GD&T Tolerance Stack-Up Workshop

September 25, 2013

Organized by: Smart Manufacturing and Lean Systems Research Group

Co-Chairs: Ahad Ali, LTU and Tom Miller, Ford Motor Company

Lawrence Technological University, 21000 West Ten Mile Road, Southfield, MI 48075

Room: Marburger Science and Engineering Auditorium (S100),

Time: 8:00 AM to 05:00 PM

What: Six Sigma and Tolerance Stack-Up, training certificate will be provided, and 0.8 CEU is available

How: Registration fee $50, Breakfast and Lunch will be provided.

Who: Subject Matter Industry Experts

07:00 – 08:00 am Networking Breakfast

Morning Session: 8:00am – 12:00pm

Overview of GD&T - Thomas Miller, Ford Motor Company

ASME Standards - Rochelle Courson, Ford Motor Company

Introduction to Tolerance Stackup - Boon Ng, Ford Motor Company

Stack Up Exercises - Brian Heersink & Brent Davis, Ford Motor Company

e-Stackup - Thomas Jacobs, Ford Motor Company

  • Online Stack-up Tool
  • Bolt Stack-up
  • Linear Stack-up
  • Bonus & Datum Shift
  • RSS & Bender
  • Monte Carlo Analysis
  • Review Process

Generic Stack Up Example - Andrew Revels, Ford Motor Company

VSA –VA (Variation Analysis) – Dimensional Management Analysis - Timothy Bohr, Ford Motor Company

12:00 – 01:00 pm Lunch (Complimentary)

Afternoon Session (Industry Case Studies): 1:00 – 5:00 pm

01:00 – 02:00pm Case Study I – Dr. Robert Karban, Executive Director, American Axle & Manufacturing

02:00 – 03:00pm Case Study II – Mr. Greg Medler, Tolerance Stack up Manager at Advanced Manufacturing System in Chrysler


03:00 – 04:00pm Case Study III – Mr. Rich Solti, Global Director of Sales, PROLIM Corporatio, Farmington Hills, MI

04:00 – 05:00pm Case Study IV – Panel Discussion lean by Mr. Miller

05:00 pm Closing remarks – Dr. Ali

05:10 – 06:00 pm Networking

 Workshop 2

Contact Info:

Ahad Ali, Ph.D.
Director, Smart Manufacturing and Lean Systems Research Group
Phone: 248-204-2531

Speaker Bios:

Tim Bohr  Senior Engineer  Ford Motor Company

Tim Bohr Mr. Bohr is a Senior Engineer at Ford Motor Company and has been working in the automotive dimensional management/tolerance analysis field for 22 years in such varied applications as wheels/suspension systems, powertrain, and interior systems. In 2007 he achieved certification in the Ford Six Sigma Black Belt program. During the last several years his primary emphasis has been developing multiple generic processes to streamline the delivery of tolerance analysis studies and drive continual product quality improvements within the Global Engine Engineering division. Mr. Bohr has received his BS in Mechanical Engineering from the University of Michigan-Dearborn and MS in Mechanical Engineering from the University of Michigan.

Rochelle Courson – Global Engine Engineering, Senior-GDT & Standards – Ford Motor Company

Rochelle Courson Rochelle Courson began her career at Ford Motor Company in 1990 and has over 30 years experience in drafting, design & CAD, with the last 8 years devoted to specifically GD&T.  She is currently Ford’s representative on the ASME Y14.5 Dimension and Tolerancing standard, is secretary for a new ASME Y14.45 Measurement Reporting standard that is still in the development phase and is also involved with several other working ASME committees.  In addition to her involvement with the ASME standards, Rochelle also works on the development of Ford corporate training materials, conducts GD&T training, and consults with engineers and designers daily on GD&T application and drawing related standards issues.  She has a BS in Industrial Administration and a Leadership Certification from Central Michigan University.

Brian Heersink – DM/GDT/Gauging CAD Primary, CAD/CAE Department – Ford Motor Company

Brian HeersinkBrian Heersink has been working for Ford Motor company for 22 years.  He began working seriously with GD&T while on a 6 year assembly plant assignment in Virginia.  Currently, Brian works in the CAD/CAE department of Transmission/ Driveline Engineering in Livonia, Michigan.  He is a primary, working in Dimensional Management Analysis, with special focus on GD&T, training and Gauging issues.  Brian completed an AA degree at Macomb Community College and BA at Dordt College in Iowa.  He is originally from Canada.  Having lived more than half his life in the US, he has lost his “eh?” and doesn’t expect to find it back.

