Measurement Systems Analysis

Define
Measure

Analyze

Improve

By: Mahender Kumar

1 Control

Learning Objectives
Understand the language of Measurement. Show the importance of Measurement. Measurement Walk away knowing how to perform a Gage R&R and how to interpret results. results Share some lessons learned.

Since Measurement systems y represent p a sub-process within a process...

They are subject to Variation. What could be the source of this variation? Why do Measurements Vary?

Sources of Measurement Variation

Equipment q p Part Operator Environment Procedure

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Sources of Measurement Variation

Measurement System C&E Matrix
Measurements
Mechanical Integrety Wear Electrical Instability Algorithm Instability

Materials
Cleanliness Temperature Dimension Weight Corrosion Hardness Conductivity Density

Men
Procedure P d Fatigue Attention Calibration Error Interpretation Speed Coordination Know ledge Dexterity Vision

Measurement System Error

Temp Fluxctuation Line Voltage Variation Vibration Cleanliness Humidity Operator Technique Standard Procedure Sufficient Work time Maintenance Standard Calibration Frequency Operator Training Ease of use Wear Stability Resolution Calibration Precision Design Temperature Cleanliness

Environment

Methods Machines Six Sigma Champion Training

Possible Sources of Process Variation

Observed Process Variation

Actual Process Variation

Measurement Variation

Long-term Process Variation

Short-term Process Variation

Variation w/i sample

Variation due to gage

Variation due to operators

Repeatability

Accuracy

Stability

Linearity

Reproducibility

We will look at repeatability and reproducibility as these ese are e the e primary p y contributors co bu o s to o measurement e su e e error. e o.
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Why MSA

RU = 0.0001 RU = 0.001

U= 0.0001

U : UNCERTAINITY
NATIONAL STANDARD

RANDOM UNCERTAINITY FOUND THRU CALIBRATION SYSTEM UNCERTAINITY OF MASTER TOTAL UNCERTAINITY SQRT( RU*RU + SU*SU)

U= 0.001005

LABORATORY STANDARD

RU = 0.01

U= 0.01005

WORK STANDARD

RU = 0.05

U= 0.05099

GAUGE FOR INSPECTION / TESTING

Process Capability
Lower Spec. Limit Upper Spec. Limit

6 Tolerance = T Process Capability = T / 6 Means, 6 < (0.75*T) > 1.33

Impact of Uncertainty
Lower Spec. Limit

ERROR identified through Calibration Process

Upper Spec. Limit

Uncertainty

6 Process P Tolerance = T

Knowledge to be obtained
How big is the measurement error? What are the sources of measurement error? Is the gage stable over time? Is the gage capable for this process? How do we improve the measurement system?
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Sources of Variation
P d t Variability Product V i bilit
(Actual variability)

Measurement Variability

Total Variability
(Observed variability)

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Effects of Measurement Error

Averages
Measurement System Bias Determined through Accuracy Study

total = product + measurement

Variability
2 2 2 = + total product measurement
Measurement System Variability Determined through R&R Study y

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Terminology
Location related terms:
True value Bias Linearity

Stability (over time) Variation related terms

Repeatability Reproducibility
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Definition of Terms
Reference Value
The theoretically or agreed upon correct value of the characteristic being measured, traceable to some standard

Resolution
The smallest increment, , or unit of measure, available from a measurement process Generally at least 1/10th of the specification range

Definition of Terms
Precision
The degree of agreement (or variability) between individual measurements or test results from measuring the same specimen(s)

Accuracy y (Bias) ( )
The difference between the average of the measurement error distribution and the reference value of the specimen measured

The Nature of Process Variation

1 2 3 4 5

Precise but not Accurate

Accurate but not Precise

Rule R l of f th thumb: b . . . . . .Test equipment MUST be a least 10 times more accurate t & precise i then th whats h t b being i t tested t d
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Measurement System Error

Precise but not accurate

Accurate but not precise

Not accurate or precise

Accurate and precise

Precision vs. vs Accuracy

Pr recision

Accuracy

Definition of Terms
Repeatability p y
The variation in repeated measurements of the same items with a single measurement system Within appraiser/system variation

Reproducibility R d ibilit
The variation in the average measurements by diff different t appraisers i or systems t measuring i th the same items Between appraiser/system variation

Terms
Linearity
The degree to which bias changes with changes in the magnitude of the characteristic measured

Stability y
The dependability, or consistency of the measurement p process over time

Measurement Systems Capability

The variability resulting from measurement error must not exceed a significant proportion of the intended specifications said to be capable In addition, it is not desirable for measurement error to exceed a significant proportion of the total process variability Capability is not the same as acceptability, acceptability must be determined on a case by b case b basis i

Measurement System Studies

Potential Studies
Assess potential of a measurement system to be capable over the long term 10 p parts measured 23 times by y one or more appraisers A quick and dirty y study y to find out if you y are in the ballpark Assesses repeatability and reproducibility Often called an R&R study

 True value:
Theoretically y correct value unknown and unknowable Reference standards NIST standards

