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 PRACTICE EXERCISES ON MSA

Use the MSA Template for the following exercises (Sheet 2 of the Gage Linearity and MSA Worksheet)

Data set 1 contains readings taken by operators with a dial bore gauge, which was set to the
nominal bore diameter. 3 operators were used for the study, each conducted 3 trials on a set of
10 parts. A dial bore gage of 0.001 mm least count was used, with zero set at the nomimal bore
dia. The values recorded are the actual dial readings, that is the deviation from the nominal
value.
Calculate the Equipment and Appraiser Variation and Gage R & R and state whether the MSA
results are acceptable.

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The Data set 2 gives the MSA study results for measurement of pin diameter of crank shaft using
micrometer of accuracy 0.001 mm. The study was carried out using 4 appraisers, 10 parts and 4
trials per part. Determine the values of Equipment Variation, Appraiser variation, and part
variation. The tolerance band is specified as 25.000 to 25.150 mm. The Control chart LCL and UCL
is 25.020 - 25.090. State whether the Gaging practice can be accepted or improvements are
needed

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Data set 3 gives measurements of cut lengths of fabric using steel tapes. 5 lengths were used for
the study. 3 operators were asked to measure each length twice with time interval of 15 minutes.
There are no specification limits for cut lengths, but the company wants to study the consistency
of measurements. Determine the Gage R & R as a percentage of total variation. Before
calculations, examine the data for any anomaly and identify any special steps needed to resolve
it.
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Data set 4 presents a MSA study results in which 3 operators participated to measure 5 samples, 3 times
each. The specification range is 1.50 to 5.50. Find out the Gage R & R from this data and comment if the
results are accpetable.
Click here to access data set

Data set 5 gives two studies for measurment results of a MSA study using dial calipers, with 3 operators,
10 parts and 3 trials. The specification limits are 4 + 0.75 mm. the first study was conducted using dial
gage with least count 0.1 mm. The second study was carried out using dial gage 0.01 mm. Compare the
two studies and highlight the key differences.
Click here to access the data set - Study 1
Click here to access the data set - Study 2
 DATA SETS FOR MSA

DATA SET 1 Back

PART No APPRAISER A APPRAISER B

Trial 1 Trial 2 Trial 3 Trial 1 Trial 2 Trial 3
1 0.29 0.41 0.64 0.08 0.25 0.07
2 -0.56 -0.68 -0.58 -0.47 -1.22 -0.68
3 1.34 1.17 1.27 1.19 0.94 1.34
4 0.47 0.5 0.64 0.01 1.03 0.2
5 -0.8 -0.92 -0.84 -0.56 -1.2 -1.28
6 0.02 -0.11 -0.21 -0.2 0.22 0.06
7 0.59 0.75 0.66 0.47 0.55 0.83
8 -0.31 -0.2 -0.17 -0.63 0.08 -0.34
9 2.26 1.99 2.01 1.8 2.12 2.19
10 -1.36 -1.25 -1.31 -1.68 -1.62 -1.5

DATA SET 2 Back

PART No APPRAISER A APPRAISER B

Trial 1 Trial 2 Trial 3 Trial 4 Trial 1 Trial 2 Trial 3
1 25.065 25.052 25.062 25.045 25.045 25.062 25.056
2 25.053 25.055 25.049 25.061 25.063 25.062 25.046
3 25.065 25.068 25.074 25.069 25.065 25.072 25.074
4 25.062 25.057 25.052 25.065 25.062 25.057 25.073
5 25.065 25.045 25.046 25.062 25.065 25.065 25.071
6 25.037 25.045 25.045 25.057 25.043 25.035 25.045
7 25.057 25.062 25.068 25.069 25.055 25.062 25.068
8 25.05 25.057 25.06 25.049 25.058 25.057 25.065
9 25.052 25.055 25.055 25.057 25.048 25.05 25.065
10 25.057 25.062 25.065 25.052 25.057 25.062 25.065

DATA SET 3 Back

Operator A Operator B Operator C

Part No Trial 1 Trial 2 Trial 1 Trial 2 Trial 1 Trial 2
1 167 162 155 157 152 155
 2 210 213 206 199 206 203
3 187 183 182 179 180 181
4 189 196 184 178 180 182
5 156 149 183 142 147 154

