David A. Panek has 18 years of experience in cost engineering. He has expertise in tolerance analysis, Monte Carlo techniques, cost estimation, and neural costing. The document discusses different methods for tolerance analysis including worst case, statistical, and six sigma approaches. It also defines terms related to process variation and discusses measures of process capability like Cp and Cpk. Guidelines are provided for designing optimized tolerances through establishing process standard deviation and computing probabilities to achieve tight assembly gaps.

1. David A. Panek Product Cost Engineering Six Sigma Mechanical Tolerance Analysis

2. BIO Name: David A. Panek Education (Degree/College): Bachelor of Science Electrical Engineering and Bachelor of Science Computer Science Area of Expertise:Tolerance analysis, Monte Carlo Techniques, Time to market improvement, Cost Estimation Techniques, Neural costing. Years of Experience: 18 (costing) Area of Focus: Improvements to cost control

3. Introduction Methods for doing Tolerance Analysis Worst Case  Individual tolerance  Statistical (RSS)   Individual tolerance/3  ² Six Sigma   Individual tolerance/(3*Cpk)  ²

4. Definition of terms Process Variation Standard Deviation Rejects   UL LL   Mean A frequency plot shows how a process varies from the mean Capability 

5. Measures of Process Capability  3   6  k Process Capability Index: Cp adjusted for k : C pk = C p (1-k) UL UL LL LL

6. 6  Variation Defined RSS : 6  : where C pk = C p (1-k) and  3  UL LL  6  k UL LL

7. Optimizing the nominal dimensions of the components Optimizing the tolerances of the components Establish the variance Pool Motorola Product Design Optimization

8. Design Analysis and Optimization Guidelines Execute Preliminary Design Activities Identify Process Standard Deviation Assign Tolerances to Related Dimensions Compute Z for Each Specified Gap Constraint Optimize the Probability for Each Specified Gap Constraint (.9999966 Probability of assembly)

9. Simple Problem 1±.001 1±.001 1±.001 3.1±.001

10. Simple Six Sigma Tolerance Analysis Spread sheet

11. Dr. Ken Chase, Brigham Young University, cats_1d spreadsheet

12. Reference information (web) http://adcats.et.byu.edu/home.html(Brigham Young University Adcats home page) http://adcats.et.byu.edu/WWW/ADCATS/software/(Excel Spreadsheet )

13. Reference information Six Sigma Mechanical Design Tolerancing - Mikel J. Harry, Reigle Stewart - 1988 - ISBN 1569460167

14. Questions and comments According to the Six Sigma Body of Knowledge from the ASQC section on Design for Six Sigma - Robust Design Process - Tolerance Design a Black Belt is suppose to know how to do Statistical Tolerancing. Thank you [email_address]