Stack Description: ________________________________________ Ref No.

_____
OBJ.: ______________________________________________ Name: ___________________________
______________________________________________ Date: _______

POSITIVE NEGATIVE ONE HALF

STEP ID DESCRIPTION FROM / TO NOMINAL NOMINAL COMPONENT
TOLERANCE

0
0

− tol
MINUS
COMMENTS: SUB TOTALS 0 0 0
SIGN
+ tol Unicode:
NOMINAL ANSWER 0 0 U+2212,
0
UTF-8: E2
DESIGN GOAL: 88 92 tol
NOMINAL MAX MIN
__________________________________

TOTAL ADJUSTED TOTAL COMP.

COMPONENT MRSS TOLERANCE MONTE
TOLERANCETOLERANCE SQUARED CARLO
0 0.000 0
0 0.000 0
0 0.000 0
0 0.000 0
0 0.000 0
0 0.000 0
0 0.000 0
0 0.000 0
0 0.000 0
0 0.000 0
0 0.000 0
0 0.000 0
0 0.000 0
0 0.000 0
0 0.000 0
0 0.000 0.000
WORST CASE MRSS RSS MC

OPTIMIZED?
YES NO
Stack Description: ________________________________________ Ref No. _____
OBJECTIVE: _______________________________________ Name: ____________________________
______________________________________________ Date: _______
Paste part sketch or drawing here. Sketch stack path on drawing.

Column for entering the +/-

component tolerance (1/2 of
This column is a verbal the total tolerance).
Letter of stack path
vector or other description of the
identifier, such as part dimension you are Nominal dimensions that
recording. are negative (down or
number.
left).
Nominal dimensions that
are positive (up or right).

POSITIVE NEGATIVE ONE HALF

STEP ID DESCRIPTION FROM / TO NOMINAL NOMINAL COMPONENT
TOLERANCE

Total of all negative

Sum of the
nominal
COMPONENT
dimensions.
TOLERANCES (1/2 of
each component's total
Total of all positive tol).
nominal dimensions.

− tol
MINUS
COMMENTS: SUB TOTALS 0 0 0
SIGN
+ tol Unicode:
NOMINAL ANSWER 0 0 U+2212,
0
UTF-8: E2
DESIGN GOAL: 88 92 tol
NOMINAL MAX MIN
__________________________________

ath on drawing.
Monte
Carlo -
Column for
you to use
process
capability
data to
simulate
production
runs and
estimate a
total
=2X tolerance.
Component
Tol

TOTAL ADJUSTED TOTAL COMP.

COMPONENT MRSS TOLERANCE MONTE
TOLERANCETOLERANCE SQUARED CARLO
0 0.000 0
0 0.000 0
0 0.000 0
0 0.000 0
0 0.000 0
0 0.000 0
0 0.000 0
0 0.000 0 Modified RSS approach
0 0.000 0 - "Benderized" stack up
(1/2 of 0 0.000 0 of all component
t's total tolerances.
0 0.000 0
0 0.000 0 Root-Sum-Squared
0 0.000 0 (best case) assembly
0 0.000 0 stack up of all
component tolerances.
0 0.000 0
0 0.000 0.000
WORST CASE MRSS RSS MC

OPTIMIZED? [Link]
YES NO
 TOLERANCE STACK ANALYSIS
Stack Description: ________________________________________ Ref. No. _____ Sheet 7 of 11
OBJECTIVE:______________________________________________ Name: ____________________________________
______________________________________________ Date: _______

MAXIMUM MINIMUM TOTAL ADJUSTED TOTAL COMP.

