Adverse combinations can place the final clearance outside its functional window. Check actual contacts, datum transfers, surface tilt and clamping deformation, then rebuild the chain around the assembly output.

They answer different questions. Worst case addresses permitted extreme combinations; statistical analysis addresses an assumed production population. Choose acceptance criteria from interchangeability needs and allowable risk.

Not automatically. Establish centering, stability, screening and the actual distribution, or state the assumption explicitly. A numerical example is not evidence of production capability.

Not necessarily. Shared movement can amplify or cancel depending on the functional sensitivity signs. Check the relationship using paired production data.

Review temperature when differential expansion is material relative to the functional margin or measurement, assembly and service conditions differ. Use component temperatures, coefficients and restraints; significant gradients need more than a uniform-expansion model.

Adding shims to a series stack reduces clearance. It does not correct an existing interference. Include thickness tolerance, stacking and seating, then recheck the final gap.

More trials improve numerical stability but cannot repair an incorrect contact model or input distribution. Compare with physical assemblies and include dependence, mean shifts and relevant adverse conditions.

Provide component and assembly drawings, functional clearance limits, datums and seating sequence, load, temperature, finishing, measurement methods and available production data.