Tolerance Stack-Up Analysis
I.D. # C0022 Duration 2 Days
This course is designed to help product design personnel create tolerance stacks for parts and assemblies that use Geometric Dimensioning & Tolerancing. Those who will benefit most are designers and engineers who are responsible for creating the GD&T callouts for engineering drawings and product models, and who want to be more confident in how the assigned geometric tolerances interact and stack up. The course begins with a quick review of Y14.5 concepts, and then introduces the benefits and uses of a tolerance stack spreadsheet. Participants then learn detailed procedures for performing tolerance stacks on parts and assemblies, beginning with coordinate tolerances and moving on to geometric tolerances.

The course will eliminate confusion over how to include the bonus and shift in a tolerance stack: for example, when using tolerance of position with the MMC modifier. The simple, manual spreadsheet method used throughout the course produces a straightforward documentation trail that is easily interpreted, and readily adaptable to any company's electronic spreadsheet program. Results can be quickly and easily checked, and revisions can be made with ease. Students receive extensive practice at creating stacks, and should bring a calculator or laptop computer equipped with MS Excel for the numerous student exercises.

Each attendee will receive a copy of the "Tolerance Stack Analysis Using GD&T" textbook and an Excel template for generating stacks.

Note: A similar course is available live online or on demand. A variety of additional GD&T and Tolerance Stacks learning products are available through SAE's GD&T training subsidiary Effective Training, Inc.,

Learning Objectives
By attending this seminar, you will be able to:
  • Correctly calculate and apply bonus, shift, virtual condition, and resultant condition
  • Perform and develop a tolerance stack-up analysis
  • Correctly enter geometric feature control frame data into a tolerance stack
Who Should Attend
This course is intended for designers and engineers who are currently generally familiar with the principles, concepts and practices contained within Y14.5, and who are looking for a comprehensive step-by-step process for getting GD&T into a tolerance stack.
Previous experience with Geometric Dimensioning & Tolerancing principles, concepts, and practices is required.
Seminar Content
  • Introduction to Tolerance Stacks
  • Review of GD&T and the Y14.5 Standard
  • Review of Virtual Condition and Resultant Condition concepts
  • Introduction to Tolerance Stack-up Analysis Procedure for parts (part stacks) using coordinate dimensions and tolerances*
  • Introduction to Tolerance Stack-Up Analysis Procedure for assemblies (assembly stacks) using coordinate dimensions and tolerances (100% interchangeability)*
  • Tolerance Stack-up Analysis for runout and concentricity*
  • Tolerance Stack-up Analysis for surface profile: bilateral and unilateral*
  • Tolerance Stack-up Analysis for tolerance of position: RFS*
  • Tolerance Stack-up Analysis for tolerance of position: MMC-bonus*
  • Tolerance Stack-up Analysis for tolerance of position: MMC-shift*
  • Tolerance Stack-up Analysis for form and orientation controls: surface and feature of size*
  • Use of Statistical Methods in Stack-up Analysis: Root-Sum-Square and its Derivatives

* Indicates hands-on practice exercises immediately follow lecture
Instructor(s): John-Paul Belanger
John-Paul Belanger is president of Geometric Learning Systems, a consulting firm specializing in geometric dimensioning and tolerancing (GD&T). For over ten years, he has trained people throughout North America and Europe in the proper interpretation and application of GD&T per the Y14.5 standard by using practical examples. Mr. Belanger is certified by the American Society of Mechanical Engineers as a Senior GD&T Professional, and has worked with a wide range of companies in the automotive, aerospace, electronic, and other industries to apply tolerances and perform stack calculations. He holds a B.S. in aerospace engineering from the University of Michigan specializing in aircraft design and safety.

"Excellent course. Definitely enhanced my ability to perform tolerance stack-ups."
Randy Zonca
Senior Designer

"Great content, good instructor, well done."
Michael Habel
Technical Expert/Six Sigma Master Black Belt
Ford Motor Co.

"Most informative subject material I've had since college!"
Bryan Hayes
Mechanical Engineer
Hitachi Automotive Systems Americas

Can't make the live class? A similar course is available as a Web Seminar delivered Online!
Tolerance Stack-up Fundamentals

Fees: $1455 SAE Members*: $1164 - $1310
* The appropriate SAE Member discount will be applied through the Registration process.  Discounts vary according to level of membership: Elite Member 20%; Premium Member 15%; Classic Member 10%
CEU 1.3