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Components
and
Acceptance Criteria
Purpose
• To understand key concepts of measurement
systems analysis
• To understand potential sources of
measurement error and its affect on both
process and part quality
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Gage Variation
Total Variation
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Gage Variation
Gage Variation
Total Variation
Total Variation
(Observed)
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Understanding Variation
What is the best course of action?
Assume the total observed variation is below
1.33 Ppk for an initial process study on a starred
Part Variation dimension (1.67 Ppk or greater required)
Total Variation
(Observed)
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MSA Components
• What does a measurement system analysis
consist of?
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MSA Components
• Resolution (Discrimination)
• Accuracy
• Linearity
• Stability
• Repeatability (Test / Retest)
Gage R&R
• Reproducibility
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Sources of Variation
• Location of the Measurements
• Accuracy / Bias
• Stability
• Linearity
• Variation of Measurement
• Repeatability
• Reproducibility
• Resolution / Discrimination
Each source of variation can result in incorrect measurements
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Resolution
• Can the gage detect change?
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Resolution - Response
• Select gages that have greater levels of
discrimination (smaller increments)
• Record all measurement data, i.e. if a gage
measures to 3 decimal points record all three
• As a general rule gage discrimination should be
1/10th of the product tolerance
• Product tolerance: 0.100
• Gage tolerance: 0.010 (Recommended minimum)
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Accuracy
What is accuracy?
• The difference between the measured average value and the
master value or the ‘Shift’ from ‘True’ value
• The master value needs to come from a traceable measurement
source (ex. CMM)
• Although accuracy and bias are often used interchangeably it is
best practice to refer to this difference in values as bias
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Accuracy
• What is accuracy?
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Bias Example
Note: With
multiple samples
a linearity study
may be completed
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Bias - Response
• Increase calibration schedule
• Implement gage operating instructions
• Verify gage was made to correct specifications
• Check gage for wear
• Cleaning of gage
• Evaluate gage environment
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Linearity
• What is linearity?
• Linearity is the change in bias across the operating
range of the gage
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Linearity
(Difference between the
Bias measured average value and
the master value)
Measured Average Value
No Bias
(Master value
equals
measured
average value)
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Linearity – Response
• Implement correction factor / table / curve
• Review gage and adjust
• Restrict use of range (Need to consider
specification limits)
• Verify proper calibration (through entire
operating range)
• Verify part / fixture is not distorted with change
in part size
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Linearity Question
Question: Is this
linearity study
acceptable?
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Stability
• What is stability?
• The variation in measurements obtained with the
same master part(s) on a single feature over a period
of time
• Also known as ‘measurement drift’ and the ‘change
in bias over time’
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Stability
Measurements Measurements
taken Monday taken Friday
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Stability – Response
• Increase frequency of calibration
• Increase frequency of PM
• Change / Adjust gage
• Establish ‘life’ of gage or master part
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The gage is not stable. www.ghsp.com
Larger ‘jumps’ appear to happen every
other day. The team should decide
how often calibration should take
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Precision
• What is precision?
• According to AIAG it is “the net effect of discrimination,
sensitivity and repeatability over the operating range of the
measurement system.” (AIAG MSA Third Edition)
• So what does that mean?
• Precision quantifies how close repeated measurements are to
each other
Precision - Components
• Repeatability • Reproducibility
• Best known as within user • Best known as between user
variation variation
• Also encompasses all ‘within’ • Also encompasses all ‘between’
variation variation
• Within part • Between systems
• Within gage • Between conditions
• Within standard • Between methods
• Within method • Between Environment
• Within user
• Within environment
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Precision - Components
Repeatability
(Within Variation)
Operator 1
Operator 2
Operator 3
Reproducibility
(Between Variation) A JSJ Business
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“Crossed” is when
the same parts are
used between trials
“Nested” is when
different parts are
used between trials A JSJ Business
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Complete Gage
Info
Click Options
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Click OK
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% Tolerance
50 10.90
10.85
0
Gage R&R Repeat Reprod Part-to-Part 1 2 3 4 5 6 7 8 9 10
Part
R Chart by Operator
IDC by Operator
DK EB JC
Sample Range
_
0.005 R=0.00427 10.90
0.000 LCL=0
1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10
10.85
Part DK EB JC
Operator
Xbar Chart by Operator
DK EB JC Part * Operator Interaction
Sample Mean
Operator
10.92 _
_ DK
UCL=10.91215
X=10.90779 10.92
Average
LCL=10.90342 EB
10.89 JC
10.89
10.86
1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10
10.86
Part 1 2 3 4 5 6 7 8 9 10
Part
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% Tolerance
50 10.90
Pay attention to the
overall sample range to 0
Gage R&R Repeat Reprod Part-to-Part
10.85
1 2 3 4 5 6 7 8 9 10
understand ‘scale’ of R Chart by Operator
Part
_
0.005 R=0.00427 10.90
0.000 LCL=0
1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10
10.85
Part DK EB JC
Operator
Xbar Chart by Operator
DK EB JC Part * Operator Interaction
Inside the Xbar r Chart
Sample Mean
Operator
10.92 _
_
control limits is the blind UCL=10.91215
X=10.90779 10.92
DK
Average
LCL=10.90342 EB
10.89
spot of the gage 10.89
JC
10.86
1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10
10.86
Part 1 2 3 4 5 6 7 8 9 10
Part
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% Tolerance
50 10.90
Xbar r Chart should be
10.85
50% out of control.
