Robust design with tolerance analysis 1

More and more companies are choosing to work with tolerance analysis and robust design in order to boost their development time, mitigate risks early in the development cycle, and achieve seamless production ramp-up. By anticipating future variation during product development, the sensitivity to variation can be minimised using a systematic approach.

In this course, you will learn efficient techniques to ensure, evaluate, and optimise design robustness of products and processes. You will be able to anticipate product and process variation by using tolerance analysis and tolerance chains to map correlations between different inputs and outputs.

Target group

This course is relevant for anyone involved in R&D, product development or design, and for everyone who is interested in making systems more robust to variation in components, and thereby allowing larger tolerance windows on component specifications.

Some of the techniques covered in this module can also be applied to e.g. process design. We welcome anyone seeking to increase robustness in their end-product.

If you are participating in a Six Sigma Green Belt or Black Belt course, this module will be voluntary. The covered tools will become useful when working with data analysis on your DMAIC project.

Your benefits

After participating in this course, you will be able to:

  • Work with tolerance chain methods such as, worst case, statistical and process tolerance chains methods
  • Calculate a theoretical error rate for an output based on a tolerance chain by using capability indices on inputs
  • Minimise the error rate on outputs, by doing simple optimisation on input.
  • Identify critical input parameters (red X’s)
  • Do tolerance chain assumptions that are enforced in quality specifications

The course involves theoretical and practical exercises in both design evaluation and subsequent tolerance analysis where you will get hands-on experience with the techniques. The techniques taught can be applied to a device design, but will to a certain extend be applicable to other disciplines such as process robustness.


  • Types of tolerances
  • Sign conventions and good practice
  • Transfer functions
  • Estimation of high volume variation using VarTran
  • Variance transmission reduction

Advanced courses

This is the first course of two within the topic of design and development where the next level course is Robust design with tolerance analysis 2. Furthermore, the courses Data-driven root cause analysis and design of experiments (DoE) 1 and 2 are both very good complementation to courses within this topic.

If you want to devote more focus on the development of performance and processes, you can get inspiration from methodical courses such as Design for Six SigmaQuality Function Deployment and Risk Management in Development Projects offered by Storm Management. These courses will help you map and operationalise customer demands and develop future processes.

Furthermore, you have the opportunity to continue your education as a Six Sigma Green Belt or Black Belt, and become more competent and able to optimise, lead and develop processes.


Venue: NNE's headquarters, Bredevej 2, 2830, Virum, Denmark

Price: DKK 5,000 + VAT (includes course materials, refreshments and lunch)

Language of instruction: The course will be held in English unless all participants speak and understand Danish

Duration: 1 day

Course dates in 2018

  • June 14
  • December 6


Sign up for the course