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1) 2) 3) 4) Refer to AIAG MSA manual for detailed information on conducting Gauge R&R's. Add reference information to cells highlighted in light yellow: Enter Operator names on "Datasheet" sheet. Add Enter test results on "Datasheet" sheet to all cells highlighted in gold: Note: Sample data is only required for the number of samples and trials actually run - If no test was made, leave field blank. Do not enter a 0 value. 5) Enter header fields on "Report" sheet. "Total Tolerance" field must be filled in order to calculate %'s. 6) Results consist of the sheets labeled "Report", "Graphs" & " Gage Performance Curve". I recommend adding pertinent information to the header/footer as needed before printing. 7) The hidden sheet labeled "Graph Worksheet" is used to format the results in order to generate the graphs. Any changes to this sheet WILL result in incorrect graphs. USE OF GAUGE PERFORMANCE CURVE 1) Tolerances must be entered on the GRR Report for USL & LSL. 2) If the curves are drawn in the negative Y direction, the USL and LSL entries may be reversed. Assumptions: The following assumptions have been made during the development of this worksheet. To ensure the proper calculations have been made, it is important that a minimum of two operators are used in the study and that the data for these operators are entered in sections A & B. Section C is checked for entries when averages are calculated. If section C is used without completing sections A & B, the average calculation will be incorrect. The same logic holds for the Trials. A minimum of two trials must be completed and the columns for Trial 1 & 2 filled. If Trial 3 is filled without entries in Trial 1 & 2, the average calculation will be incorrect. The Total Tolerance cell in the Report sheet must be entered as the tolerance band width (i.e., a tolerance of +/- 3, must be entered as 6) Interpreting the Results: ndc (Number of distinct categories should be >= 5, %GRR Under 10% generally considered to be an acceptable measurement 10% to 30% - may be acceptable based upon importance of application, cost of measurement system, cost of repair, etc Over 30% - considered to be not acceptable - every effort should be made to improve the measurement system Repeatability > Reproducibility (large factor) The instrument needs maintenance The gage may need to be redesigned to be more rigid the clamping or location for gaging needs to be improved. There is excessive within-part variation Reproducibility > Repeatability (large factor) The appraiser needs to be better trained in how to use and read the gage instrument Calibration on the gage dial are not clear Notes: This form is a representation of the form found in the Measurement Systems Analysis manual Third Edition Constants are found in the form and derived from the D2* table found on page 195 There has been some confusion for constants as the Second Edition used Manual used constants that are 5.15 the values In the 3rd edition, this was changed to constants *1 and then using a divide by 6 in the TV calculation from tolerance The formula for TV has two options: the first is if the Tolerance value = "", it uses the primary (SQRT(GRR^2+PV^2)) If Tolerance is a value, then the formula calculates TV= Tolerance/6 The 6 is now used instead of 5.15 to change the spread to 99.73% which is a variation of +-3 and represents the full spread of a normal curve The D4 values to calculate the UCLr value is 3.27 for 2 trials and 2.58 for 3 trials. Reference pg. 117 pg. 77 pg. 77 pg. 77 pg. 123 pg. 123 pg. 123 pg. 123 pg. 123 pg. 123 pg. 123 pg. 123 Reference pg. 113 & 114 pg. 114 pg. 114 pg. 114 pg. 116 pg. vi pg.113

Part No. & Name Part Characteristic Total Tolerance USL 2.55 2.28 Scale LSL uA -0.27 Gage Name Gage Make Gage Model LT1101 Gage resolution: 0.06 Date Performed By

FALSE

0.049

% EV = 100[(EV)/(TOLERANCE)]

% EV = 100[(EV)/(TV)]

% EV = 100[(sEV2)/(sTV2)]

StdDev EV = 0.01260944

6 * StdDev 0.0756567

% EV =

2.97%

% EV =

42.17%

% EV =

17.78%

% AV = 100[(AV)/(TOLERANCE)]

% AV = 100[(AV)/(TV)]

% AV = 100[(sAV2)/(sTV2)]

% AV =

5.97%

% AV =

84.81%

% AV =

71.93%

% GRR = 100[(R&R)/(TV)]

% GRR = 100[(sR&R2)/(sTV2)]

P/T Ratio =

6.66%

% GRR =

94.72%

% GRR =

89.71%

% PV = 100[(PV)/(TOLERANCE)]

% PV = 100[(PV)/(TV)]

% PV = 100[(sPV2)/(sTV2)]

% PV =

2.26%

% PV =

32.08%

% PV =

10.29%

(effective resolution of a single measurement)

PME =

0.01897725

DR =

0.40

1 2

Product Control - Answers the question: Is this gauge good enough to inspect this part to this tolerance? Process Control - Answers the question: Is this gauge good enough for SPC or statistical analysis? 3 Answers the question: What components of variation are candidates for improvement? 4 Based on GRR (Repeatability and Reproducibility) 5 Based on EV (Repeatability) Border/Text Color Key: GREEN = Acceptable; ORANGE= Marginal; RED = Unacceptable 7/20/2013; 8:51 AM

1 Operator A Sample # 1 2 3 4 5 6 7 8 9 10 Totals 1st Trial -0.06098 -0.06098 -0.06098 0.00000 -0.06098 -0.06098 -0.06098 -0.06098 -0.06098 -0.06098 -0.54882

