Scribd Logo
Upload

Welcome to Scribd!

  • 684 views

    One-Dimensional Assembly Tolerance Stack-Up

    Uploaded by

    KakoDa
    This document provides an overview of CATS 1-D, a one-dimensional tolerance stackup spreadsheet. It summarizes different models for predicting assembly tolerance stackup, including worst case, statistical, six sigma, and measured data models. It also discusses how controlling process variation can lead to higher yields and fewer defects through techniques like centering the mean, decreasing standard deviation, and accounting for mean shifts. The spreadsheet allows users to input process data and view the effects on yield, rejects, and capability.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PPT, PDF, TXT or read online from Scribd

    One-Dimensional Assembly Tolerance Stack-Up

    Uploaded by

    KakoDa
    684 views26 pages
    This document provides an overview of CATS 1-D, a one-dimensional tolerance stackup spreadsheet. It summarizes different models for predicting assembly tolerance stackup, including worst case, statistical, six sigma, and measured data models. It also discusses how controlling process variation can lead to higher yields and fewer defects through techniques like centering the mean, decreasing standard deviation, and accounting for mean shifts. The spreadsheet allows users to input process data and view the effects on yield, rejects, and capability.

    Original Description:

    One-Dimensional Assembly Tolerance Stack-Up

    Copyright

    © Attribution Non-Commercial (BY-NC)

    Available Formats

    PPT, PDF, TXT or read online from Scribd

    Did you find this document useful?

    Is this content inappropriate?

    This document provides an overview of CATS 1-D, a one-dimensional tolerance stackup spreadsheet. It summarizes different models for predicting assembly tolerance stackup, including worst case, statistical, six sigma, and measured data models. It also discusses how controlling process variation can lead to higher yields and fewer defects through techniques like centering the mean, decreasing standard deviation, and accounting for mean shifts. The spreadsheet allows users to input process data and view the effects on yield, rejects, and capability.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PPT, PDF, TXT or read online from Scribd
    Download as ppt, pdf, or txt
    684 views26 pages

    One-Dimensional Assembly Tolerance Stack-Up

    Uploaded by

    KakoDa
    This document provides an overview of CATS 1-D, a one-dimensional tolerance stackup spreadsheet. It summarizes different models for predicting assembly tolerance stackup, including worst case, statistical, six sigma, and measured data models. It also discusses how controlling process variation can lead to higher yields and fewer defects through techniques like centering the mean, decreasing standard deviation, and accounting for mean shifts. The spreadsheet allows users to input process data and view the effects on yield, rejects, and capability.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PPT, PDF, TXT or read online from Scribd
    Download as ppt, pdf, or txt
    of 26

    CATS 1-D XL

    One-Dimensional Tolerance Stackup Spreadsheet


    by Ken Chase and Jonathan Wittwer
    Brigham Young University

    Complex Assemblies

    Process Variation
    Mean Standard Deviation

    +1
    Rejects

    LL

    3 3
    Capability

    +3

    UL

    A frequency plot shows how a process varies from the mean

    Models for Predicting Assembly Tolerance Stackup

    Worst Case (WC) Statistical (RSS) Six Sigma (6 ) Measured Data (Meas)

    TASM = Ti

    ASM ASM

    Ti = 3

    Ti = 3CPK

    ASM =

    i2

    Models for Predicting Assembly Tolerance Stackup


    Mode l Worst Case (WC ) Statistic al (RSS ) Six Sigma (6s) Measu red Dat a (Meas ) Stac k Formula TASM =

    Ti

    ASM =
    ASM =

    Ti 3

    Predict s Extreme limits of variation. Not statistical. Probable variation. Percent rejects Long term variation Percent rejects. Variation using existing parts. Percent rejects.

    Ti 2 3C PK

    Applica tion Critical systems. No rejects permitted. Most costly. Reasonable estimate. Some rejects allowed. Less costly. Drift in mean over time is expected. High quality levels desired. After parts are made. What-if? studies.

