Gage R&R Values

Gage R&R
Average & Range Method
Operator 1
Enter your data here->

Operator 2
Enter your data here->

Operator 3
Enter your data here->

Range Average
XDiff
UCL
LCL
Repeatability(EV)
Reproducibility(AV)
Gage Capability(R&R)
Spec Tolerance
Acceptability(%)

Part Number
1
2
3
4
5
6
Trial 1
161.1899
162.1104 157.1285 161.2429 163.7232
Trial2
161.4891
162.2997 157.7459 161.5013 163.5255
Trial3
161.4290
162.6977 157.2557 161.8469 163.4616
Trial4
161.6444
162.7538 157.5094 161.3375 163.3667
Trial 5
161.1528
162.0473 157.4562 161.5411 163.5249
Total
806.9050421 811.90892 787.0956 807.46969 817.6018
Average-Appraiser 1 161.3810084 162.38178 157.4191 161.49394 163.5204
Range1
0.491612909 0.7064857 0.617433 0.6039989 0.356463
Trial 1
161.7731
162.9170 157.4630 161.9159 163.5230
Trial2
161.1081
162.4238 157.2057 161.9493 163.5901
Trial3
161.9853
162.4247 157.8147 161.5566 163.8671
Trial4
161.6363
162.4130 157.8271 161.8817 163.3264
Trial 5
161.9100
162.0168 157.4473 161.9510 163.1308
Total
808.4128134 812.19529 787.7578 809.25448 817.4373
Average-Appraiser 2 161.6825627 162.43906 157.5516 161.8509 163.4875
Range2
0.877161896 0.9001544 0.62142 0.394372 0.736316
Trial 1
161.6166
162.0164 157.9265 161.8290 163.4514
Trial2
161.9304
162.1458 157.2887 161.2861 163.5523
Trial3
161.6728
162.1285 157.5023 161.1321 163.4921
Trial4
161.3056
162.6616 157.0695 161.3488 163.8212
Trial 5
161.7436
162.8511 157.8672 161.9484 163.0660
Total
808.2690578 811.80344 787.6543 807.54453 817.3829
Average-Appraiser 3 161.6538116 162.36069 157.5309 161.50891 163.4766
Range3
0.624801673 0.8346508 0.85703 0.8163341 0.755133
0.6796
0.1631
1.4339
0.0000
0.2921
0.0621
0.2987
0.0100
29.87

% Using
% Using
AIAG - Automotive Industry Action Group Formula
TV
Tolerance
Equipment Variation (Repeatability)
0.2921
%EV
12.0%
17529%
Appraiser Variation (Reproducibility)
0.06215
%AV
2.6%
3729%
R&R (Gage Capability)
0.2987

Constants
4 Trials 3 Trials
2 Trials # Trials
2.11
2.28
2.58
3.27
D4
0
0
0
0
D3
0.577
0.729
1.023
1.88
A2
0.4299 0.4857
0.5908 0.8862
K1
0.7071 0.5231
K2
2 Ops
3 Operators
5 Trials

5
2.11
0
0.577
0.4299
0.5231

%R&R
PV (Part Variation)
%PV
TV (Total Variation)

12.3%
2.4157
99.2%
2.4341

17921%
144942%

Conclusions / Recommendations
Gage system may be acceptable based on importance of application and cost
Gage may need maintenance, redesign, or better clamping
# Parts

#Trials
5

Calculate GageR&R using Anova

Anova Source
Appraiser

df

SS
2

MS
###

#Ops
5

With Interaction
Without Interaction
P
P
F
F
-4
Err:502
-34
Err:502
###

4
309.3567 77.339184 0.00033
8
### 234204.77 3E+006
60
4.8139
0.0802
68
###
###
74 314.9277255

Parts
Appraiser x Part
Gage w AP Interaction
Gage w/o AP Interaction
Total

Estimate of Variance

Repeatability
Appraiser
AppraiserxPart
R&R
Part

Std. Dev

1.00000 0.00281 0.99998

0.00000

% Study
Variation

5.15* Stdev

0.08023 0.28325337
46840.9388463787 216.4276758
46840.9379407333 216.4276737
93681.95702 306.075084
15608.49538 124.9339641

EV
AV
INT
R&R
PV
TV

1.458755
1114.603
1114.603
1576.287
643.4099
1702.544

%
Contributio
n

0%
65%
65%
93%
38%

0%
43%
43%
86%
14%

Part by Appraiser Plot (Stacked)