Thomas Jacobs – Primary Designer – Ford Motor Company

Thomas Jacobs Thomas Jacobs has been employed with Ford Motor Company since 1991. Mr. Jacobs is a Primary Designer – serving in the Analytical Design Department of Global Engine Engineering. His responsibilities include leading design projects, improving CAD tools and technologies, generating training and process documentation, and mentoring other designers. He is currently the lead on such projects as e-Stackup, Pro-Duct and Web Feature Chart, and is also a Subject-Matter-Expert for Catia Template and UDF development. Mr. Jacobs was the recipient of a Ford Powertrain Technology Excellence Award in 2004 for e-Stackup, and received a second award that same year for “Low Cost Exhaust Manifold for Low Emissions.” He has either initiated or been a principal contributor to many internal Powertrain classes, including Introduction to Stack-ups, Stack-ups 442, Stack-up Reviewer Training, Pro-Duct, and Catia Layouts/GSD/Drafting. Each semester he donates time to Schoolcraft College Engineering students, relating his experiences as a Primary Designer at Ford. Mr. Jacobs received his Bachelor of Science degree in Industrial Technology (CAD) from Eastern Michigan University in 1991.

Greg Medler – Tolerance Analysis Manager – Chrysler Group LLC

Greg MedlerGreg Medler is the Advanced Manufacturing Engineering/Product Tolerance Analysis Manager at Chrysler LLC.  He has been working in the Dimensional Management area for 26 years.  In his current role with Manufacturing Engineering he is responsible for Tolerance Analysis of all the Body-In-White assemblies that are measured at the Assembly Plant, all final vehicle Exterior and Interior fit and finish tolerances, and all the tolerances associated with the feasibility of Chassis/ Powertrain decking dimensional requirements.

Thomas J. Miller Technical Representative  Ford Motor Company

Thomas J. MillerTom Miller is a supervisor and technical representative at Ford Motor Company. He joined Ford Motor Company in 1977.  Tom is responsible for the training organization for GD&T at Ford and he is also the chairman the Ford Drafting Standards Committee.  His section is responsible for CAD checking, tolerance analysis, and illustration within Ford’s Global Engine Engineering Organization.  Mr. Miller is seated on two ASME committees, ASME Y14.41 which deals with Digital Product Definition Practices and ASME Y14.45 a standard which will cover the reporting of geometric tolerances.

Boon Peng Ng – Powertrain Instructor – Ford Motor Company

Boon Peng NgBoon Peng Ng is a Powertrain instructor at Ford Motor Company. He has over ten years’ experience in developing and delivering methods based training with a focus on C3P powertrain applications using traditional instructor lead training, online training and blended training. He is a certified instructor for ASME Y14.5 2009 GDT and Applied Stackup by Ford GDT Technical Committee. Mr. Ng has received a Bachelor of Science (B.S) and Master of Science (M.S.) in Mechanical Engineering from Michigan Technological University.

Andrew Revels – Senior Checker – Ford Motor Company

Andrew RevelsAndy Revels is the Engine Product Design Senior Checker in the Global Engine Engineering Organization at Ford Motor Company.  He holds a degree in Drafting Technology from Henry Ford Community College.  Mr. Revels was employed as a designer at Jervis B. Webb and Detroit Diesel Allison corporations prior to joining Ford in 1987. At Ford, Mr. Revels has served as a major component designer in various gasoline and diesel engine programs.   Mr. Revels works with Ford and its suppliers to ensure compliance to standards and the proper application of geometric controls.  He is a member of ASME and is Senior Level Certified in ASME 14.5M as a GD&T professional.

Mr. Rich Solti, Global Director of Sales, PROLIM Corporation, Farmington Hills, MI

Rich SoltiRich brings to PROLIM, over 25 years of experience in providing IT, Engineering, Consulting , and outsourced solutions for a wide variety of industries including aircraft, automotive, computer, defense, furniture, government, insurance, manufacturing, and pharmaceutical. He has managed both sales and recruiting teams for small and large Fortune 500 companies. He brings a strong understanding of providing solutions to solve today's complex business needs. He has been a recognized proven performer as a top sales and recruiting professional by helping grow several organizations throughout his career.

Rich has managed several outsourced  IT, design, and engineering projects including:  Software development for an SQL automotive parts database for Tier 1 brake supplier. An outsourced PC Help Desk for major Tier 1 automotive interiors and seating supplier. Complete design responsibility of interior trim parts for a large Tier 1 automotive supplier. Full Dimensional Engineering including 3D Tolerance Analysis and GD&T for a seat system for both a furniture and automotive Tier 1 supplier. Customized Engineering training manuals for several aerospace manufacturers, automotive OEM's, computer manufacturers, and defense contractors.

Rich has had management responsibilities for up to 500 people. He has managed sales teams as large as 12 people. He has held management roles with over $20 million in annual sales including full P & L responsibility. He has also run full desk as both the sales person filling client requirements and thus has a strong understanding of what it takes to meet customer demands and fill niche requirements.

Rich has a Bachelors Degree in Business Management from the University of Phoenix and is also fluent in Hungarian and proficient in German. Rich currently lives in Warren, Michigan USA, a suburb of Detroit, in the heart of the automotive industry.