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

Rejects

LL

Capability

A frequency plot shows how a

process varies from the mean

UL

Models for Predicting

Assembly Tolerance Stackup

Worst Case (WC)

Statistical (RSS)
Six Sigma (6)
Measured Data (Meas)

TASM Ti

ASM
ASM

Ti

Ti

3CPK

ASM

i2

Models for Predicting

Assembly Tolerance Stackup
Model
Worst
Case (WC)
Statistical
(RSS)
Six Sigma
(6s)
Measured
Data
(Meas)

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.

Centering the Mean

Center

Rejects

LL

Xmean

Centering the process in the LL/UL

window minimizes rejects

UL

Decrease Variation
Decrease Standard Deviation

Reduce rejects

LL

Capability

UL

Higher Values Mean

Higher Quality
LL

UL

Controlling Variation Leads to

Higher Yields and Fewer Defects

Limits
3

Yield
99.73%

4.5

99.99966%

99.9999998%

Defects
2700 / Million
3.4 / Million
2 / Billion

Controlling Variation Leads to

Higher Yields and Fewer Defects

Limits
3

Yield
99.73%

4.5

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

LL

4.5

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

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

where Cpk= Cp (1-k)

and

CP

UL LL
6

LL

UL

Six Sigma
Dynamic Mean Shift
99.73%
(Short Term)
95.45%
(Long Term)

LSL

USL

Capability

Comparing Short and Long Term Variation

Requirements for High Quality

99.9999998%
(Short Term)

LL

UL

99.99932%
(Long Term)

Capability

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

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

Reject Fraction (1- )

3
6
0.001349898031629990
0.000000000987000000
0.001349812528196100
0.000000001248061000
0.001349967223235000
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

ZL

ZU

Transformation
x x
Z
x
Mean
X=0
Standard Deviation

Z ( units)

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.