1. Dimensional Variation Analysis

2. Dimensional Variation Analysis (DVA) Mission
A Group Dedicated to Deploying
Advanced Processes and Tools
in Statistical Tolerance Analysis
for Improved Reliability, Cycle Time,
Comparative Advantage, and ROE.
Interviewed Several Engineering Leaders & Designers:
- No Time
- Stack-ups done on AS NEEDED BASIS -> $$$$$$$$$$
- Communication Issues Between Entities
- Want Training, TOOLS & SUPPORT

3. 4 Tier Approach Tier 1; Nom. Clearances & Worst Case (WC) Analysis &
Tier 2; Modified WC and RSS Statistical Analysis
# Tolerances
Assembly Tolerance
W/C
Reality
RSS
Increasing Firepower
Tier 3; Monte Carlo Simulation
&
Tier 4; VSA/PRO-E 3-D Variation Simulation

4. Greg Steinrock & Mike Baker
DVA Team Concept
AHD
Engineering Leader
PDE
Engineering Leader
Signature
Engineering Leader
DVA Team
Greg Steinrock & Mike Baker
Class II
Engineering Leader
Class I
Engineering Leader
CEP
Engineering Leader
CTC
Engineering Leader
JEP
Engineering Leader

5. Standard Graphical User Interface

6. Potentially Saved 4.20 RPH & $8.12 CPE!!
Angular Misalignment (Degrees)
CPK= 1.0
Angular Misalignment (Degrees)
CPK= 1.67
Tornado Diagram For Tolerance Allocation
Potentially Saved 4.20 RPH & $8.12 CPE!!
Piston Rod Interference at Kreystone Angle
Liner Block Interference
Piston Cooling Nozzle Clearance
Fuel Pump Gear Clearance

7. Design “No Fly Zone” Fuel Pump DVA Results DVA Simulation
Geometry, GD&T...
Assembly, FEA, Wear ...
DVA Results
End Clearance
Radial Clearance
Design “No Fly Zone”
DVA Simulation
Add Structural Effects
Nominal Shift
ROBUST FINAL DESIGN
Add Thermal Effects
Dimensional Variation
Add Wear Effects --> Net Cumulative Distribution
Tolerance Reallocation
Gear Design Change

8. Hydraulic Control Valve
Solenoid Spacer

9. Questions?