Bias
Distance between average value of all measurements and true value Amount gage is consistently off target Systematic error or offset
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BIAS Definition BIAS Is the difference between the

observed average of the measurement and the reference value. The referencevalue is the value that serves as an agreed-upon reference. The reference value can be determined by averaging several measurements with a higher level (e.g., metrology lab) of measuring equipment. Reference Value

ACCURACY IS THE SAME AS BIAS

Observed A Average V Value l

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Linearity
Difference in the accuracy values of a gage through the expected operating range of the gage Good Linearity
Regression Plot

Bad Linearity
Linearity is N ot G ood

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Trials

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Y=0.934227+0.994959X R -Squared=0.981

Trials

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35 Y=0.245295+0.99505X R -Squared=0.982

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15

15

5 10 20 30 40 50

5 10 20 30 40 50

S tandard

S tandard

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Stability
The distribution of measurements remains constant and predictable over time for both mean and standard deviation Total variation in the measurements obtained with a gage, on the th same master t or master t parts, t when measuring a single characteristic over an extended time period period. Evaluated using a trend chart or multiple measurement analysis studies over time
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Stability (drift) Definition

Stability Is the total variation in
the measurement obtained with a measurement system (test / gage ) on the same master p parts when measuring g a single characteristic over an extended time period. Magnitude g Time-2

Ti Time-1 1

Points to the frequency of Mean center Calibration

time Stability
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 Total variation in the measurement system p Measure of natural variation of repeated measurements Terms: Random Error, Spread, Test/Retest error Repeatability and Reproducibility

2 MS

= +
2 G

2 O
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Repeatability p y

The inherent variability of the measurement system Variation in measurements obtained with a gage when used d several l ti times b by one operator t while hil measuring i a characteristic on one part. Estimated by the pooled standard deviation of the distribution of repeated measurements R
G =
* d2

Repeatability is less than the total variation of the measurement system

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R Repeatability t bilit Definition D fi iti

Repeatability The variation in measurements obtained with one measurement instrument when used several times by one appraiser while measuring the identical characteristic on same part.

REPEATABILITY

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Reproducibility p y

Operator variability of the measurement system Variation in the average of the measurements made d b by diff different operators using i the h same gage when measuring a characteristic on one part Must M t be b adjusted dj t d f for gage variation i ti Reproducibility is less than the total variation of the measurement system

R = * d2

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Reproducibility Definition
Operator-B

Reproducibility Is the
variation in the average of the measurements made by different appraisers using the same measuring instrument when measuring the identical characteristic on the same part.

Operator-C Ope ato C

Operator-A Reproducibility d ibili

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Accuracy of Measurement
Broken down into three components: 1. Stability: y the consistency y of measurements over time. 2. Accuracy: y a measure of the amount of bias in the system. 3. Linearity: y a measure of the bias values through the expected range of measurements.

Precision of Measurement
Precision, Measurement Variation, can be broken down into two components: p
1. Repeatability (Equipment variation): variation in measurements under exact conditions. 2. Reproducibility (Appraiser variation): variation in the average of measurements when different operators measure the same part.

Measurement System y Discrimination

Least count should be at most one-tenth of the total process capability or tolerance (6 sigma) Process capability 10 Max Least count 1 Part to Part variation must be greater than the smallest unit it of f measure

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Types of R&R Studies

Variable Gage R&R

Numbers Units of measure

Attribute Gage R&R

Subjective (cosmetic defects) Scatter of defects feel/visual
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Basic Terms
EV= Equipment Variation (Repeatability) AV AV= Appraiser Variation (Reproducibility) R&R= Repeatability & Reproducibility PV= Part Variation TV= Total Variation of R&R and PV K1-Trial, K2-Operator, & K3-Part Constants

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Gage R&R study

Generally two or three operators Generally 10 units to measure Each unit is measured 2-3 times by each operator

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Preparation p for a Measurement Study

Determine if reproducibility is an issue. If it is, select the number of operators to participate. Operators selected should normally use the measurement system. Select samples that represent the entire operating range. Gage must have graduations that allow at least one-tenth of the expected process variation. Insure defined gaging procedures are followed followed. Measurements should be made in random order. Study must be observed by someone who recognizes the importance of conducting a reliable study.
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Procedure for Performing g R&R Study

Calibrate the gage, or assure that it has been calibrated. Have the first operator measure all the samples once in random order. Have the second operator measure all the samples once in random order. Continue until all operators p have measured the samples p once (this is Trial 1). Repeat above steps for the required number of trials. Use GR&R form to determine the statistics of the study. y
Repeatability, Reproducibility & %GR&R Standard deviations of each of the above % Tolerance analysis

Analyze results and determine action, if any.

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Variable Gage g R&R

Guidelines
% R&R
10% 10% 30% Over 30%

Results
Gage is OK Maybe acceptable based upon importance of application, and cost factor Gage system needs improvement/corrective action

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Xbar Chart by Operator

40 35 30

Operator*Part No. Interaction

ABC-

40 35 30

Sample Mean n

25 20 15 10 5 0

Average

25 20 15 10 5 0 1 2 3 4 5 6 7 8 9 10

Part No.

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Thanks

For any query pl. pl mail me at mahender.kumar@yahoo.co.in mahender kumar@yahoo co in

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