A new grouping method to minimize surplus parts in selective assembly for complex assemblies

Abstract

Selective assembly is the method of obtaining high precision assemblies from relatively low precision components. The mating parts are manufactured with wide tolerances. The mating part population is then partitioned to form selective groups. The corresponding selective groups are then assembled interchangeably. The mating parts are manufactured in different processes and in different machines. The standard deviation of the mating parts will be different. The probability of the number of parts in the selective group cannot be the same. A large number of surplus parts is expected according to the difference in standard deviations of the mating parts. In this paper, a complex assembly with three mating parts (as in a ball bearing: an inner race, ball and outer race) is considered for analysis. A new method is proposed for partitioning the lots to form selective groups. By this method, the number of surplus parts is reduced to a large extent. The variation in clearance is minimized and the total number of groups is also less when compared with traditional methods.