Identify the Tolerance Range
A shaft diameter is specified as 50.00 mm ± 0.04 mm.
What is the minimum acceptable value and the maximum acceptable value?
50.00 mm ± 0.04 mm
Minimum = 49.96 mm
Maximum = 50.04 mm
A bolt length is specified as 120 mm ± 1 mm.
Measured length: 120.6 mm
Is this measurement in tolerance or out of tolerance? Explain.
Spec 120 mm ± 1 mm → 119 to 121 mm
Measured 120.6 mm = Pass (in tolerance)
A shaft diameter is specified as 40.00 mm ± 0.02 mm.
Measured value: 40.02 mm
Is this value acceptable? Explain carefully.
Spec 40.00 mm ± 0.02 mm → 39.98 to 40.02 mm
Measured 40.02 mm = Pass (exactly at maximum limit)
A clearance specification requires values between 2.00 mm and 2.10 mm.
Measured values over time:
2.02 mm, 2.05 mm, 2.08 mm, 2.10 mm
Are these acceptable, and what concern should be noted?
Spec range 2.00 to 2.10 mm
2.02, 2.05, 2.08, 2.10 = All Pass (in tolerance)
Concern: upward trend is approaching the max limit, monitor/re-check
A specification lists a shaft length as 2.000 m ± 0.005 m.
A measurement is recorded as 2.006 m.
Is this within tolerance? Show how you know.
Spec 2.000 m ± 0.005 m → 1.995 to 2.005 m
Measured 2.006 m = Fail (above maximum)
A clearance is specified as 1.25 mm ± 0.10 mm.
What range of values is acceptable?
25 mm ± 0.10 mm
Minimum = 1.15 mm
Maximum = 1.35 mm
A base plate thickness is specified as 16.0 mm ± 0.5 mm.
Measured thickness: 15.4 mm
Is this acceptable? Why or why not?
Spec 16.0 mm ± 0.5 mm → 15.5 to 16.5 mm
Measured 15.4 mm = Fail (below minimum)
A bearing seat diameter is specified as 75.00 mm ± 0.03 mm.
Measured value: 75.031 mm
Should this measurement be accepted or rejected?
Spec 75.00 mm ± 0.03 mm → 74.97 to 75.03 mm
Measured 75.031 mm = Fail (above maximum)
A vibration limit is specified as a maximum of 4.5 mm/s.
Recorded readings:
3.8, 4.1, 4.4, 4.6 mm/s
Which reading fails, and why?
Max allowed 4.5 mm/s
3.8 Pass, 4.1 Pass, 4.4 Pass, 4.6 Fail
Fail reading: 4.6 mm/s (above maximum)
A pump alignment tolerance allows a maximum offset of 0.20 mm.
Measured offset: 0.18 mm
Is this acceptable, and how should it be reported?
Max allowed offset 0.20 mm
Measured 0.18 mm = Pass (in tolerance)
Report example: “Offset is 0.18 mm, within the 0.20 mm maximum.”
A base plate thickness is specified as 20.0 mm ± 0.5 mm.
What is the allowable tolerance range?
20.0 mm ± 0.5 mm
Minimum = 19.5 mm
Maximum = 20.5 mm
A shaft diameter is specified as 40.00 mm ± 0.02 mm.
Measured value: 39.97 mm
Does this pass or fail?
Spec 40.00 mm ± 0.02 mm → 39.98 to 40.02 mm
Measured 39.97 mm = Fail (below minimum)
A plate thickness is specified as 10.0 mm ± 0.1 mm.
Measured value: 9.90 mm
Is this exactly on tolerance or out of tolerance?
Spec 10.0 mm ± 0.1 mm → 9.9 to 10.1 mm
Measured 9.90 mm = Pass (exactly at minimum limit)
A bearing temperature should not exceed 80 °C.
Recorded temperatures over a shift:
72, 75, 78, 81 °C
What does the trend suggest?
Max allowed 80 °C
72 Pass, 75 Pass, 78 Pass, 81 Fail
Trend suggests increasing temperature; investigate before damage/failure
A bore diameter is specified as 60.00 mm ± 0.02 mm.
Measured value: 59.98 mm
Interpret this result using correct terminology.
Spec 60.00 mm ± 0.02 mm → 59.98 to 60.02 mm
Measured 59.98 mm = Pass (at the minimum limit)
A bearing bore diameter is specified as 75.00 mm ± 0.03 mm.
Identify the lower and upper tolerance limits.
75.00 mm ± 0.03 mm
Minimum = 74.97 mm
Maximum = 75.03 mm
A clearance is specified as 2.00 mm ± 0.15 mm.
Measured clearance: 2.12 mm
Is this measurement acceptable?
Spec 2.00 mm ± 0.15 mm → 1.85 to 2.15 mm
Measured 2.12 mm = Pass (in tolerance)
A clearance is specified as 1.80 mm ± 0.05 mm.
Measured clearance: 1.85 mm
Is this a pass or fail? Why?
Spec 1.80 mm ± 0.05 mm → 1.75 to 1.85 mm
Measured 1.85 mm = Pass (exactly at maximum limit)
A shaft runout tolerance allows a maximum of 0.20 mm.
Measurements over three checks:
0.12 mm, 0.17 mm, 0.21 mm
Which measurement is unacceptable?
Max allowed runout 0.20 mm
0.12 Pass, 0.17 Pass, 0.21 Fail
Fail measurement: 0.21 mm (above maximum)
A clearance is specified as 1.50 mm ± 0.10 mm.
Measured clearance: 1.39 mm
Does this meet the specification?
Spec 1.50 mm ± 0.10 mm → 1.40 to 1.60 mm
Measured 1.39 mm = Fail (below minimum)
A bolt length is specified as 120 mm ± 1 mm.
What values are considered acceptable?
120 mm ± 1 mm
Minimum = 119 mm
Maximum = 121 mm
A support height is specified as 1.500 m ± 0.005 m.
Measured height: 1.496 m
Determine pass or fail and justify your answer.
Spec 1.500 m ± 0.005 m → 1.495 to 1.505 m
Measured 1.496 m = Pass (in tolerance)
A shaft length is specified as 2.000 m ± 0.010 m.
Measured length: 1.990 m
Is this acceptable?
Spec 2.000 m ± 0.010 m → 1.990 to 2.010 m
Measured 1.990 m = Pass (exactly at minimum limit)
A motor alignment offset limit is 0.15 mm.
Measured offsets:
0.10 mm, 0.13 mm, 0.15 mm, 0.16 mm
Which value fails, and what action should be taken?
Max allowed offset 0.15 mm
0.10 Pass, 0.13 Pass, 0.15 Pass, 0.16 Fail
Fail value: 0.16 mm (above maximum)
Action: re-check measurement, then adjust alignment if confirmed
A machine base flatness tolerance allows a maximum deviation of 0.25 mm.
Measured deviation: 0.27 mm
How should this result be interpreted and communicated?
Max allowed deviation 0.25 mm
Measured 0.27 mm = Fail (exceeds maximum)
Report example: “Deviation is 0.27 mm, exceeds 0.25 mm limit; out of tolerance.”