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.