Tolerance chart optimization for quality and cost

This paper introduces a mathematical model for tolerance chart balancing during machining process planning. The criteria considered in this study are based on the combined effects of manufacturing cost and quality loss, under the constraints of process capability limits, design functionality restrictions, and product quality requirements. Manufacturing cost is expressed in geometrical decreasing functions, which represent tolerances to be assigned. Process variability is expressed in quadratic loss functions, which represent the deviation between part measurement and the target value. Application of this model minimizes the total cost of manufacturing activities and quality issues relating to machining process planning, particularly in the early stages of planning.