A computer device for generating a computer model of a non-nominal component includes a memory device and a communication interface device coupled to the memory device and includes a processor. The processor is programmed to generate a nominal outer surface and a nominal inner surface; generate a tool having a first tool position; move the tool to a second tool position within the nominal component, the second tool position based on a simulated local geometric deviation of a parameter; segment the tool into a first portion and a second portion at the nominal inner surface component; return the first portion to the first tool position out of the nominal component; segment the first portion at the nominal outer surface into a hole portion; and simulate a non-nominal cooling hole represented by the hole portion to facilitate computer modeling of the non-nominal component.