TOLERANCE STACK ANALYSIS

Stack Description: ________________________________________ Ref. No. _____ Sheet 1 of 12

OBJECTIVE______________________________________________ Name: ___________________________________
______________________________________________ Date: _______

MAXIMUM MINIMUM COMPONENT FACTORED COMPONENT

STEP ID DESCRIPTION FROM/TO + MAX + MIN TOLERANCE TOTAL TOLERANCE
- MIN - MAX TOLERANCE SQUARED
### ### 0 0.000 0
### ### 0 0.000 0
### ### 0 0.000 0
### ### 0 0.000 0
### ### 0 0.000 0
### ### 0 0.000 0
### ### 0 0.000 0
### ### 0 0 0.000 0
### ### 0 0.000 0
### ### 0 0.000 0
### ### 0 0.000 0
### ### 0 0.000 0
### ### 0 0.000 0
### ### 0 0.000 0
COMMENTS: SUB TOTALS 0 0 0 0.000 0.000
ANSWER WORST CASE MRSS RSS
OPTIMIZED?
DESIGN GOAL:
YES NO

gd-t.com
 TOLERANCE STACK ANALYSIS Sheet 2 of 12
_______________

ONENT
MONTE
CARLO

MC

gd-t.com
Stack Description: ________________________________________ Stack No. _____
OBJECTIVE:______________________________________________ Name: _________________________________
______________________________________________ Date: _______
Paste part sketch or drawing here. Sketch stack path on drawing.
Columns G and J are for
entering the appropriate
sign (+/-) required based on
the direction.
This column is a verbal
Letter of stack path description of the
vector or other dimension you are
identifier, such as Column for totaling
recording. the maximum limit
part number. Column for totaling
dimension.
the minimum limit
dimension.

MAXIMUM MINIMUM COMPONENT FACTORED

STEP ID DESCRIPTION FROM/TO + MAX + MIN TOLERANCE TOTAL
- MIN - MAX TOLERANCE
### ### 0 0.000
Factored total tolerance -
### ### 0 0.000 of getting from worst
method
### Component
### tolerance 0 0.000(for 1 or 2 components) t
case
is the total tolerance
### ### 0 0.000
the MRSS approach (for 6 or
calculated from the
### ### 0 more
0.000 components).
max & min limits.
### ### 0 0.000
### ### 0 0.000
### ### 0 0 0.000
### ### 0 0.000
Root-Sum-Squared (best
### ### 0 0.000
case) assembly stack up
### ### 0 of all component
0.000
### ### 0 tolerances.
0.000
### ### 0 0.000
### ### 0
Modified RSS0.000
### assembly
Worst case ### 0
approach -0.000
###
stack up of all ### "Benderized"
0 stack
0.000
component
### tolerances.
### up of
0 all component
0.000
tolerances.
### ### 0 0.000
### ### 0 0.000
### ### 0 0.000
COMMENTS: SUB TOTALS 0 0 0 0.000
ANSWER WORST CASE MRSS
OPTIMIZED?
DESIGN GOAL:
YES NO
____________________________

awing.
are for Column for you to use
opriate process capability data
d based on to simulate production
runs and estimate a
total tolerance.

Column for totaling

the minimum limit
dimension.

COMPONENT
TOLERANCE MONTE
SQUARED CARLO
0
Factored total tolerance -
method of getting0from worst
0
case (for 1 or 2 components) to
the MRSS approach 0 (for 6 or
more components). 0
0
0
0
0
Root-Sum-Squared (best
case) assembly 0 stack up
of all component
0
tolerances. 0
0
fied RSS 0
oach - 0
derized" stack 0
f all component 0
ances.
0
0
0
0.000
RSS MC
Stack Description: ________________________________________ Ref No. _____
OBJ.: ______________________________________________ Name: _____________________________
______________________________________________ Date: _______

POSITIVE NEGATIVECOMPONENT
STEP ID DESCRIPTION FROM / TO NOMINAL NOMINAL TOLERANCE
+/-

COMMENTS: SUB TOTALS 0 0 0

+ tol - tol
NOMINAL ANSWER 0
0 0
OPTIMIZED?
DESIGN GOAL:
YES NO
______________________________

FACTORED COMPONENT
TOTAL TOLERANCE MONTE
TOLERANCE SQUARED CARLO
0.000 0
0.000 0
0.000 0
0.000 0
0.000 0
0.000 0
0.000 0
0.000 0
0.000 0
0.000 0
0.000 0
0.000 0
0.000 0
0.000 0
0.000 0
0.000 0.000
MRSS RSS MC
Stack Description: ________________________________________ Ref No. _____
OBJECTIVE: _______________________________________ Name: _____________________________
______________________________________________ Date: _______
Paste part sketch or drawing here. Sketch stack path on drawing.

