Do it right the first time…

A Dimensional Engineering approach

to Closed-Loop Quality Management

Dimensional Control Systems, Inc. 2011 1

 Prevention
Deaths in Rhode Island from Smoking
Adults who die each year from
1,600
their own smoking
Kids now under 18 and alive
in Rhode Island who will
23,000
ultimately die prematurely
from smoking

Smoking kills more people than alcohol, AIDS, car crashes, illegal drugs, murders,
and suicides combined — and thousands more die from other tobacco-related causes
— such as fires caused by smoking (more than 1,000 deaths/year nationwide) and
smokeless tobacco use.

Dimensional Control Systems,

Inc. 2010
Problems to Mitigate…

Process Inconsistency Product Non-Conformance

Traceability Gaps
3
Closed-Loop Quality

DE Process that will

Meet / Exceed
Predict Customer Expectations

Resolve Plan
Problem
Mitigation
APPROACH

Speedy Resolution
Find
Intended Quality
at Target Cost

4
Dimensional Engineering...
Program Directives
Applied Early and Throughout Product Lifecycle
Build Objectives

Build Strategies

GD & T Requirements

Tolerance Analysis

Measurement Plans

Dimensional Data Reports

Root Cause Analysis

Final Product
“Build Objective”

Sub-Assemblies
Process Strategy
Detail Part
Dimensional Requirement
Why Dimensional Engineering?

“Robust” Design
Includes Process!

6
 Key Elements of a Robust DE Process

Variation Analysis Validates:

• Build Objectives
• Process Strategies
Build Objectives
• GD&T Requirements
Process Strategies
GD & T Requirement
Variation Analysis

Measurement Plans
Build Quality Reports

Program Root Cause Analysis

Directives
Final Product
Build Objectives
Sub-Assembly
Process Strategy Detail Part
Dimensional Requirements

7
Tool Alignment to DE Process

3DCS-PQS (Perceived Quality Study)

Program Directives
3DCS Variation Analyst
Build Objectives •Adv Analyzer Optimizer
Process Strategies •Compliant Modeler
GD & T Requirement
Variation Analysis
GDM-3D
Measurement Plans

Build Quality Reports

Final Product
Build Objectives
Root Cause Analysis
Sub-Assembly
Process Strategy Detail Part
Dimensional Requirements

GDM-WEB
GDM-PDA 8
DVA Process Alignment to PLM

Dimensional
Variation
Analysis
Complete Process Support
For Engineering & Manufacturing Quality
3DCS
Product Lifecycle

Stage Concept Design Process Manufacture In-Service

Rigid Body Variation Analysis

DVA Perceived Quality GD&T Optimization As-Built Correlation
Process
Compliant Variation Analysis

9
DVA Application Domains…

Structures / Chassis

Mechanisms

Enclosures

Aesthetic Fits

Any Assembly

10
Visualize Variation Impact Early

Perceived Quality Study

11
General Motors Results…

8. Verification 1. DTS
• Final DTS verification Define gap, flush
• Lessons learned workshops and radii targets

1 2. Concept Creation
7. Validation tools 8 and Investigations
• Vendor part gages 2 • Simulation of new concepts
• Vendor part measurement • Digital visualization
devices
7 DE • Benchmark of different
3 concepts
6. DTS / Drawing Review
• Check DTS against latest data
Circle 3. CDLS
• Check and release drawings • Develop coordinated
6 datum locating C
• Check tolerance studies for data 4 B
changes strategy A Z
5 Y
• MDM support
X

5. GD&T 4. Tolerance Studies

CFTs for all drawings related • Review design & evaluate
items quality achievement.
like dimensions, tolerances and • Virtual validation of DTS
DTS requirements requirements.

Dimensional Control Systems, Inc. 2011 12

General Motors Results…

"Successful tolerance analysis

product execution played a
major role in our achievement
of high quality across our
product vehicle line.
The Chevrolet Volt, Chevrolet
Silverado, Chevrolet
Malibu and Cadillac CTS
were all named Car/Truck
of the Year winners."
Richard Korynski
Body Tolerance Analysis Manager-
General Motors

13
In-depth Tolerance Studies

Model Based
Dimensional Variation Analysis

Simulate-
- Thousands of Assembly
builds in Minutes

14
Airbus: Tolerance management
during early concept phase
Evaluation of:

assembly process regarding
global aircraft requirements

different assembly strategies

new manufacturing technologies
(CFRP, bonding, water-jet
cutting, One-Shot-Single-Barrel)

new assembly technologies
(indoor-GPS, Laser-
scanner/tracker)
Tolerance management during early
concept phase
Analyse different engine concepts for aerodynamic
efficiency

Tail or wing mounted

Geared turbo fan

Open rotor configuration
Associativity to CAD Model & GD&T

17
Tolerance Optimization to Cost Constraints

Advanced Analyzer/Optimizer

18
Peterbilt Results…

"3D tolerance analysis has provided the

foundation for our dimensional
management process here at Peterbilt as
well as throughout the PACCAR
organization.
We have seen the fit & finish and overall
quality of our products improve since the
implementation of tolerance simulation /
dimensional management.
We rely on tolerance analysis to help
manage design quality and support our
objective to be best in class."

- Jacob Conley
Dimensional Management
Group Leader

19
Compliant Variation Analysis

Clamp/Weld Clamp/Weld

Consider Effects of:

– Force
– Gravity
– Thermal
Compliant Modeler

20
Automated Reporting

Automated Report Generator

21
Measurement Plan Authoring

22
Leverage Analysis within QA Process

As a powerful root-cause analysis toolset

GDM-Web 3DCS-
Quality Management System Root Cause Analysis

23
Chrysler Results…

“Chrysler has realized significant cost savings over

the years by using tolerance analysis as part of
our overall
dimensional engineering process.
We've applied tolerance analysis in the early
design stages of our programs in order to identify
potential build issues early in the product lifecycle.
This has enabled us to reduce physical prototypes,
minimize costly gage & tooling changes,
and avoid quality issues during production.”
- Greg Medler
Chrysler Tolerance Analysis Manager

24
TOKAMAK Project
Dimensional Engineering…
Program Directives
Applied Early and Throughout Product Lifecycle
Build Objectives

Build Strategies

GD & T Requirements

Tolerance Analysis

Measurement Plans

Dimensional Data Reports

Root Cause Analysis

Final Product
“Build Objective”

Sub-Assemblies
Process Strategy
Detail Part
Dimensional Requirement
Questions???
Don Jasurda
248-321-1378
djasurda@3dcs.com

www.3dcs.com