A new method for tolerance/ variation analysis of multi-station assemblies of compliant parts is presented. Based mainly on the 'unit displacement' and 'sensitivity matrix' method, it allows for the use of statistical variations in key points to predict the final shape variation of multi-station assemblies. ‘Linear contacts’ between parts are included to avoid part-to-part intersections. The evaluation of what happens at the end of the assembly process enables users to analyse different assembly configurations in the early design phase. Implemented in the Matlab environment, it requires two linear FEA runs for each assembly station. Two case studies are presented and discussed.