Measurement System Analysis

Measurement Data

Professional Management calls for taking decisions

based on facts, as expressed in terms of data
The decision to adjust a process or not, is based on the
measured values of the output characteristic
Benefits of using data based procedures largely depends
on the Quality of the measurement data
The Quality of the measurement data is related to the
Statistical properties of multiple measurements from a
measurement system
If all the measurements are close to a master value, the
Quality of data is said to be high
If, instead, measurements are away from the master
value, the Quality of the data is low.
2

Measurement System
A measurement system consists of
Measuring instrument(s)
Accessories
Inspector
Environmental conditions
Measured part

Measurement Process
Measurement can be considered as a process, similar to a
manufacturing process
Measurement is the assignment of numbers to material
things to represent the relations among them with respect
to particular properties.
3

The parameters of the measurement process are

Input :
Component to be measured
Process factors :
Equipment, Inspector, etc.
Output
:
Measured value
Thus, we can compare the measurement process to a
manufacturing process.

Manufacturing process

Measurement Process

Manufacturing equipment / machine

Inspection equipment

Machine accessories

Inspection accessories

Operator

Inspector

Raw material

Component to be measured

Product output

Measured value of the

characteristic

Statistical Properties of Measurement System

An ideal measurement system will produce only
measurements that will always agree with a master
value, when repeat measurements are taken in an item.
Such a measurement system will have the statistical
properties of ZERO variance and ZERO bias.
Such systems have Zero probability of mis-classifying
the items it measured.
Measurement systems with such properties seldom
exist.
Measurement systems have variations.
They do not necessarily provide the same numbers even
if repeat measurements on the same part are taken.
It is necessary to recognize this variation and to provide
systems in such a way that this variation is within the
required capability of the measurement system.
5

Measurement System Requirements

Measurement system must be in a state of
Statistical Control.
The variation in the measurement system should
be due to common causes only.
No special causes of variations should be present
in a measurement system.
Variability of the measurement system must be
small compared to manufacturing process
variability.
Measurement system variability must be small
compared to the specification tolerance.

Measurement System Requirements

The increments of measurement must be small
relative to the smaller of either the process
variability or the specification limits.
A common rule of thumb is for the increments to
be no greater than one-tenth of the smaller of
either the process variability or the specification
limits.
Statistical properties of the measurement
system may change as the items being
measured vary.
The largest variation of the measurement system
must be small relative to the smaller of either the
process variability or the specification limits.
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The Measurement System Errors

Bias (AIAG: Accuracy)
Repeatability
Reproducibility
Stability
Linearity
8

Key Measurement Concepts

Bias (Accuracy:AIAG)

The difference between the observed average of

measurement sand the reference value.
A reference value is the one that is agreed upon for the
measured values.
A reference value could be determined by averaging several
measurements with a higher level measuring equipment.

Repeatability

The variation in measurements obtained.

With one measuring instrument.
When used several times.
By one appraiser.
While measuring the identical characteristics.
On the same part.

10

Reproducibility

The variation in the average of measurements made.

By different appraisers.
Using the same measuring equipment.
While measuring the identical characteristics.
On the same part.

Stability
The total variation in the measurements obtained with
a measurement system.
On the same master or parts.
When measuring a single characteristic.
Over an extended period of time.

Linearity
The difference in the bias values.
Through the expected operating range of a measuring
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instrument.

Methods used to determine R & R %

1. Average and range method
2. Ford / Chrysler / GM method
3. ANOVA method

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Data Sheet

Trials/Part
1
2
3
Average
Range

1
217
216
216
216.3
1.0

Operator 1
2
3
4
220
217
214
216
216
212
218
216
212
218.0 216.3 212.7
4.0
1.0
2.0

5
216
219
220
218.3
4.0

1
216
219
220
218.3
4.0

Operator 2
2
3
4
216
216
216
216
215
212
220
216
212
217.3 215.7 213.3
4.0
1.0
4.0

5
220
220
220
220.0
0.0

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Repeatability: (Gauge Variation)

Fixing all other parameters at some level. Take
repeated readings. The variation in the repeat
values can be assumed to be due to the gauge.
To ensure that Ris are reliable, we use R-chart, to
check the stability of Ris.
n

Ri

i 1

se R

n
, m = 3, g = 10

Repeatability 6 se
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Repeatability: (Gauge Variation)

Measures of variation
Range (max-min)
Standard deviation (s)

sR

d2

d2 is a constant depends on the sample size.

15

Reproducibility: (Operator Variation)

Ro max opt.1 average, ..., opt.k average

min opt.1 average, ..., opt.k average

so

Ro

d 2

, m = 2, g = 1

Reproducibility = 6 so

6 se

Ro
Adjusted Reproducibility 6
d 2
nr

n : samplesize 3; r : # of trials 10
2

6 so adj
so adj
GR & R

R o
6
d 2

s e2 s02 adj

6 se
nr

6
16

Part-to-Part Variation:
(Due to process chance causes)
R p max part 1 average, ..., part 5 average

min part 1 average, ..., part 5 average

sp

Rp

d 2

, m = 5, g = 1

Part to part variation 6 s p

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1. If

se2 so2 adj 6 s p

then, the measurement system is satisfactory.