STEP ID DESCRIPTION FROM/TO + MAX + MIN COMPONENT MRSS TOLERANCE
− MIN − MAX TOLERANCE TOLERANCE SQUARED
0 0.000 0
0 0.000 0
0 0.000 0
0 0.000 0
0 0.000 0
0 0.000 0
0 0.000 0
0 0 0.000 0
0 0.000 0
0 0.000 0
0 0.000 0
0 0.000 0
0 0.000 0
0 0.000 0
COMMENTS: SUB TOTALS 0 0 0 0.000 0.000
ANSWER WORST CASE MRSS RSS
DESIGN GOAL: OPTIMIZED?
MAX MIN YES NO

[Link]
 TOLERANCE STACK ANALYSIS Sheet 8 of 11
_______________

COMP.
MONTE
CARLO

MC

[Link]
Stack Description: ________________________________________ Stack No. _____
OBJECTIVE:______________________________________________ Name: ________________________________
______________________________________________ Date: _______
Paste part sketch or drawing here. Sketch stack path on drawing.
This column is a verbal Columns G and I are for entering
description of the the appropriate sign (+/-) required
dimension you are based on the direction. Factored tot
recording. Gilson corre
Letter of stack path to get from
vector or other Column for Column for
totaling the totaling the The total (for 1 or 2 c
identifier, such as part to the MRSS
maximum minimum limit tolerance
number. (for 6 or mo
limit dimension. calculated from
components
dimension. the max & min
limits.

MAXIMUM MINIMUM TOTAL ADJUSTED

STEP ID DESCRIPTION FROM/TO + MAX + MIN COMPONENT MRSS
- MIN - MAX TOLERANCE TOLERANCE
0 0.000
0 0.000 Correction factor (9
components/values
0 0.000
0 0.000
0 Correction factor (80%)
0.000
0 0.000
0 0.000
Correction factor (72%) for
0 0 0.000
Modified RSS 0 0.000
approach - 0 0.000
Root-Sum-Squared (best
"Benderized" 0 case)0.000
assembly stack up
stack up of all 0 0.000
of all component
component 0 0.000
tolerances.
tolerances.
0 0.000
0 0.000
Worst case
assembly stack 0 0.000
up of all 0 0.000
component 0 0.000
tolerances. 0 0.000
0 0.000
COMMENTS: SUB TOTALS 0 0 0 0.000
ANSWER WORST CASE MRSS
DESIGN GOAL: OPTIMIZED?
MAX MIN YES NO
_____________________________

wing.

Factored total tolerance -

Gilson correction factors
to get from worst case
The total (for 1 or 2 components)
tolerance to the MRSS approach
(for 6 or more Column for you to
calculated from
components).
the max & min use process
limits. capability data to
simulate production
runs and estimate a
total tolerance.
TOTAL COMP.
TOLERANCE MONTE
SQUARED CARLO
0
Correction0factor (92%) for 3
components/values.
0
0
Correction factor
0 (80%) for 4 components/values.
0
Correction factor 0(72%) for 5 components/values.
0
0
0
Root-Sum-Squared (best
case) assembly stack up 0
of all component 0
tolerances. 0
0
0
0
0
0
0
0
0.000
RSS MC
We developed the MAX/MIN (limit) spreadsheet based on Alex Krulikowski's
method for calculating stacks, then added a couple of columns to help users
develop more realistic tolerances (RSS, MRSS).

Special thanks to Zachary Amico who replaced some clumsy logic on the
MAX/MIN form and set-up a more professional looking pull-down menu for
entering plus and minus signs!

The nominal/plus/minus spreadsheet is optional for companies who mandate

nominal/plus/minus tolerancing. Special thanks to Marc Adorian who pointed out
some improvements needed on the nominal/plus/minus spreadsheet!

To make use of the Monte Carlo column, it's best to have statistical data
describing the tolerance. (The column is really just a place holder for you to play
with and arrive at a simulated tolerance based on process capabilities; it doesn't
calculate anything.)

You can use this form in any way you like, as long as you:
1. Include all worksheets whenever you copy the file (and don't change the
Acknowledgements and License)
2. Send any improvements and comments to: [Link]@[Link]
Please visit [Link] to find out more about training on tolerance stacks using
GD&T.

Thanks!

John Stolter
(586) 693-0219