What is a common outcome of poor tolerance stack-up in assembly?

Poor tolerance stack-up can lead to various challenges in the assembly process, with one of the primary outcomes being a poor fit and function of the final product. When components do not have the correct tolerances, even if they are manufactured within specified limits, the cumulative effect can result in parts not aligning properly or not functioning as intended once assembled. This misalignment can cause issues such as increased friction, reduced durability, and overall failure of the product to meet its designed performance specifications.

Additionally, tolerance stack-up can lead to problems in assembly sequences, requiring further adjustments or rework that can delay the production process and impact product quality. While increased manufacturing costs can arise from the need for adjustments and corrective actions, the immediate and most noticeable issue is the failure of the final product to meet its intended use due to the poor fit of the assembled components. This highlights the critical importance of proper tolerance management in ensuring that all parts work together effectively to achieve the desired performance and functionality.