DETERMINING THE MAXIMUM ROBOT REPEATABILITY NECESSARY FOR ROBOTIC WELDING WITH A PARTICULAR WELDING PROCESS IS USUALLY DETERMINED BY EXPERIENCE OR RULES OF THUMB. THESE METHODS, THOUGH THEY HAVE PROVIDED A BASIS FOR CHOOSING A ROBOT, OFTEN LEAD TO SELECTING A ROBOT WHICH HAS A ROBOT REPEATABILITY THAT IS MUCH SMALLER THAN WHAT IS ACTUALLY REQUIRED. THIS MAY UNNECESSARILY INCREASE THE COST OF THE ROBOTIC SYSTEM. IF AN UNDERSTANDING OF ROBOT REPEATABILITY IS INCORPORATED WITH WELD PARAMETERS WHICH DICTATE WELD BEAD GEOMETRY, AND ACTUAL PART TOLERANCES ARE USED, TOLERANCE STACKING CAN DETERMINE THE ACTUAL ROBOT REPEATABILITY REQUIRED FOR THE ROBOTIC WELDING SYSTEM. A STEP-BY-STEP PROCEDURE FOR DETERMING THE REQUIRED ROBOT REPEATABILITY IS PRESENTED.