A review on dimensional tolerance synthesis: paradigm shift from product to process

Purpose – The purpose of this paper is to present a state-of-the-art review of dimensional tolerance synthesis and to demonstrate the evolution of tolerance synthesis from product to process-oriented strategy, as well as to compare the same for single stage and multistage manufacturing systems (MMS). The main focus is in delineating the different approaches, methods and techniques used with critical appraisal of their uses, applicability and limitations, based on which future research directions and a generic methodology are proposed. Design/methodology/approach – Starting with issues in tolerancing research, the review demonstrates the critical aspects of product and process-oriented tolerance synthesis. The aspects considered are: construction of tolerance design functions; construction of optimization functions; and use of optimization methods. In describing the issues of process-oriented tolerance synthesis, a comparative study of single and multistage manufacturing has been provided. Findings – This study critically reviews: the relationship between the tolerance variables and the variations created through manufacturing operations; objective functions for tolerance synthesis; and suitable optimization methods based upon the nature of the tolerance variables and the design functions created. Research limitations/implications – This study is limited to dimensional tolerance synthesis problems and evolution of process-oriented tolerance synthesis to counteract dimensional variation problems in assembly manufacturing. Originality/value – The paper provides a comprehensive and step-by-step approach of review of dimensional tolerance synthesis.