Cost and product quality are significant attributes in manufacturing processes, such as multistation assembly. We use multiobjective optimization for integrated tolerance allocation and fixture layout design to address their interaction and to quantify tradeoffs among cost, product quality, and assembly process robustness. Design decisions relate to product tolerances, assembly process tolerances, and fixture locating positions. A nested optimization strategy is adopted, and the proposed methodology is demonstrated using a vehicle side frame assembly example. The obtained results provide evidence for the existence of tradeoffs, based on which we can identify critical quality and budget requirements.

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