Title: Six sigma tolerance analysis for functionality and assemblability: designing locking systems

Authors: Panteleimon G. Kalpaxidis; George J. Besseris; Constantinos I. Stergiou

Addresses: Department of Mechanical Engineering, University of West Attica, P. Ralli & Thivon Avenue 250, Egaleo 12224, Athens, Greece; Kingston University, Penrhyn Road, Kingston upon Thames, KT1 2EE, London, England, UK ' Department of Mechanical Engineering, University of West Attica, P. Ralli & Thivon Avenue 250, Egaleo 12224, Athens, Greece; Kingston University, Penrhyn Road, Kingston upon Thames, KT1 2EE, London, England, UK ' Department of Mechanical Engineering, University of West Attica, P. Ralli & Thivon Avenue 250, Egaleo 12224, Athens, Greece; Kingston University, Penrhyn Road, Kingston upon Thames, KT1 2EE, London, England, UK

Abstract: Assembling can be seen as process of joining manufactured parts to create final product-assembly. In Six Sigma terms, overall performance of final product is highly affected by design/manufacturing characteristics of each component. The key role for successful fitting plays the specified target of dimensions/tolerances of parts. Assembling parts are designed/studied using CAD/CAM systems, which are great for reducing design time but lack methods/functions to allow selecting optimal geometrical/functional parameters. This slows down the design for Six Sigma (DFSS) process. In this work, the following issues are addressed while elucidated through a case study: 1) method for Six Sigma designers to check for possible part defects which may present misalignment opportunities during assembly; 2) approach for evaluating part/assembly dimensions/tolerances while ensuring functionality; 3) corrective action approach for design changes which avoids endangering increasing of overall cost. The simple unified framework may aid Six Sigma designers assessing/making product-assembly decisions by offering more robust information.

Keywords: Six Sigma; assembling process; tolerance analysis; CAD; statistical process control; SPC; non-parametric methods.

DOI: 10.1504/IJSSCA.2019.103558

International Journal of Six Sigma and Competitive Advantage, 2019 Vol.11 No.4, pp.277 - 302

Received: 28 Nov 2018
Accepted: 28 Feb 2019
Published online: 11 Nov 2019 *

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