0
1 2 3 4 5 6 7 8 9 10
Gage R&R Repeat Reprod Part-to-Part
Part
This indicates each
R Chart by Operator
IDC by Operator
operator can tell a good
DK EB JC
part from a bad part
Sample Range
_
0.005 R=0.00427 10.90
0.000 LCL=0
Want:
1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10
10.85 Small spread around
Part DK EB JC
Operator mean
Xbar Chart by Operator
DK EB JC Part * Operator Interaction Similar mean and
Sample Mean
10.92 _
_
Operator
DK
spread by operator
UCL=10.91215
X=10.90779 10.92
Average
LCL=10.90342
10.89
EB
JC
Lines to be close to
10.89
10.86 being on top of each
1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10
Part
10.86
1 2 3 4 5 6 7 8 9 10
other
Part
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Report %Study
or %Tolerance
(Whichever
applies) More
on this later…
Report number
of distinct
categories A JSJ Business
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Why ANOVA?
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Xbar/R GRR
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ANOVA GRR
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• WHY?
• The Xbar/R method ignores operator to part
interaction and as a result can appear to ‘boost’
gage performance
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Understanding %Tolerance
Understanding %Study
Product Specification
Total Variation
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Distinct Categories
Distinct Categories
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LS L 48.42
_
_
48.460 U S L 48.52
X=48.459167
48.456
LCL=48.455443 18 31 44 57 70 83 96 09
.4 .4 . 4 .4 .4 . 4 .4 .5
1 2 3 4 5 6 7 8 9 10 11 12 48 48 48 48 48 48 48 48
0.005 _
R=0.00364
0.000 LCL=0
1 2 3 4 5 6 7 8 9 10 11 12 48.450 48.455 48.460 48.465
Cp 7.75 Pp 6.03
48.460
Cpk 6.07 O v erall Ppk 4.73
PPM 0.00 Cpm *
PPM 0.00
48.455
S pecs
2 4 6 8 10 12
Sample
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Average Measurement
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Attribute GRR
What is the goal of an attribute GRR?
• 100% match within and between operators
measurement and the correct (master) attribute
• To have all Kappa values greater than 0.75
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Attribute GRR
What you need
1. At least 50 parts
2. At least 3 appraisers
3. Each appraiser should measure each part 3 times
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LSL USL
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Attribute GRR
How to conduct an attribute GRR
1. Select parts for study (50 minimum)
2. Select appraisers for study (recommend 3)
3. Measure all 50 parts on a master measurement
system (ex. CMM)
4. Build a master truth table
This table lists the known disposition of each part
(pass/fail) as well as associated variable data
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Attribute GRR
5. Conduct the GRR study (Measure parts in
random order, observe study while in progress.
6. Input data into Minitab
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If appraiser data
is in multiple
columns fill in
here
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Percent
97 97
96 96
95 95
94 94
1 2 3 1 2 3
Appraiser Appraiser
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(Repeatability)
Kappa Values
(Must be greater
than 0.75)
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(Reproducibility)
Kappa Values
(Must be greater
than 0.75)
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Kappa Value
What is a kappa value?
• Fleiss’ kappa value is used to measure the level of
agreement between two appraisers rating the same
data set
Attribute Agreement
How many Kappa values are calculated?
• Within Appraiser
• Between Appraiser
• Each Appraiser to Standard
• All Appraisers to Standard
• All Kappa values must be greater than 0.75
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Guard Banding
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LSL USL
Let’s assume a gauge has 20% Tolerance Variation measurement error (GRR)
What would you do?
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