DFSS for Robust Tooling Design with Concurrent Virtual Dimensional Analysis (CVDA) Methods

Dimensional variation analysis is a critical step of the dimensional management process for understanding the predicted dimensional variation from manufacturing process. Through analysis, product and process capabilities were evaluated, and the variation can be predicted and documented at each step of the build. The objective to develop the concurrent virtual dimensional analytical (CVDA) methods was to concurrently design a product and manufacturing process insensitive to part and process variations by integrating various analytical tools in literatures and in industry practice.

The allowable variation targets of the product that meet the functional requirements are defined with the geometric dimensioning and tolerancing (GD&T) drawings. If at all possible, each part’s datum features defined on the drawing are required to be coordinated with the locating features of production tools. Based on the concept of DFSS (Design for Six Sigma) to design a product and process right the first time, this paper presents an integrated approach that uses variation analysis and Taguchi’s robust statistics to a robust tooling design by selecting a part’s optimized locating or claming schemes.