Stack Description: ________________________________________ Ref No.

_____
OBJ.: ______________________________________________ Name: ____________________________
______________________________________________ Date: _______

POSITIVE NEGATIVE COMPONENT

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.

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

Nominal dimensions
that are positive (up or
right).

POSITIVE NEGATIVE COMPONENT

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 plus nominal stack minu
subtotal). subtotal component subtotal componen
tolerance). tolerance).
Maximum (total Maximum (total
nominal stack plus nominal stack minu
subtotal component subtotal componen
tolerance). tolerance).
_______________________________

drawing.

Factored total Monte 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 Correction
0 factor (92%) for 3 components/values.
0.000 0
Correction factor (80%) for 4 components/values.
0.000 0
0.000 0
Correction factor (72%) for 5 components/values.
0.000 0
0.000 0
0.000 0
0.000 0 Modified RSS
embly approach -
0.000 0 "Benderized" stack
erances. 0.000 0 up of all component
tolerances.
0.000 0
0.000 0 Root-Sum-Squared
(best case) assembly
0.000 0
stack up of all
0.000 0 component
0.000 0 tolerances.
0.000 0.000
MRSS RSS MC

gd-t.com f

Maximum (total
nominal stack minus
subtotal component
tolerance).
Maximum (total
nominal stack minus
subtotal component
tolerance).
Stack Description: ________________________________________
TOLERANCE STACK ANALYSISRef. No. _____ Sheet 7 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 8 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 part Column for totaling
recording.
number. the maximum limit
dimension. Column for totaling
the minimum limit
dimension.

MAXIMUM MINIMUM COMPONENT FACTORED

STEP ID DESCRIPTION FROM/TO + MAX + MIN TOLERANCE TOTAL
- MIN - MAX TOLERANCE
## ## 0 0.000
## ## 0 0.000
## Component
## tolerance is 0 0.000 Co
## the
## total tolerance 0 0.000
## calculated
## from the 0 0.000
max & min limits. Co
## ## 0 0.000
## ## 0 0.000 C
## ## 0 0 0.000
## ## 0 0.000
Root-Sum-Squared (bes
## ## 0 0.000
case) assembly stack u
## ## 0 0.000
of all component
## ## 0 tolerances.
0.000
## ## 0 0.000
## ## 0
Modified 0.000
RSS
##
Worst case assembly ## 0
approach 0.000
-
stack up##of all ## 0 0.000
"Benderized" stack
component
## tolerances.
## up0of 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
_____________________________

wing.
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.

Factored total tolerance -

method of getting from worst
case (for 1 or 2 components) to
COMPONENT the MRSS approach (for 6 or
TOLERANCE MONTE more components).
SQUARED CARLO
0
0
0 Correction factor (92%) for 3 components/values.
0
0 Correction factor (80%) for 4 components/values.
0
0 Correction factor 792%) for 5 components/values.
0
0
Root-Sum-Squared (best
case) assembly0 stack up
0
of all component
tolerances. 0
0
ified RSS 0
roach - 0
nderized" stack 0
f all component 0
rances. 0
0
0
0.000
RSS MC
I developed the limit spreadsheet based on Alex Krulikowski's method for calculating stacks,
then added a couple of columns to help users develop more realistic tolerances (RSS, MRSS).

I developed the nominal/plus/minus spreadsheet because many companies avoid limit tolerancing.

To make use of the Monte Carlo column, you need to have statistical data describing the tolerance.
(The column is really just a place holder for you to play with and arrive at a simulated tolerance based on

You can use this form in any way you like, as long as you solemnly swear to:
1. Include all worksheets whenever you copy the file (and don't change the Acknowledgements and Licens
2. Send any improvements and comments to: john.stolter@gd-t.com

Please visit gd-t.com to find out more about training on tolerance stacks using GD&T.

Thanks!

John Stolter
(586) 693-0219
RSS, MRSS).

limit tolerancing.

ng the tolerance.
ed tolerance based on process capabilities.).

wledgements and License)