Column for entering Factored total

the +/- component tolerance - method of
tolerance (1/2 of the getting from worst case
total tolerance). (for 1 or 2 components)
Letter of stack path This column is a verbal to the MRSS approach
vector or other description of the (for 6 or more
identifier, such as part dimension you are components).
recording. Nominal dimensions
number. that are negative (down
or left).

Nominal dimensions
that are positive (up or
right).

POSITIVE NEGATIVECOMPONENT
STEP ID DESCRIPTION FROM / TO NOMINAL NOMINAL TOLERANCE
+/-

Total of all negative

nominal dimensions. Worst case assembly
stack up of all
component tolerances.

Total of all positive

nominal dimensions.

COMMENTS: SUB TOTALS 0 0 0

+ tol - tol
NOMINAL ANSWER 0
0 0
OPTIMIZED?
DESIGN GOAL:
YES NO

Total Nominal Stack

(positive subtotal Maximum (total
Maximum (total
minus negative nominal stack minus
nominal stack plus
subtotal). subtotal component
subtotal component
tolerance).
tolerance).
Total Nominal Stack
(positive subtotal Maximum (total
Maximum (total
minus negative nominal stack minus
nominal stack plus
subtotal). subtotal component
subtotal component
tolerance).
tolerance).
 ______________________________

n drawing.

Monte
Factored total
Carlo -
tolerance - method of
Column for
getting from worst case
you to use
(for 1 or 2 components)
process
to the MRSS approach
capability
(for 6 or more
data to
components).
simulate
production
runs and
estimate a
total
tolerance.

FACTORED COMPONENT
TOTAL TOLERANCE MONTE
TOLERANCE SQUARED CARLO
0.000 0
0.000
Root-Sum-Squared0
(best
0.000 case) assembly
0
stack up of all
0.000 0
component tolerances.
0.000 0
0.000 0
Modified
0.000RSS 0
approach -
0.000
"Benderized" stack 0
sembly up of0.000
all component0
tolerances.
erances. 0.000 0
0.000 0
0.000 0
0.000 0
0.000 0
0.000 0
0.000 0.000
MRSS RSS MC

Maximum (total
nominal stack minus
subtotal component
tolerance).
Maximum (total
nominal stack minus
subtotal component
tolerance).
This spreadsheet was developed by my colleague John Stolter, based on Alex Krulikowski's method for
calculating stacks, then embellished with columns to help users develop more realistic tolerances (MRSS

Spreadsheet distributed with permission of Geometric Learning Systems and Stolter LLC.

There are two templates (see tabs at the bottom of the page): the "Limit Stack Form" is the main one taug
"Nom-Plus-Minus Form" is only included because many companies are used to that style of performing st
involved, the Limit form is usually easier.)

The "Factored Total Tolerance" column adds a statistical element to the stack using the
methods known as Modified Root-Sum-Square (MRSS), as proposed by Bender and Gilson.
The "Component Tolerance Squared" column finds the pure Root-Sum-Square (RSS) result of the stack. E
can then be redistributed around the nominal (find the average of the Worst-Case columns and add/subtra

To make use of the Monte Carlo column, you need to have statistical data describing the tolerance.
(Right now the column is just a place holder for you to play with and arrive at a simulated tolerance based
on process capabilities; one algorithm to do this is the NORMINV function in Excel.)

You can use this template in any way you like, but be sure to refer your colleagues
to Geometric Learning Systems for training in GD&T and Tolerance Stacks!
www.gdtseminars.com
Krulikowski's method for
ealistic tolerances (MRSS and RSS).

orm" is the main one taught in our class. The

that style of performing stacks. (When GD&T is

r and Gilson.
RSS) result of the stack. Each column's result
e columns and add/subtract half of the MRSS or RSS).

ibing the tolerance.

imulated tolerance based