    ASM =

    i2

    Centering the Mean


    Center

    Rejects

    LL

    Xmean

    UL

    Centering the process in the LL/UL window minimizes rejects

    Decrease Variation
    Decrease Standard Deviation

    Reduce rejects

    LL

    3 3
    Capability

    +3

    UL

    Higher Values Mean Higher Quality


    LL UL

    6 5 4 3 2 1

    0 +1 +2 +3 +4 +5 +6 3 4.5 6

    Controlling Variation Leads to Higher Yields and Fewer Defects

    Limits 3 4.5 6

    Yield 99.73% 99.99966% 99.9999998%

    Defects 2700 / Million 3.4 / Million 2 / Billion

    Controlling Variation Leads to Higher Yields and Fewer Defects

    Limits 3 4.5 6

    Yield 99.73% 99.99966% 99.9999998%

    Defects 2700 / Million 3.4 / Million 2 / Billion

    Mean Shifts Happen


    Mean Shift

    Mean variation is time-dependent due to tool wear, temperature, etc.

    Accounting for Mean Shifts

    1.5

    4.5

    LL

    UL

    The Six Sigma Model allows the engineer to model assembly variation due to mean shifts

    Measures of Process Capability


    Process Capability Index:
    CP = UL LL 6
    LL 3 UL

    Cp adjusted for k:
    Cpk= Cp (1-k)

    k
    LL UL

    6 Variation Defined
    LL UL 3

    RSS: ASM

    Ti = 3

    6: ASM

    Ti = 3CPK
    UL LL 6

    k
    LL UL

    where Cpk= Cp (1-k) and


    CP =

    Six Sigma Dynamic Mean Shift


    99.73% (Short Term) 95.45% (Long Term)

    LSL

    3 3
    Capability

    +3

    USL

    Comparing Short and Long Term Variation

    Requirements for High Quality


    99.9999998% (Short Term)

    LL 99.99932% (Long Term)

    UL

    6 6 Capability

    +6

    A goal of 4.5 long term requires a 6 process in the short term

    Excel Statistical Functions


    NORMDIST(x,mean,stand_dev,T/Fflag) =area under the Normal distrib at point x NORMSDIST(z) =area under the Standard Normal distrib STANDARDIZE(x,mean,stand_dev) =(x - mean)/stand_dev NORMSINV(Probability) =z corresp to a given probability (for z <5) SUMSQ(G1:G25)^0.5 =square root of the sum of squares of i

    Statistical Function Accuracy


    Yield

    (1- ) Rejects

    Z
    Source 15 Place Math Tables 6th Order Polynomial Fit Excel Yield Fraction 3 6 0.998650101968370000 0.999999999013000000 0.998650187471804000 0.999999998751939000 0.998650032776765000 0.999999999009878000

    Source 15 Place Math Tables * 6th Order Polynomial Fit Excel

    3 0.001349898031629990 0.001349812528196100 0.001349967223235000

    Reject Fraction (1- )

    6 0.000000000987000000 0.000000001248061000 0.000000000990122000

    * the 6 value is from an alternate source, accurate to 12 places.

    CATS 1-D Spreadsheet

    CATS 1-D Inputs

    Mean and Variance Comparison

    Yield and Rejects

    Calculated in units, %, or parts-per-million

    Standard Normal Distribution


    Transformation x x Z= x Mean X=0 Standard Deviation Z ( units)

    ZL

    ZU

    x = 1.0

    Used to determine % rejects from standard tables. Does not show mean shift. Transformed data all looks alike.

    Modified Normal Distribution

    LL

    UL

    Shows the mean shifts Shows the quality levels Allows all 3 curves to be plotted for comparison

    Plot Controls

    What can CATS 1-D users expect?


    Probably wont see: An end to poverty and misery All men treating each other as brothers World peace But, you might notice: An increased understanding of the role of statistics in design Fewer problems on the factory floor Engineering and production talking to each other without shouting.

    You might also like