REPEAT
5 152 148

DATA SET 4 Back

PART No APPRAISER A APPRAISER B

Trial 1 Trial 2 Trial 3 Trial 1 Trial 2 Trial 3
1 3.29 3.41 3.64 3.04 2.89 2.85
2 2.44 2.32 2.42 1.92 1.87 2.04
3 4.34 4.17 4.27 3.88 4.09 3.87
4 3.25 3.5 3.64 3.14 3.2 3.11
5 2.2 2.08 2.16 1.78 1.93 1.84

DATA SETS 5 Back

STUDY 1

PART No APPRAISER A APPRAISER B

Trial 1 Trial 2 Trial 3 Trial 1 Trial 2 Trial 3
1 4 4.1 4 4.1 4.1 3.9
2 4.1 4.1 4.2 3.9 4 4.1
3 3.8 3.7 3.7 3.6 3.8 3.9
4 3.5 3.5 3.4 3.4 3.4 3.5
5 4.5 4.5 4.4 4.4 4.3 4.5
6 3.9 4 3.9 4 3.8 3.8
7 3.7 3.8 3.8 3.8 3.9 3.7
8 4.1 4.1 4.1 4.2 4.3 4.2
9 3.6 3.7 3.6 3.5 3.6 3.7
10 4.2 4.1 4.1 4.2 4.2 4.3

STUDY 2

PART No APPRAISER A APPRAISER B

Trial 1 Trial 2 Trial 3 Trial 1 Trial 2 Trial 3
1 4.04 4.12 3.96 4.13 4.08 3.87
2 4.14 4.14 4.25 3.9 4.04 4.1
 3 3.85 3.74 3.69 3.59 3.84 3.94
4 3.47 3.52 3.43 3.37 3.4 3.46
5 4.49 4.48 4.35 4.41 4.27 4.46
6 3.87 4.04 3.93 3.96 3.8 3.76
7 3.66 3.79 3.81 3.79 3.86 3.74
8 4.09 4.06 4.07 4.16 4.28 4.24
9 3.56 3.69 3.64 3.52 3.57 3.68
10 4.25 4.07 4.13 4.19 4.21 4.29
 APPRAISER C
Trial 1 Trial 2 Trial 3 TOLERANCE
0.04 -0.11 -0.15 LSL USL
-1.38 -1.13 -0.96 -1.5 1.5
0.88 1.09 0.67
0.14 0.2 0.11
-1.46 -1.07 -1.45
-0.29 -0.67 -0.49
0.02 0.01 0.21
-0.46 -0.56 -0.49
1.77 1.45 1.87
-1.49 -1.77 -2.16

AISER B APPRAISER C APPRAISER D

Trial 4 Trial 1 Trial 2 Trial 3 Trial 4 Trial 1 Trial 2 Trial 3
25.067 25.06 25.046 25.042 25.057 25.056 25.052 25.062
25.065 25.043 25.045 25.036 25.045 25.053 25.065 25.056
25.06 25.065 25.062 25.074 25.061 25.065 25.062 25.057
25.065 25.055 25.055 25.052 25.065 25.062 25.067 25.074
25.062 25.065 25.045 25.046 25.062 25.065 25.045 25.074
25.048 25.037 25.035 25.045 25.05 25.037 25.035 25.054
25.057 25.057 25.062 25.058 25.069 25.057 25.062 25.074
25.077 25.05 25.057 25.065 25.049 25.05 25.057 25.07
25.057 25.052 25.045 25.045 25.057 25.062 25.06 25.044
25.057 25.057 25.052 25.065 25.053 25.057 25.062 25.074

Calculate Gage R & R as a percent of total variation

 APPRAISER C
Trial 1 Trial 2 Trial 3
3.08 3.25 3.07
2.65 1.68 2.32
4.19 3.94 4.34
3.01 4.03 3.2
2.56 1.8 1.6

APPRAISER C
Trial 1 Trial 2 Trial 3 TOLERANCE
4 3.9 4.1 LSL USL
4.1 3.9 4 3.25 4.75
3.7 3.7 3.8
3.4 3.5 3.5
4.4 4.4 4.5
3.8 3.9 3.9
3.6 3.7 3.8
4 3.9 4.1
3.6 3.5 3.5
4.1 4.2 4.3

