Tolerance management in robot-based assembly optimizes product, process and system deviations

Abstract Deviations of individual parts, assemblies, modules, processes, and equipment interact in assembly and can lead to rework or rejects of the finished product. In general, deviations cannot be avoided but must be managed. There are many analysis methods, however only few abstract methods concentrate on optimization. Thus, there is a lack of concrete, easy and feasible optimization methods for deviation reduction. This paper presents a novel method for assembly optimization by combining tolerance chains and a developed optimization tree, which gives a holistic overview of practical improvement measures. The method is validated on an automated robot process in engine production.