Five Ways Statistical Tolerancing Can Fail and What to Do About Them
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In this article we explore the general non-robustness of traditional root sum of squares statistical tolerancing and describe, in particular, how it can fail. These are  deficiencies in the functional model,  lower process capability in inputs that what is desired of outputs,  biases,  correlations, and  non-normality. We also show that statistical tolerancing is extremely non-robust to the first four types of causes. Moreover we provide examples of each type and discuss what to do about each.