The life cycle of an assembled product faces various uncertainties considering the current state of the manufacturing line. Varied of activities are integrated with the manufacturing line including processing, inspection, reworking, assembly, etc. Therefore, any decision taken concerning each activity, will affect the end-product of the manufacturing line. In an early stage, designers define tolerances on parts to ensure the functionality of the end-product. In this regard, this paper integrates resource allocation (as a decision to assign practical resources to parts) and reworking decision (as a decision to improve parts conformity rate) into the tolerance allocation problem. A modular-based cost modelling approach is proposed objecting to minimisation of manufacturing cost concerning resource allocation and reworking decisions. Eventually, a genetic algorithm and Monte-Carlo simulation are adapted to analyse the applicability of the model