In practice, we want this.

se2 so2 adj 0.3 6 s p

Ideally, we want

se2 so2 adj 0.1 6 s p

2. Use X -chart to compare (1) pictorially. If all of the
points get plotted inside the control limits, we infer
that the gauge variation is much larger than the
process variation.
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d2* values for the distribution of the average range

m

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
>15

2
1.41
1.28
1.23
1.21
1.19
1.18
1.17
1.17
1.16
1.16
1.16
1.15
1.15
1.15
1.15
1.128

3
1.91
1.81
1.77
1.75
1.74
1.73
1.73
1.72
1.72
1.72
1.71
1.71
1.71
1.71
1.71
1.693

4
2.24
2.15
2.12
2.11
2.10
2.09
2.09
2.08
2.08
2.08
2.08
2.07
2.07
2.07
2.07
2.059

5
2.48
2.40
2.38
2.37
2.36
2.35
2.35
2.35
2.34
2.34
2.34
2.34
2.34
2.34
2.34
2.326

6
2.67
2.60
2.58
2.57
2.56
2.56
2.55
2.55
2.55
2.55
2.55
2.55
2.55
2.54
2.54
2.534

7
2.83
2.77
2.75
2.74
2.73
2.73
2.72
2.72
2.72
2.72
2.72
2.72
2.71
2.71
2.71
2.704

8
2.96
2.91
2.89
2.88
2.87
2.87
2.87
2.87
2.86
2.86
2.86
2.85
2.85
2.85
2.85
2.847

9
3.08
3.02
3.01
3.00
2.99
2.99
2.99
2.98
2.98
2.98
2.98
2.98
2.98
2.98
2.98
2.970

10
3.18
3.13
3.11
3.10
3.10
3.10
3.10
3.09
3.09
3.09
3.09
3.09
3.09
3.08
3.08
3.078

11
3.27
3.22
3.21
3.20
3.19
3.19
3.19
3.19
3.18
3.18
3.18
3.18
3.18
3.18
3.18
3.173

12
3.35
3.30
3.29
3.28
3.28
3.27
3.27
3.27
3.27
3.27
3.27
3.27
3.27
3.27
3.26
3.258

13
3.42
3.38
3.37
3.36
3.35
3.35
3.35
3.35
3.35
3.34
3.34
3.34
3.34
3.34
3.34
3.336

14
3.49
3.45
3.43
3.43
3.42
3.42
3.42
3.42
3.42
3.42
3.41
3.41
3.41
3.41
3.41
3.407

15
3.55
3.51
3.50
3.49
3.49
3.49
3.48
3.48
3.48
3.48
3.48
3.48
3.48
3.48
3.48
3.472

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Gage Repeatability & Reproducibility Study

(Gage R&R Study)
For variable measuring equipment

Initial considerations
Use the engineering judgement to assess the
variation factors
Critical dimensions require more parts and/or
trials (repeat measurements)
Bulky/heavy parts may dictate fewer samples and
more trials
Appraisers should be selected from those who
normally operate the instrument
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Gage Repeatability & Reproducibility Study

Gage R&R Study)
For variable measuring equipment

Initial considerations (Contd)

Sample parts must be selected from the process
and they should represent its entire operating range
Instrument must have a discrimination (resolution)
that allows at least one-tenth of the expected
process variation of the characteristic
The measurement method is well defined
Measurements should be made in a random order.

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Conducting the R&R Study

Select ten parts from the process at random,

preferably one part from every days production

Identify them with a serial number, than cannot be

observed by the appraisers

Select two or three appraisers, who normally operate

the measuring system

Measure the parts randomly so that all the parts are

measured by all the appraisers for two or three times
(trials)

Record the observations

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Conducting the R&R Study

Calculate the variations due to different factors,
according to the formulae given
A measurement system with a R&R% of 10% or less
is considered good
A measurement system with R&R% more than 30%
requires review and is considered not acceptable
A measurement system with R&R% between 10% to
30% may have to be evaluated for acceptance,
considering the criticality of the part.

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Table for recording R&R study observations

Operator

Trial

Parts
1

Avera
ge

10

1
2
3

Avg

Xa-bar

Ra-bar

1
2
3

Avg

Xbbar

Rbbar

1
2
3

Part
Avg
Xp-bar

Avg

Xc-bar

Rc-bar

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Rp

Formulae
Xa-bar, Xb-bar, Xc-bar = Average of all the measurements made
by A, B & C, respectively
Ra-bar, Rb-bar, Rc-bar = Average of the range of the trials made
on 10 parts by A, B & C, respectively
Rp = Maximum part average Minimum part average
R-bar = (Ra-bar + Rb-bar + Rc-bar) / No. of operators
X-bar Dif = Max X-bar Min X-bar
UCLR = R-bar * D4
D4 = 3.27 for 2 trials; 2.58 for 3 trials
LCLR = R-bar * D3
D3 = 0 for both 2 & 3 trials
Homogenize the data for Range

Calculate R-bar, X-bar Diff and R p only after homogenizing.

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Formulae
Equipment Variation (EV) = R-bar * K1
(K1 = 4.56 for 2 trials; 3.05 for 3 trials)
Appraiser Variation (AV) = Sqrt{(X-bar Diff * K 2)2 [EV2/(nr)]}
(K2 = 3.65 for 2 operators; 2.70 for 3 operators)
(n : No. of parts; r : No. of trials)
Repeatability & Reproducibility (R&R) = Sqrt{EV 2 + AV2}

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Formulae
Part Variation (PV) = Rp * K3

K3

K3

K3

3.65

2.08

1.74

2.70

1.93

1.67

2.30

1.82

10

1.62

Total Variation (TV) = SQRT{R&R2 + PV2}

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Formulae
% EV =

(EV / TV) * 100

% AV =

(AV / TV) * 100

% R&R

% PV =

(PV / TV) * 100

(R&R / TV) * 100

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