164
163
162
161
160
Averagge
159
158
157
156
155
154
1

6
Part

Part by Appraiser Plot

164
163
162
161

163
162
161
160
Averagge
159
158
157
156
155
154
1

10

Appraiser 1

10

Range of Parts by Appraiser (Stacked)

1
0.9
0.8
0.7
0.6
Range
0.5
0.4
0.3
0.2
0.1
0
1

6
Parts

Range of Parts by Appraiser

1
0.9
0.8

Ap

Appraiser 2

Range of Parts by Appraiser

1
0.9
0.8
0.7
0.6
Range
0.5
0.4
0.3
0.2
0.1
0
1

Appraiser 1

10

Appraiser 2

10

Ap

0.8
0.7
0.6
Range
0.5
0.4
0.3
0.2
0.1
0
1

10

Appraiser 2

Appraiser 1
Instructions

10

Ap

1. Select 10 DIFFERENT parts and at least two "appraisers" and one gage
(If you don't use enough parts, part variation will be small and magnify the appraiser/equipment variation)
2. RANDOMLY, have appraisers measure each part at least twice
3. Then enter the results of each measurement in Cells C3:L7, C11:L15, C19:L23
4. The template will automatically calculate all of the values based on your data
5. Evaluate your measurement system based on %R&R and make adjustments as required.

Gage Repeatability and Reproducibility

Measurement is one common cause of variation. Gage R&R helps improve measurement systems
If repeatability (EV - Can the same person using the same gauge measure the same thing consistently)
is larger than reproducibility, reasons include:
1. Gage instrument needs maintenance
2. Gage needs to be redesigned
3. Clamping or location needs to be improved
4. Excessive within-part variation
If reproducibility (AV-can two appraisers measure the same thing and get the same result)
is larger than repeatability, reasons include:
1. Operator needs to be better trained in how to use and read gage
2. Calibrations on gage are not clear
3. Fixture required to help operator use gage more consistently
Gage System Acceptability
%R&R<10%
%R&R<30%
%R&R>30%

Gage System Okay (Most variation caused by parts, not people or equipment)
May be acceptable based on importance of application and cost of gage or repair
Gage system needs improvement (people and equipment cause over 1/3 of variation

Verified using AIAG Measurement Systems Analysis 3rd Edition

Gage R&R Values

Gage R&R Percentages

10

Sum

805.395
806.561
806.691
806.612 Xbar1
805.722 161.239245

Reference
12.500 <-Insert Reference Value Here
Bias

Rbar1
0.55519856
807.592
806.277
807.648
807.085 Xbar2
806.456 161.40231

148.739

Reference
12.500
Bias

Rbar2
0.70588484
806.840
806.203
805.928
806.207 Xbar3
807.476 161.306169

148.902

Reference

Rbar3
0.77758995

UCL represents the limit of the individual R's

Circle those beyond the limit.
Identify and correct causes
LCL = 0 D3=0 for up to 7 trials

12.500

Bias
148.806

cked)

AverageAppraiser 1

10

10

10

Appraiser 3

Stacked)

ser

Rang
e1

10

ser

10

Appraiser 3

10

10

Appraiser 3

n caused by parts, not people or equipment)

ortance of application and cost of gage or repair
(people and equipment cause over 1/3 of variation)

10

Range Method

Range Method
Part
Appraiser 1
Appraiser 2
Range

2
12
11
1

GR&R

2.521008

Insert Process
Standard
Deviation
%GR&R

5.121849
49%

Insert Your Data Here

3
4
22
12
10
23
13
12
1
1
2

Page 13

Average

11
21
10

13.4
16 d2
3
1.19

Bias

Reference
Value
Value
Bias
5.8
6.0
5.7
5.9
5.9
6.0
6.1
6.0
6.1
6.4
6.3
6.0
6.1
6.2
5.6
6.0

-0.2
-0.3
-0.1
-0.1
0.0
0.1
0.0
0.1
0.4
0.3
0.0
0.1
0.2
-0.4
0.0

tAverage/
Stdev(r)
Statistic/
n
Mean
Stdev
Stdev(b) critical
15
6.006667 0.21202 0.2251409 0.114683
Bias
0.0067
0.0581311
2.2064
95% Confidence
Lower
Upper
-0.118656 0.131989
Bias Acceptable
Reference: AIAG MSA Version 3 pgs 85-88

