
Adding to tolerance values;
Big variation!
0 .2  0 .3  0 .2  0 .7
(image)

+ + =
-0.2 +0.2 -0.3 +0.3 -0.2 +0.2 -0.7 +0.7

적절한 공차 값은??
[RSS (Root Sum Square)]
Square root of added square tolerance values;
Allow few% failure!
0.2 2  0.32  0.2 2  0.41
(image)
-0.41 +0.41

+ + =
failure failure
-0.2 +0.2 -0.3 +0.3 -0.2 +0.2
the procedure of tolerance analysis (2)
[Worst Case vs. RSS]

Depends on product characteristic

High quality is required or not
Small-lot production or not
…etc.

WC는 모든 조건을 충족하지만,

시간과 비용이 많이 든다는 단점이 있다.

RSS Quality =>cost

Quality => human life

WC
(medical devices, automotiv
e parts… )
1D Tolerance Analysis
1D
1차원 공차 계산
어렵지 않게 수 계산으로 가능

40± 1.0
TRSS  T1  T2  T3  T4  T3  T5
2 2 2 2 2 2
BLOCK1

 1.0 2  1.52  1.0 2  2.0 2  1.0 2  1.0 2

 3.2
60± 1.5

How is the v
BLOCK2
TWC  T1  T2  T3  T4  T3  T5
ariation of h
20± 1.0 BLOCK3 eight?  1.0  1.5  1.0  2.0  1.0  1.0
 7.5
30± 2.0 BLOCK4
BLOCK4
Easy!
BLOCK3
R20± 1.0
BLOCK5 BLOCK5

（25） （25）
 2D Tolerance Analysis
2D
2차원 공차 계산
조금 복잡 하지만 수 계산 가능

40± 1.0
BLOCK1

How is the v
60± 1.5 ariation of h
eight?
BLOCK2

TRSS  T1  T2  T3  T' 4a  T' 4b  T3  T' 5a  T' 5b

2 2 2 2 2 2 2 2
20± 1.0 BLOCK3
・・・
1.0  1.5  1.0  0.5  2.0   0.5  2.0  
2 2 2 2 2

30± 2.0 BLOCK4 

1.0 2  0.5  1.0   0.5  1.0 
2 2
BLOCK4

BLOCK3  2.78
R20± 1.0
BLOCK5 BLOCK5 TWC  T1  T2  T3  T' 4a T' 4b T3  T' 5a T' 5b
 1.0  1.5  1.0  1.0  1.0  1.0  0.5  0.5
（25） （25）
 7.5
3D Tolerance Analysis
3D
3차원 공차 계산
수 계산으로 불가능

How is the v
ariation of h
eight?

Calculate 3D Tolerance Analysis exactly or not

=> determine the quality of assembly variation check
Relation of tolerance - manufacturing

CONCEPT DESIGN Determine quality requirement (from function, cost, …)

Break down to assembly quality

DETAIL DESIGN
Break down to part tolerance

PROTOTYPE (checking function by special spec)

Design how to product to satisfy assembly quality require

PILOT ment and part tolerance
(assembly order, machineries, tools, checking plan…)

PRODUCTION Product have to satisfy the quality requirement

제품 제조 과정에 대한 트리
Relation of tolerance
Determine quality requirement (from function, cost, …)
Example 1
This product is high grade
type. That’s why, beautiful
exterior is one of value…

Example 2 Example 3
printer’s function: socket’s function: interdigitation
paper transfer

Concept Design 과정 (컨셉 설계 과정)

Relation of tolerance
Break down to assembly quality

bracket

The gap of two lu

Corner lump mps represent the
Tail lump “quality”!

Break down to dimensioning and tolerancing

“How do you fix tolerance values?”

Re-use past similar design
Refer standard (internal / national)
Just put small tolerance (over spec)
…etc.

“Do you check assembly quality?” Excel? Calculator? or…

Detail design과정 (상세 설계 과정)

Relation of tolerance

(checking function by special spec)

Okay!
It’s possible to assembly!
There aren’t exterior problems!

Like an artist…

Assembled by parts which is manufactured

almost “nominal” value

Prototype과정 (시제품 제작 과정)

Relation of tolerance
Design how to product to satisfy assembly quality requirement
and part tolerance
(assembly order, machineries, tools, checking plan…)

What “high quality” requirement

(small tolerance) brings?

High-quality machinery
High-quality tool
Too much check point in line
Prepare checking jig
Prepare measure tool
Needed manpower
“high quality” requirement brings “hig
h cost” production.

Pilot 생산 과정 (생산 과정)

Relation of tolerance
Product have to satisfy the quality requirement

Cannot assembly!
=> failure tolerance analysis?
Assembly quality cannot achieve the
requirement!
=> failure tolerance analysis?
OK! Part quality cannot achieve the requir
ement!
=> over spec?
Take a lot of time to check!
NG!
=> over spec? …etc.
Assembly quality cannot achieve the requirement!

Production 과정 (제품의 품질)

Relation of tolerance
If you can calculate tolerance analysis exactly…

Assembly trouble will be reduced.

If you can fix tolerance exactly…

“over spec” quality requirement will be

reduced.

“정확한 공차분석”과 “정확한 공차값”이

품질과 비용관리의 핵심 입니다.
Relation of tolerance
If you can calculate tolerance analysis exactly…

Assembly trouble will be reduced.

If you can fix tolerance exactly…

“over spec” quality requirement will be

reduced.

“정확한 공차분석”과 “정확한 공차값”이

품질과 비용관리의 핵심 입니다.