The lack of empirical data describing the cost of precision in manufacturing processes is restricting the development of cost driven computer-based engineering design tools for such tasks as: tolerance analysis, process planning, tool design and manufacturability evaluations. The objective of this study is to evaluate the applicability of existing manufacturing data to the determination of empirical relations for the relative cost of produced tolerances. This initial study will examine a limited number of machining processes. A cooperative research effort with United States manufacturers will provide actual production data. The cost of precision is the result of many simultaneous factors, including: process, size, shape material, tooling, amount of perform, etc. The question to be resolved is whether a factorial design may be implemented successfully to isolate the effects of each factor and determine a quantitative representation. Relative cost will be determined from time studies and charge rates. The resulting cost versus tolerance functions will be plotted for discrete sizes of parts for each process, with additional multiplicative factors for the effects of material, shape, etc.
