Design Review Tolerance Checklist
Before presenting your tolerance stack-up in a design review, run through this checklist. A complete, well-documented analysis gets approved faster and with fewer questions.
Pre-Review Checklist
Use this as a final check before your design review. Print it, check items off, and address any gaps before presenting.
Tolerance Stack-Up Review Checklist
1. Problem Definition
- Critical dimension clearly identified (gap, clearance, interference, fit)
- Target min/max specification stated with units
- Functional reason for limits documented (why these values?)
- Reference to assembly drawing or CAD model included
2. Dimension Chain
- All contributing dimensions listed (none missing from loop)
- Nominal values match current drawing revision
- Tolerances match drawing (bilateral converted correctly)
- Direction signs verified (+ adds to gap, − subtracts)
- Source noted for each dimension (drawing #, vendor spec, measured)
3. GD&T Handling
- GD&T callouts converted to bilateral equivalents
- Conversion method documented (position Ø ÷ 2, profile ÷ 2, etc.)
- Bonus tolerances (MMC/LMC) accounted for if applicable
4. Calculations
- Nominal result calculated and shown
- Worst-Case (WC) analysis completed
- RSS analysis completed (if applicable)
- Pass/fail status clearly stated for each method
- Math spot-checked or verified by calculation tool
5. Sensitivity Analysis
- Contribution percentages calculated for each dimension
- Top 2–3 contributors identified and highlighted
- Improvement options identified for dominant contributors
6. Assumptions
- Temperature/thermal conditions stated
- Material assumptions noted (CTE, deflection considered?)
- Process capability assumptions stated (centered tolerances, Cpk)
- Excluded factors listed (wear, deflection, form error, etc.)
7. Recommendation
- Clear recommendation stated (proceed, modify, or redesign)
- If RSS-based acceptance, fallout rate/risk acknowledged
- Specific tolerance changes quantified if recommending modification
8. Documentation
- Report dated and author identified
- Revision level noted (matches current design state)
- Format is professional and readable
- File saved/archived in project documentation
Generated with TolReport — tolreport.com
Why This Checklist Matters
Design reviews are gatekeepers. A stack-up that's missing context, has questionable math, or lacks clear recommendations will get sent back for rework. Worse, it erodes confidence in your analysis.
This checklist represents what experienced reviewers look for. Completing every item doesn't guarantee approval, but missing items almost guarantees questions.
Common Review Questions (And How to Preempt Them)
"Where did this tolerance come from?"
→ Include source column in your dimension table
"Why is RSS acceptable here?"
→ Document production volume and process capability assumptions
"What happens at temperature?"
→ State thermal assumptions explicitly, even if "room temperature"
"Which dimension should we focus on?"
→ Highlight top contributors in sensitivity analysis
"What do you recommend?"
→ End with a clear, actionable recommendation
Quick Reference: Must-Haves vs. Nice-to-Haves
Must-Haves
- • Critical dimension + target spec
- • Complete dimension chain
- • WC and/or RSS results
- • Pass/fail determination
- • Clear recommendation
Nice-to-Haves
- • Sensitivity analysis
- • Detailed assumptions
- • GD&T conversion notes
- • Improvement options
- • Historical context
For internal quick reviews, the must-haves may be enough. For customer deliverables, regulatory submissions, or complex designs, include everything.