Advanced GD&T and Tolerance Stack up Analysis

Advanced GD&T has found its greatest application in mass production, where interchangeability of blindly selected parts is essential. Without GD&T and tolerance analysis, there is no way to know what parts have been designed such that all manufactured parts will fit together at assembly. This is becoming more critical today due to ever more powerful design tools and more restrictive business practices.

GD&T Advanced- Tolerance Stack-Up Analysis

Course Objective

Participants will be trained to apply tolerance stack-up analysis techniques to a wide variety of assemblies per GD&T requirements.

Demonstrate a thorough understanding of GD&T Fundamentals and Tolerance Stackup.

Properly apply frequently used tolerancing schemes

Locate the proper GD&T applications in reference materials.

Who Should Attend

Manufacturing Managers

Product Engineers and Managers

Quality Engineers and Managers

Project Engineers

Technical Staff

Quality Professionals

Suppliers Quality Assurance

HR Managers

Benefits of Attending

Geometric Dimensioning and Tolerancing (GD&T) and the tolerance stack-up Analysis eliminates the trial and error approach to product design.  It should be viewed as a design methodology ensuring dimensions and tolerances are developed to suit feature function and mating relationships. Thus by leaning Advanced GD&T, one could be benefitted:

  • It helps in eliminating guessing at product tolerancing, resulting in fewer prototype iterations and drawing revisions.
  • It specifies the maximum available tolerance for manufacturing while protecting feature function.
  • It provides clear instructions for quality control by using established rules governing part setup and tolerance zone interpretation, ensuring repeatable measurement results.
  • It helps in controlling machine allowances, wall thickness and interface dimensions on castings and fabrications.
  • It helps in developing multiple sources of supply by providing a complete product definition with a single dimensional interpretation.

Workshop Agenda


Dimensioning and Tolerancing

Converting Plus/Minus Dimensions and Tolerances into Equal-Bilaterally Toleranced Dimensions

Variation and Sources of Variation

Worst-Case Tolerance Analysis

Worst-Case Tolerance Stackup with Dimensions

Assembly Shift

Worst-Case Tolerance Stackup Examples

Tolerance Stackups and Assemblies

Statistical Tolerance Analysis

Statistical Tolerance Stackup with Dimensions

Statistical Tolerance Stackup Examples

Geometric Dimensioning and Tolerancing in Tolerance Analysis

Converting GD&T into Equal-Bilateral ± Tolerances.

Datum Feature Shift

Form Tolerances,  Orientation Tolerances, Run out Tolerances, Concentricity Tolerances, Symmetry Tolerances

Simultaneous Requirements and Separate Requirements

Converting Plus/Minus Tolerancing to Positional Tolerancing

Coaxial Error and Positional Tolerancing

Radial and Axial Tolerance Stackups in an Assembly

Specifying Material Condition Modifiers and Their Effect on Tolerance Stackups

Material Condition Modifier Selection Criteria

The Tolerance Stackup Sketch

Tolerance Stackup Sketch Content

Steps for Creating a Tolerance Stackup Sketch on Parts and Assemblies

The Tolerance Stackup Report Form

Filling Out the Tolerance Stackup Report Form

Dimension and Tolerance Entry

Tolerance Stackup Direction and Tolerance Stackups with Trigonometry

The direction of Dimensions and Tolerances in the Tolerance Stackup

Rotation of Parts within a Linear Tolerance Stackup

Floating Fastener and Fixed Fastener Formulas and Considerations

Floating Fastener Situation

Fixed Fastener Situation

Form Tolerances in Tolerance Stackups

Datum Feature Form Tolerances

Form Tolerances Treated as Adding Translational Variation Only

Form Tolerances Treated as Adding Rotational Variation

Training Deliverables

Feedback From Past Participants

“This training program has helped to take complete knowledge on manufacturing variations on the design”

“ Now we can design the products better from what we have learned from the training session”

“Advanced GD&T should be introduced in all manufacturing companies for better dimensioning and understanding”

Know Your Trainer


B tech from NIT Rourkela, PGDM  from IIM Calcutta with 14+ yrs of intensive experience in various sector. He is a certified coach for Manufacturing Management and System Development

He has helped companies turn-around by implementing Manufacturing Excellence through Lean, Statistical Quality Control, Six Sigma, Strategy Management

He is a passionate reader and have inclination to solve complex business problems within very short span of time.

@Tetrahedron Manufacturing Services Pvt Ltd

Phone : +91 7042140046         Email:

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