Optimal tolerance design of assembly for minimum quality loss and manufacturing cost using metaheuristic algorithms

Abstract Tolerance design bridges design and manufacturing. Concurrent design of tolerances and manufacturing processes may ensure the manufacturability, reduce the manufacturing and other related costs, decrease the number of fraction nonconforming (or defective rate), and shorten the production lead time. Since process capability indices relate tolerance specifications to manufacturing process capabilities, it is quite natural to apply them to concurrent design of tolerances and processes. As process shifts often exist in a manufacturing process, using Cp does not yield a good estimation of fraction nonconforming. Index Cpk does not precisely measure process shift either, but Cpm does. Therefore, this research compares the applications of Cp, Cpk and Cpm based on a numerical example of non-linear mechanical tolerance synthesis. In addition, the Taguchi quality loss function is used together with the manufacturing cost as the objective function.

Download Full-text

Concurrent Tolerance Design Based on Manufacturing Cost and Quality Loss

Applied Mechanics and Materials ◽

10.4028/www.scientific.net/amm.687-691.4996 ◽

2014 ◽

Vol 687-691 ◽

pp. 4996-4999

Author(s):

Zhang Rong

Keyword(s):

High Performance ◽

Low Cost ◽

Engineering Application ◽

Manufacturing Cost ◽

Tolerance Design ◽

Quality Loss ◽

Product Loss ◽

Parameterized Model ◽

The Cost ◽

Design And Manufacture

With the constraints on manufacturing capacity, the satisfaction of product performance and the cost of manufacture are contradictory, the problem between high-performance and low-cost must be solved at the period of design and manufacture for product. To solve this problem, the product loss model has been analyzed, the parameterized and non-parameterized model of anticipant losses has been researched, with concurrent design, in connection with the product with multiple correlated assembly functional dimensions, the relation function between quality loss and process dimension tolerance has been provided, the concurrent tolerance design mathematical model based on lowest-cost and quality loss has been established. The applied case shows that this method has important guiding significance for engineering application.

Download Full-text

Make or Buy Analysis Model Based on Tolerance Design to Minimize Manufacturing Cost and Quality Loss

Makara Journal of Technology ◽

10.7454/mst.v18i2.400 ◽

2014 ◽

Vol 18 (2) ◽

pp. 86 ◽

Cited By ~ 2

Author(s):

Cucuk Nur Rosyidi ◽

Reza Rizkichani Akbar ◽

Wakhid Ahmad Jauhari

Keyword(s):

Manufacturing Cost ◽

Tolerance Design ◽

Quality Loss ◽

Analysis Model ◽

Model Based

Download Full-text

Robust Tolerance Design With the Integer Programming Approach

Journal of Manufacturing Science and Engineering ◽

10.1115/1.2831193 ◽

1997 ◽

Vol 119 (4A) ◽

pp. 603-610 ◽

Cited By ~ 45

Author(s):

Chang-Xue (Jack) Feng ◽

A. Kusiak

Keyword(s):

Integer Programming ◽

Loss Function ◽

Programming Approach ◽

Manufacturing Cost ◽

Tolerance Design ◽

Quality Loss ◽

Quality Loss Function ◽

The Cost ◽

Manufacturing Yield ◽

Selection Of

The quality loss function incorporates the cost of tolerances, however, it does not consider the manufacturing cost and design constraints. In this paper, a stochastic integer programming (SIP) approach is presented for simultaneous selection of tolerances and manufacturing processes. A direct link between the minimum manufacturing cost and the required level of manufacturing yield is established through the process capability index Cpk. As the tolerances in SIP are discrete, the solution generated is acceptable for manufacturing. It is shown that the integer programming models are applicable in the quality loss function and six sigma design approaches. The SIP approach is illustrated with a classical example of nonlinear tolerance design. The comparison of the proposed SIP approach, the Taguchi method, and the conventional mathematical models in tolerance synthesis is presented.

Download Full-text

Concurrent process tolerance design based on minimum product manufacturing cost and quality loss

The International Journal of Advanced Manufacturing Technology ◽

10.1007/s00170-003-1911-8 ◽

2004 ◽

Vol 25 (7-8) ◽

pp. 714-722 ◽

Cited By ~ 46

Author(s):

M.F. Huang ◽

Y.R. Zhong ◽

Z.G. Xu

Keyword(s):

Manufacturing Cost ◽

Tolerance Design ◽

Quality Loss ◽

Concurrent Process ◽

Process Tolerance ◽

Product Manufacturing

Download Full-text

Make or Buy Analysis Model Based on Tolerance Design to Minimize Manufacturing Cost and Quality Loss

Makara Journal of Technology ◽

10.7454/mst.v18i2.2947 ◽

2014 ◽

Vol 18 (2) ◽

pp. 86 ◽

Cited By ~ 3

Author(s):

Cucuk Nur Rosyidi ◽

Reza Rizkichani Akbar ◽

Wakhid Ahmad Jauhari

Keyword(s):

Manufacturing Cost ◽

Tolerance Design ◽

Quality Loss ◽

Analysis Model ◽

Model Based

Download Full-text

Applying Life Cycle Six Sigma in Tolerance Design Methodology

Advanced Materials Research ◽

10.4028/www.scientific.net/amr.443-444.881 ◽

2012 ◽

Vol 443-444 ◽

pp. 881-887

Author(s):

Jian Jun Wu ◽

Yi Zhen Wang

Keyword(s):

Life Cycle ◽

Six Sigma ◽

Life Cycle Cost ◽

Product Life Cycle ◽

Quality Characteristic ◽

Quality Level ◽

Manufacturing Cost ◽

Tolerance Design ◽

Product Life ◽

Sigma Level

Setting of tolerances to meet a required specification of quality characteristic and keep low manufacturing cost is one of common problems in the process quality control. But generally traditional tolerance design only focus on cost of manufacturing, few consider product Life Cycle Cost. In these situations, to obtain a satisfactory six sigma quality level as well as keep lower life cycle total cost should be considered. This paper expands tolerance optimization based on the manufacturing cost to the product life cycle cost, which can improve product quality to the six sigma level and keep lower LCC simultaneously.

Download Full-text

Assembly Tolerance Design Based on Skin Model Shapes Considering Processing Feature Degradation

Applied Sciences ◽

10.3390/app9163216 ◽

2019 ◽

Vol 9 (16) ◽

pp. 3216 ◽

Cited By ~ 5

Author(s):

Ci He ◽

Shuyou Zhang ◽

Lemiao Qiu ◽

Xiaojian Liu ◽

Zili Wang

Keyword(s):

Design Method ◽

Joint Probability ◽

Joint Probability Distribution ◽

Manufacturing Cost ◽

Tolerance Design ◽

Sampling Point ◽

Skin Model ◽

Machined Surface ◽

Assembly Tolerance ◽

Five Axis

To increase the reliability and accuracy of tolerance design, more and more research works are considering not only orientation and position deviations; they are also forming errors in tolerance modeling. As a direct cause of form errors in industrial mass production, the processing features of the machining system degrade over time. Under the Industry 4.0 paradigm, an assembly tolerance design method based on Skin Model Shape is proposed to take the effect of degrading processing features into consideration. A continuous-time multi-dimensional Markov process is trained through maximum likelihood estimation based on the nodal sampling point set on the machined surface. Degradation of the machined surface is modeled based on the joint probability distribution of nodal displacements. Assembly force constraints and assembly entity constraints are applied to spatial assembly simulations. Tolerance synthesis takes the manufacturing cost and assembling probability as design objectives. A design example of the rotary feed component in a five-axis machine tool is proposed for explanation and verification.

Download Full-text