An integrated resource allocation and tolerance allocation optimization: A statistical-based dimensional tolerancing

Abstract

Today's industrial world is facing rising demand for highly reliable and safe products. Complex industries, such as automobiles, medical, and aircraft, require a well-designed engineering plan which has a comprehensive understanding of the various certainties and uncertainties that occur in reality. Consequently, the need for reliable and precise parts has impacted the tolerancing activity. Key functions of complex products can often be realized by high precision part use. Thus, producers are confronted with high-quality requirements, cost pressure, and a rising number of demands. The introduction of new technologies and the need to meet the requirements have broadened the scope of tolerancing. In this paper, a statistical tolerance allocation model is developed to study the economic impact of allocated tolerances on an assembled product. The problem is aimed at optimizing the allocated tolerances to each part of the product while minimizing manufacturing costs. A modular cost model is proposed to determine the manufacturing costs related to each activity and part. The manufacturing costs include processing cost, inspection cost, scrap cost, assembly cost, and warranty cost. Furthermore, a genetic algorithm is adapted to study the applicability of the model developed on an exemplary assembled product.