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Producing assemblies that experience little to no rework during assembly fit-up is a perennial challenge in offsite construction. While the traditional response has been to solve geometric issues onsite at the expense of large rework costs, manufacturing optimisation techniques can mitigate these issues upstream. Tolerance analysis is one such method that is widely used in manufacturing to predict if problems will occur from the accumulation of tolerances and dimensional variability. This article demonstrates Monte Carlo tolerance simulation on a prefabricated construction assembly, where variations up to 37 mm are identified compared to as-built deviations which range up to 30 mm. Process optimisation is also explored, where risk of rework related to dimensional variability is reduced by 65.6% through selection of alternate fabrication processes. To compare the Monte Carlo method to traditional analysis …