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One-Dimensional Tolerance
Stackup Spreadsheet
by Ken Chase
and
Jonathan Wittwer
Brigham Young University
Complex Assemblies
Process Variation
Mean
Standard Deviation
Rejects
LL
Capability
UL
TASM Ti
ASM
ASM
Ti
Ti
3CPK
ASM
i2
Stack Formula
TASM
ASM
ASM
ASM
Ti
Ti
3
Ti 2
3C PK
i2
Predicts
Extreme limits of
variation.
Not statistical.
Probable variation.
Percent rejects
Long term variation
Percent rejects.
Variation using
existing parts.
Percent rejects.
Application
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.
Rejects
LL
Xmean
UL
Decrease Variation
Decrease Standard Deviation
Reduce rejects
LL
Capability
UL
UL
Limits
3
Yield
99.73%
4.5
99.99966%
99.9999998%
Defects
2700 / Million
3.4 / Million
2 / Billion
Limits
3
Yield
99.73%
4.5
99.99966%
99.9999998%
Defects
2700 / Million
3.4 / Million
2 / Billion
LL
4.5
UL
UL LL
6
Cp adjusted for k:
UL
LL
LL
Cpk= Cp (1-k)
6
UL
6 Variation Defined
UL
LL
RSS: ASM
6: ASM
Ti
Ti
3CPK
CP
UL LL
6
LL
UL
Six Sigma
Dynamic Mean Shift
99.73%
(Short Term)
95.45%
(Long Term)
LSL
USL
Capability
LL
UL
99.99932%
(Long Term)
Capability
(1- Rejects
Z
Source
15 Place Math Tables
6th Order Polynomial Fit
Excel
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
ZU
Transformation
x x
Z
x
Mean
X=0
Standard Deviation
Z ( units)
x = 1.0
LL
UL
Plot Controls