Page 14

Bias

d2*/d2
df
3.55333
3.47193

g
10.8 d2*
df
d2
t crit 95%

2
1.41421
1
1.12838
4.303

3
1.91155
2
1.69257
3.182

ersion 3 pgs 85-88

Page 15

4
2.23887
2.9
2.05875
2.776

5
2.48124
3.8
2.3593
2.571

6
2.67253
4.7
2.53441
2.447

Bias

7
2.82981
5.5
2.70436
2.365

8
2.96288
6.3
2.8472
2.306

9
3.07794
7
2.97003
2.262

10
3.17905
7.7
3.07751
2.228

11
3.26909
8.3
3.17287
2.201

Page 16

12
3.35016
9
3.25846
2.179

13
3.42378
9.6
3.33598
2.16

14
3.49116
10.2
3.40676
2.145

Bias

15
3.55333
10.8
3.47193
2.131

16
3.61071
11.3
3.53198
2.12

17
3.66422
11.9
3.58788
2.11

18
3.71424
12.4
3.64006
2.101

19
3.76118
12.9
3.68896
2.093

Page 17

20
3.80537
13.4
3.735
2.086

Linearity

Trials

1
2
3
4
5
6
7
8
9
10
11
12
Average
Reference
Values
Bias
Range
bias=
slope*ref+b
Slope=
b=
Goodness of fit
Insert Process
Variation
Linearity
%Linearity

Part
3

2.7

<- Insert Your Data Here

Linearity evaluates a g
to measure accurately
Imagine measuring a b
1. at the grip
2. in the middle
3. and at the widest pa

2.70
2.00
0.70
0.00

<- Insert Known Reference Values

0.00

0.00

0.00

0.00

Err:502
Err:502
Err:502

Err:502
Err:502
Linearity Plot

0.80
0.70
0.60
0.50
Bias
0.40
0.30
0.20
0.10
0.00
1.50

2.00

2.50

3.00

Re ference Value

Page 18

3.50

4.00

Linearity

our Data Here

Linearity evaluates a gauge's ability

to measure accurately across a wide range
Imagine measuring a baseball bat:
1. at the grip
2. in the middle
3. and at the widest part

nown Reference Values Here

Page 19

Appraiser A
Part #

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40

Appraiser B

Appraiser C

Trial 1

Trial 2

Trial 3

Trial 1

Trial 2

Trial 3

Trial 1

Trial 2

1
0
1

1
0
1

1
0
0

1
0
1

1
0
1

1
0
0

1
0
1

1
0
0

Reference Results
Ref Value Code
0.476901
+
0.576459
0.544951
X
-

Trial 3 Reference

1
0
0

1
0
1
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0

LSL
USL
0.45
0.55
1. Enter Spec Limits Above
2. Have 3 appraisers accept/reject 10+ p
3. Enter pass/fail in columns B-J
4. Enter Reference value in column L
5. Evaluate effectiveness columns AJ-AV

41
42
43
44
45
46
47
48
49
50

0
0
0
0
0
0
0
0
0
0
0 = Fail
1 = Pass

+ = within spec limits

- = outside spec limits
x = gray area around spec limits

%R&R Gray zone

25%
0.02500
er Spec Limits Above
e 3 appraisers accept/reject 10+ parts
er pass/fail in columns B-J
er Reference value in column L
uate effectiveness columns AJ-AV

A-B
1 2
1 1
0 0
1 1

3
1
0
0

B-C
1 2
1 1
0 0
1 -1

3
1
0
0

C-A
A-REF
1 2 3 1 2 3
1
1 1 1 1 1
0
0 0 0 0 0
1 -2 0 1 1 -2

B-REF
1 2 3
1 1 1
0 0 0
1 1 -2

C-REF
1 2 3
1 1 1
0 0 0
1 -2 -2

Crosstabulation
B
Total
A
0
1
0
4
0
4
1
0
5
5
Total
4
5
9

B
0
1
Total

C
0
1
Total

C
0
4
0
4

1
1
4
5

A
0
4
1
5

1
0
4
4

Crosstabulation
REF
Total
A
0
1
0
3
0
3
1
1
5
5
Total
4
5
9

Total
B
5
4
9

0
1
Total

Total
C
4
5
9

0
1
Total

REF
0
3
1
4

1
0
5
5

Total

REF
0
3
2
5

1
0
4
4

3
6
9
Total
3
6
9

around spec limits

Miss
Effectiveness
Rate
A 89%
11%
B 89%
11%
C 78%
22%
System
85%
15%
85%
Effectiveness
Acceptable
>= 90%
Marginal
>=80%
Unacceptable
<80%