Abstract

This article is the first part of a four-part mini-series exploring key aspects of modern tolerance management in product development. It focuses on Dimensional Management (DM) — a simulation-based engineering methodology essential for ensuring dimensional quality across a product's lifecycle.

Tolerances play a critical role in product design, manufacturing, cost, and time-to-market. Poorly defined tolerances can lead to delays, increased scrap, and high production costs. DM addresses these challenges by integrating tolerance considerations early in the product development process (PDP), aligning design, manufacturing, and quality teams to manage variation proactively.

DM provides a structured approach across concept, design, prototyping, and production phases. It helps define reference structures, optimize tolerances using 3D simulations, guide inspection planning, and support continuous improvement through statistical process control. It emphasizes collaboration, data-driven decision-making, and clear communication of design intent through 2D drawings or 3D CAD models.

Ultimately, DM is not just a quality control tool—it's a foundational strategy for delivering high-quality products efficiently and confidently in today’s complex engineering environments.

Future articles in the series will cover:

• ISO GPS – Geometrical Product Specifications
• Statistical Simulation of 3D Tolerance
• QIF format for Model-Based Definition (MBD) and digital continuity.