Measurement Systems Analysis

Define
Measure

Analyze

Improve

By: Mahender Kumar

Control1

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
4

Sources of Measurement Variation

Measurement System C&E Matrix
Measurements

Materials

Men

Cleanliness

Mechanical Integrety

Temperature
Dimension

Wear

Weight
Corrosion

Electrical Instability

Hardness
Algorithm Instability

Conductivity
Density

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

Measurement System Error

Temp Fluxctuation
Line Voltage Variation
Vibration
Cleanliness

Standard Procedure
Sufficient Work time
Maintenance Standard
Calibration Frequency
Operator Training

Humidity

Environment

Wear

Operator Technique

Ease of use

Stability
Resolution
Calibration
Precision
Design
Temperature
Cleanliness

Methods
Machines
Six Sigma Champion
Training

Possible Sources of Process Variation

Observed Process Variation

Actual Process Variation

Measurement Variation

Long-term

Short-term

Variation

Variation due

Variation due

Process Variation

Process Variation

w/i sample

to gage

to operators

Repeatability

Accuracy

Stability

Linearity

Reproducibility

We will look at repeatability and reproducibility as

these
ese aree thee primary
p
y contributors
co
bu o s too measurement
e su e e error.
e o.
6

Why MSA

RU =
0.0001

U=
0.0001

U : UNCERTAINITY
NATIONAL
STANDARD

RU =
0.001

U=
0.001005

RANDOM UNCERTAINITY
FOUND THRU
CALIBRATION

LABORATORY
STANDARD

SYSTEM UNCERTAINITY OF
MASTER
TOTAL UNCERTAINITY
SQRT( RU*RU + SU*SU)

WORK

RU = 0.01

U=
0.01005

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

ERROR identified through

Calibration Process

Lower Spec. Limit

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?
11

Sources of Variation
P d t Variability
Product
V i bilit
(Actual variability)

Measurement
Variability

Total Variability
(Observed variability)

12

Effects of Measurement Error

Averages

Measurement
System Bias
Determined through
Accuracy Study

total = product + measurement

Variability

Measurement System
Variability
Determined through
R&R Study
y

2
2total = 2product + measurement

13

Terminology
Location related terms:
True value
Bias
Linearity

Stability (over time)

Variation related terms
Repeatability
Reproducibility
14

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

Precise but not Accurate

Accurate but not Precise

Rule
R
l off th
thumb:
b
. . . . . .Test equipment MUST be a least 10 times
more accurate
t & precise
i then
th whats
h t b
being
i ttested
t d
17

Measurement System Error

Precise but
not accurate

Accurate but
not precise

Not accurate
or precise

Accurate
and
precise

Prrecision

Precision vs.
vs Accuracy

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 byy one or more
appraisers
A quick and dirty
y studyy to find out if you
y are in
the ballpark
Assesses repeatability and reproducibility
Often called an R&R study

 True value:
Theoreticallyy 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.

ACCURACY IS THE SAME AS BIAS

Reference
Value

Observed
A
Average
V
Value
l
25

Linearity
Good Linearity

Bad Linearity

Regression Plot

Linearity is Not Good

55

55

45

45

35

35

Y=0.934227+0.994959X

25

R-Squared=0.981

Trials

Trials

Difference in the accuracy values of a gage

through the expected operating range of the gage

15

15

5
10

20

30

Standard

40

50

Y=0.245295+0.99505X

25

R-Squared=0.982

10

20

30

40

50

Standard

26

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
27

Stability (drift) Definition

Time-2

Stability Is the total variation in

the measurement obtained with a
measurement system (test / gage ) on
the same master pparts when measuringg
a single characteristic over an
extended time period.
Magnitude
g

Points to the frequency of Mean center Calibration

Ti
Time-1
1

time
Stability
28

 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
29

Repeatability
p
y

The inherent variability of the measurement system

Variation in measurements obtained with a gage when
used
d severall titimes 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 =

d 2*

Repeatability is less than the total variation of the

measurement system

30

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 ffor gage variation
i ti
Reproducibility is less than the total variation of
the measurement system

R
= *
d2

32

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
33

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

36

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
37

Basic Terms
zEV= Equipment Variation (Repeatability)
zAV= Appraiser Variation (Reproducibility)
zAV
zR&R= Repeatability & Reproducibility
zPV= Part Variation
zTV= Total Variation of R&R and PV
zK1-Trial, K2-Operator, & K3-Part Constants

38

Gage R&R study

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

39

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.

41

Variable Gage
g R&R

Guidelines
% R&R

Results

10%

Gage is OK

10% 30%

Maybe acceptable based upon importance

of application, and cost factor

Over 30%

Gage system needs improvement/corrective

action

42

Xbar Chart by Operator

Operator*Part No. Interaction

A-

40

35

15
10
5

30

Average

Sample Mean
n

30

20

C-

40

35

25

B-

25
20
15
10
5
0

10

Part No.

43

Thanks

For any query pl.

pl mail me at mahender.kumar@yahoo.co.in
mahender kumar@yahoo co in

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