2 2nd Trial -0.06098 -0.06098 -0.06098 -0.06098 0.00000 -0.06098 -0.06098 -0.06098 0.00000 -0.06098 -0.48784 -0.54882 #N/A

3 3rd Trial

5 1st Trial 0.00000 0.00000 0.00000 0.00000 0.00000 0.00000 -0.06098 0.00000 0.00000 0.00000 -0.06098

6 2nd Trial 0.00000 0.00000 0.00000 0.00000 -0.06098 0.00000 0.00000 -0.06098 0.00000 0.00000 -0.12196 -0.06098 #N/A

7 3rd Trial

9 1st Trial -0.06098 -0.06098 0.00000 -0.06098 -0.06098 -0.06098 -0.06098 -0.06098 -0.06098 -0.06098 -0.54882

10 2nd Trial -0.06098 -0.06098 -0.06098 -0.06098 -0.06098 -0.06098 -0.06098 -0.06098 -0.06098 -0.06098 -0.6098 -0.54882 #N/A Sum -1.15862 XC -0.057931

11 3rd Trial

12 Range 0 0 0.06098 0 0 0 0 0 0 0

#N/A

0.18294 0.018294 RA

#N/A

0.18294 0.018294 RB

#N/A

0.06098 0.006098 RC

Sum

-1.03666

0.0465277

* Limit of individual R's. Circle those that are beyond this Limit. Identify the cause and correct. Repeat these readings using the same appraiser and unit as originally used or discard and reaverage and recompute R and the limiting value UCL R from the remaining observations

Notes:

7/20/2013;8:51 AM

Xbar Chart by Operator

0

-0.01

ABC-

0 1 -0.01 -0.02 2 3 4 5 6 7 8 9 10

-0.02

Sample Mean

Average

-0.06

-0.07

-0.07

Part No.

R Chart by Operator

0.07

Response by Operator

0

1 2 3

0.06 0.05

-0.01 -0.02

Sample Range

Operator

0

Components of Variation

100.00% 90.00% 80.00%

70.00%

% Contribution

% Study Var

0.00000 0

-0.01000

% Tolerance

10

-0.02000 -0.03000

Percent

10.00% -0.04000

0.00%

Part No.

7/20/2013

8:51 AM

R Chart by Operator

0.07

Sample Range

Step 1 Measurement Stability A stable measurement system shows no out of control points or "non-random" patterns or trends in the range chart

Step 2 Resolution / Discrimination Adequate resolution or discrimination means that the measurement units (inches, tenths of inches, thousandths of inches,) are sufficiently small enough to be able to "see" variation. - Stratification on a range chart is a good indication that there is a problem with inadequate resolution. - The number of stratified levels on the Range Chart is an indicator of the degree of the problem. - Fewer "levels" means less adequate resolution: - A rule of thumb: There should be approximately 5 levels of resolution between the control limits on the Range Chart and less than 25% of the ranges equal to zero to be considered adequate.

0 A-A-A-A-A-A-A-A-A-A-B-B-B-B-B-B-B-B-B-B-C-C-C-C-C-C-C-C-C-C-0.01

Sample Mean

Step 3 Bias Bias in a measurement study is a "shift" in the pattern on the X-bar chart between operators (i.e., the same part pattern is evident, but one operator reads consistently higher or lower than the others). Step 4 Measurement Capability Measurement capability is the comparison of Measurement Variation to Product Variation to determine whether the current measurement process can see part to part differences. More than 50% of the part measurements should be out-of-control to be considered marginally acceptable.

Operator Bias

0 -0.01 1 -0.02

Averages

-0.03 -0.04

-0.05 -0.06 -0.07 -0.08 -0.09

Operator

Step 5 Operator Bias Operator Bias is the comparison of Between-Operator variation to Within-Operator variation. An out-of-control chart indicates that a Bias does exist between operators, while a chart exhibiting control indicates that no Bias exists between operators.

Operator Inconsistency

0.05 0.045 0.04 0.035 0.03 0.025 0.02 0.015 0.01 0.005 0

Averages

Operator

Step 6 Operator Inconsistency Operator Inconsistency is the comparison of Within-Operator variation for a specific operator to the overall Within-Operator variation. An out-of-control chart indicates that a Inconsistency does exist between operators, while a chart exhibiting control indicates that no Inconsistency exists between operators.

Intraclass Correlation Plot

0 -0.07 -0.06 -0.05 -0.04 -0.03 -0.02 -0.01 0

-0.01

-0.02

-0.03 Y value

-0.04

-0.05

-0.06

-0.07 X value

Intraclass

Step 7 Interclass Correlation & Discrimination Ratio The major axis reflects product variation, and the minor axis reflects measurement error. The Discrimination Ratio is the ratio of the major axis to the minor axis. DR = 0.40 Gage may not be able to discrimate product variation

100%

90%

Pa (Probability of Acceptance) 80% 70% 60% 50% 40% 30% 20% 10%

0.0000

0.5000 1.0000 1.5000 2.0000 2.5000 3.0000

Specifications Pa Part Variation Gage Error Total Variation

-1.5000

-1.0000

-0.5000

Dimension

7/20/20138:51 AM

3.5000

0%

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