Consumer Goods need to both function and look good. Variation can affect both of these characteristics, and not always at the same time. Gaps and flushes can be uneven or large, making the products look poorer quality than their function dictates, or internal components may be out of alignment from a tolerance stack-up, causing heat issues and functional problems without affecting the outward appearance.
To manage these complications from variation, engineers use tolerance analysis software to simulate the assembly process and part tolerances, allowing them to see how the parts will fit together and how they will look before production begins. This allows manufacturers to design out these issues without having to make expensive tooling and production design changes down the line.
Example Model Shown for Demonstration Only
Demo Model Only - Customer Model Not Shown
Issue: Customer was concerned that the current design, when built, may have offset components such as doors, buttons or control nobs at extreme tolerance situations (ie. One side at maximum condition, and one side at minimum condition).
Solution: High End Visualization was added to various scenarios using design tolerances to show possible extremes.
Results: Customer modified some tolerances in order to reduce the chance of certain scenarios while leaving others the same due to lack of change to product appearance.