Selective assembly is a generally accepted method for producing high precision assemblies from relatively low precision components. The mating parts are manufactured with wide tolerances. The mating part population is partitioned to form selective groups. The corresponding selective groups are then assembled interchangeably. The accuracy of selective assembly is mainly based on the number of selective groups (fixed before the assembly) and the range of selective groups. However, there are often surplus parts in some groups due to the imbalance of mating parts, especially in the case of undesired dimensional distributions. This paper presents a new approach to nullify the surplus parts in selective assembly. Copyright © 2011 Inderscience Enterprises Ltd.