APPRAISER C TOLERANCE
Trial 1 Trial 2 Trial 3 LSL USL
3.98 3.89 4.08 3.25 4.75
4.11 3.94 3.96
3.67 3.72 3.78
3.38 3.47 3.48
4.38 4.41 4.47
3.79 3.87 3.91
3.57 3.67 3.77
3.99 3.91 4.09
3.58 3.52 3.46
4.09 4.24 4.32
AISER D TOLERANCE CONTROL LIMITS
Trial 4 LSL USL LCL UCL
25.057 25.000 25.150 25.020 25.090
25.065
25.075
25.065
25.062
25.042
25.069
25.052
25.053
25.047
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 SOLUTIONS

The initial calculated values are EV = 1.042, AV = 1.185 and Gage R & R = 1.578, which is 52.61 % of the
specification range. After discarding the readings for Part 4 (as Range for Operator B was out of control), the Gage
R& R works out to 52.41 %. As this is more than 30 %, the MSA results are not acceptable. You can see that both
Equipment variation and Apprasier variation are on the higher side 33.78 % and 40.08 %. The Company will have to
make improvements both in terms of using a more precise gage as well as in operator training to ensure consistent
and accurate measurements. You must have also noticed that a major contributor to the overall variation is the
part variation itself, which is generally a good indicator from a MSA perspective.

The values are EV = 0.038, AV = 0.129 and PV = 0.555.

The Gage R & R works out to 26.79 % as a percentage of specification range, which is wiithin acceptable range.
However, if you consider the process control limits, the gage R & R is likely to cause process capability to appear
lower than actual.
Among the variations observed, the lowest variation is caused due to appraiser variation - 5.37 % of the total. this
means all appraisers are giving consistent and similar results. The major contributors are Equipment variation and
Part variation - both approx 47 % of total. We need to be concerned about Equipment variation, and can improve
the Gage R & R by changing the gage to a more precise one.

Before you proceed to calculate Gage R & R, you need to eliminate one data point, which is the measurement of
Length 5 by Operator B, as the Range of 41 is outside UCL R. The repeat reading for Length 5 is given below the data
set. Replace the new values and then calculate Gage R & R as a % of the Total variation, which works out to 22.75
%. You should note that the major variation (PV) is because of actual variation in the lengths of the fabric.

As in the previous example, you should have noted something unusual in the Range control chart. 3 out of 5
readings taken by Operator C are outside the UCL R. Hence we need to eliminate the complete set of readings taken
by Operator C. After the elimination, you will find that the readings of Operators A and B are within the revised
UCLR. As the remaining data satisfies the minmimum requirement (minimum 2 trials if the no of operators X no of
parts is less than 15 but more than 7) we can go ahead to compute the Gage R&R which works out to 37. 48 % of
Specification tolerance band and 32.39 % of the Total variation, which is marginally higher than 30 % acceptance
criteria.
The comparative results of both the studies are given in the adjacent columns. For your additional information, we
have deliberately kept the values in the second study close to the first one, so that if you round them off to 0.1
mm, the values will exactly replicate the first study readings. This has been done to highlight the power of
discrimination. As you can see there is an increase in EV, AV and G R&R values in the second study, and in
percentages of the tolerance band as well as in % of total variation.
Why did this happen. As we can see the number of distinct range values in the first study was only 4, whereas the
second study was able to discriminate the resutls into 15 distinct readings, hence there was increased accuracy in
calculations. As the tolerance is specified in the order of 0.01 mm, we should have anyway used a gauge of
accuracy 0.01mm or better 0.001mm.
A major finding is that in the second study, the Gage R & R has gone beyond 30 % and will lead to further
investigations.
 Study 1 Study 2
0.1 mm lc 0.01mm lc
Resolution:
Distinct range values 4 15
EV, Value 0.427 0.4697
EV as % of Tolerance 28.47 31.31
EVas % of TV 25.98 28.50
AV, Value 0.9899 0.1406
AV as % of Tolerance 6.6 9.3700
AVas % of TV 6.02 8.53
G R & R, Value 0.4383 0.4903
G R & R as % of Tolerance 29.22 32.69
G R & Ras % of TV 29.67 29.75
TV, Value 1.6435 1.6478
PV 1.573 1.584