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Tolerance Stack-up Analysis in Manufacturing-Based Capstone Projects

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2019 ASEE Annual Conference & Exposition


Tampa, Florida

Publication Date

June 15, 2019

Start Date

June 15, 2019

End Date

October 19, 2019

Conference Session

A Technology Potpourri III

Tagged Division

Engineering Technology

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Paper Authors


Mustafa Shraim Ohio University

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Dr. Mustafa Shraim is an Assistant Professor in the Department of Engineering Technology & Management at Ohio University in Athens, Ohio. He received both of his B.S. and M.S. degrees from Ohio University in 1986 and 1989, respectively. He received his Ph.D. in Industrial Engineering from West Virginia University in 1996.

Dr. Shraim’s research interests are in the area of quality engineering. Specifically, they cover Lean / Six Sigma methods and including incorporating experimental design to optimize operations. Other research interests include the Deming System of Profound Knowledge (SoPK), developing continuous improvement programs as well as sustainable management systems based on ISO 9001, ISO 14001, and other international standards.

He has over 20 years of industrial experience in the quality management field as a quality engineer, corporate quality manager, consultant and trainer. His experience is extensive in quality management systems as wells as Lean and Six Sigma methods. In addition, he coached and mentored Green & Black Belts on process improvement projects in the manufacturing and service industries.

Dr. Shraim is a Certified Quality Engineer (CQE) & a Certified Six Sigma Black Belt (CSSBB) by The American Society for Quality (ASQ). He is also a certified Quality Management Systems (QMS) Lead Auditor by the International Register of Certificated Auditors (IRCA) in London. He was elected a Fellow by ASQ in 2007.

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Neil Littell Ohio University

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Dr. W. Neil Littell is an Assistant Professor at Ohio University within the Russ College of Engineering in the department of Engineering Technology and Management. Dr. Littell earned a Doctorate of Philosophy in Instructional Systems and Workforce Development (2013) from Mississippi State University. Dr. Littell also received a Masters in Technology from Mississippi State University (2005). Additionally, he holds Bachelor of Science degrees in both Industrial Technology and Trade and Technical Studies from Mississippi State University (2004). Dr. Littell also has an Associate of Applied Science degree in Drafting and Design from Holmes Community College (2002).

Dr. Littell is an accomplished manager with more than 10 years of experience providing results-oriented leadership. His previous positions include the PLM Coordinator at the Center for Advanced Vehicular Systems at Mississippi State University from 2004-2008. He was Director at Large for COE, the World’s largest users group of Dassault Systemès PLM products from 2008 to 2012, where he was acknowledged with the BJ Fries Award of Merit for making balanced contributions to the organization's activities and growth. His most recent position was as the Engineering Program Manager and CAD/PLM Administrator at Viking Range LLC, located in Greenwood, Mississippi from 2008 to May 2014.

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Most manufactured products typically consist of multiple components assembled in specified configurations. Such components have specifications for important dimensional characteristics to ensure adequate performance once assembled. The specifications are typically given as tolerances within which components must be produced. Consequently, parts produced outside the specifications are rejected and not used in the assembled product. As dimensional variation is to be expected in produced components, it may accumulate, or stack up, to cause unwanted variation in the assembled product. When this happens, additional costs in scrap and rework would result and may extend to warranty charges and customer dissatisfaction should unacceptable products find their way to the customer. In this paper, issues resulting from tolerance stack-up in capstone production will be addressed. The questions this paper will attempt to answer are: (1) Are students aware of the impact of tolerance stack-up in product development, and (2) What can be done to minimize the potential effects of tolerance stack-up before product launch.

Shraim, M., & Littell, N. (2019, June), Tolerance Stack-up Analysis in Manufacturing-Based Capstone Projects Paper presented at 2019 ASEE Annual Conference & Exposition , Tampa, Florida. 10.18260/1-2--33444

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