Model based definition driven tolerance analysis: Revolutionising precision engineering
Project challenges
Design is the cornerstone of product development, with up to 80% of manufacturing costs determined at the design stage.
Business challenge
Process Innovation
Sector
Electrification
Technology or capability
Additive Manufacturing
MTC is leading the way in transforming product development by harnessing the power of Model-Based Definition (MBD) and advanced tolerance analysis tools. By integrating cutting-edge software into the product lifecycle, MTC is unlocking new levels of efficiency, precision, and cost savings in manufacturing.
The Challenge
Design is the cornerstone of product development, with up to 80% of manufacturing costs determined at the design stage. A key factor in these costs is engineering tolerances — the acceptable limits for the features of a manufactured part. While precise tolerances are critical for certain components, over-specification can lead to unnecessary expenses, such as increased scrap, rework, and inspection times. These inefficiencies can erode profitability, reduce product competitiveness, and strain overall operational efficiency.
It might seem obvious that careful attention should be paid to engineering tolerances to avoid these pitfalls. However, tolerance evaluation often becomes a manual, laborious process, particularly with complex products or when physical prototypes are involved. This makes it crucial for engineering teams to strike a balance between precision and the economic realities of manufacturing.
Recognising this need, MTC’s engineering design experts set out to accelerate and simplify the process of defining tolerances within a manufacturing environment. To achieve this, MTC collaborated with industry and software providers to identify capabilities that could enhance the tolerance assignment process and deliver significant manufacturing efficiencies.
MTC's Solution
Engaging with MTC’s industrial members, MTC brought together a group of like-minded professionals committed to radically improving their understanding of the tolerance assignment process.
MTC then identified a range of software solutions from both established vendors and emerging players in the industry. Thanks to MTC’s agile and innovative approach, we worked closely with these software providers to gain a deep understanding of their tolerance analysis toolsets. The evaluations were thorough, focusing not only on functionality but also on how these tools could be seamlessly integrated into the broader digital manufacturing ecosystem, contributing to the digital thread through a model-based engineering approach.
The MTC team applied these tools to real-world scenarios, demonstrating their effectiveness in members’ organisational models. This hands-on approach provided clear knowledge transfer and a practical path to integration, showcasing the tangible benefits of adopting these advanced tools.
Working on this project helped demonstrate the potential the MBD driven tolerance analysis has for validation of tolerancing and design optimisation. Our partners have learned about new digital engineering tools and will soon be seeing the benefits of lower manufacturing costs, improved process optimisation, and faster time-to-market for their products.
Kieran Ciniewicz, Research Engineer, MTC
The Outcome
As a result of this programme, MTC has empowered its members with the tools and knowledge to implement model-based engineering in their own organisations. MTC has also established a Model-Based Engineering user group, dedicated to the promotion and advancement of the of digital manufacturing tools to drive innovation and cost competitiveness in the UK and beyond.
In one notable example, our engineers applied these software tools to a product previously assessed using a manual tolerancing approach. MTC quickly identified a miscalculation that had been driving up rework and scrap rates. The product owner is already benefiting from significant cost savings thanks to a seemingly minor design adjustment.
Benefits to the Client
Adopting Model-Based Engineering for tolerance analysis offers multiple advantages:
- Data-Driven Decision Making: Validate and communicate tolerancing decisions with numerical data and comprehensive tolerance studies
- Accelerated Product Development: Assess and visualise tolerance assignments more quickly and in greater detail than with manual methods
- Cost Savings and Operational Efficiency: Reduce scrap and rework rates caused by over-specification or poor specification of engineering tolerances
If your organisation is looking to enhance its competitiveness through product optimisation or innovation, or if you’d like to join our MBE User Group, please contact MTC to discover how we can support your journey towards excellence.
