MSA 4th Edition Case Studies & Guidelines

MSA CASE STUDIES

BIAS

Difference between observed average

of measurements and reference value.
Reference Value

Reference value, also known as

accepted reference value or master
value, is a value that serves as an
agreed upon reference for measured
values.

A reference value can be determined

Observed Average by
averaging several measurements
Value with a
higher level of measuring equipment.

BIAS WORK INSTRUCTION & CASE STUDY:

The inside diameter of a coupling is measured fifteen times repeatedly by the same
operator. The data is given below. The reference value is 6.00.

Average (X-bar) = Trials OD Values Individual Bias

1. 5.8

2. 5.7

3. 5.9

4. 5.9

5. 6.0

6. 6.1

7. 6.0

8. 6.1

9. 6.4

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MSA 4th Edition Case Studies & Guidelines

10. 6.3

11. 6.0

12. 6.1

13. 6.2

14. 5.6

15. 6.0

 DRAW HISTOGRAM FOR THE INDIVIDUAL BIAS & INTERPRET FOR

NORMALITY

 Compute the average bias of the n readings.

Avg. bias = (Sum of Bias) / n

 Compute the repeatability standard deviation

Sigma repeatability = σ r = sqrt{(Sum ( Xi – X-bar) 2) / (n-1)}

If a GRR study is available (and valid), the repeatability standard deviation should
be based on the study results.

 Determine if the repeatability is acceptable by calculating the

%EV = 100 (EV/TV) = 100 (σ r / TV)

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MSA 4th Edition Case Studies & Guidelines

If the % EV is large, then the measurement system variation may be

unacceptable. Since the bias analysis assures that the repeatability is acceptable,
continuing the analysis with a measurement system with a large %EV will lead to
misleading and confusing results.

 CALCULATE SIGMA BIAS = SIGMA r / SQRT n

 Bias is acceptable at the α level, if

Zero falls within the 1- α confidence bounds based on the bias value. (Use the t-
distribution table).

Average Bias – [σb (tν, 1 – α/2)] ≤ 0 ≤ Average Bias + [σb (tν, 1 – α/2)]

Where ν = n-1, tν, 1 – α/2 from t - table

REPEATABILITY

Variation in measurements
obtained with one measurement
instrument when used several
times by one Appraiser while
measuring identical characteristic
on same part.
Repeatability

REPRODUCIBILITY

Variation in average of
measurements made
by different Appraisers Appraiser B
using same measuring
instrument when
measuring identical
characteristic on same Appraiser C
part.

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Appraiser A
Reproducibility
MSA 4th Edition Case Studies & Guidelines

GAGE R & R STUDY ( X bar and R method)

GAGE R & R WORK INSTRUCTIONS

1. Select three appraisers who are users of the measurement system

2. Obtain a sample of 10 parts that represent actual or expected range of process

variation

3. Number parts 1 through 10 so that numbers are not visible to appraisers

4. Calibrate gage if this is part of the normal gauging procedures

5. Measure 10 parts in random order by appraiser a, with an observer recording

results

6. Repeat step 5 with other appraisers, conceal other appraisers readings

7. Repeat step 5 and 6 using a different random order of measurement

8. Calculate the average and ranges for all readings for each appraiser

9. Using the attached GR & R report, enter part averages and range averages

10. Calculate repeatability for equipment variation

11. Calculate reproducibility for appraiser variation

12. Calculate GR & R

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MSA 4th Edition Case Studies & Guidelines

13. Calculate part variation.

14. Calculate % EV, %AV, % R&R against TV or tolerance based on the following
guidelines:

(i) Using process variation

 Process variation, taken from the parts in GRR study itself

 Use when the selected sample represents the expected process
variation (preferred option)

(ii) Surrogated process variation

 Use when sufficient samples to represent the process are not
available but an existing process with similar process variation
is available

(iii) Pp (or Ppk) target value

 Use when sufficient samples to represent the process are not

available and an existing process with similar process variation
is not available or the new process is expected to have less
variability than an existing process

Formula to be used –

Pp = (USL-LSL) / (6*σp) = (USL-LSL) / (6*TV)

Therefore, TV = (USL-LSL) / (6*Pp)

(iv) Specification tolerance

 Use When the measurement system is to be used to sort the

process, and the process has a Pp < 1.0

15. Calculate number of distinct data categories

GR & R ACCEPTANCE GUIDELINES

Acceptance criteria based on estimated value of R&R of system

GRR Decision Comments

Under Generally considered to be Recommended, especially useful when trying
10% an acceptable measurement to sort or classify parts or when tightened
system process control is required
10% to May be acceptable for some Decision should be based upon, for example,

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MSA 4th Edition Case Studies & Guidelines

30% applications importance of application measurement, cost

of measurement device, cost of rework or
repair.

Should be approved by the customer

Over Considered to be Every effort should be made to improve the
30% unacceptable measurement system.

This condition may be addressed by the use

of an appropriate measurement strategy; for
example, using the average result of several
readings of the same part characteristic in
order to reduce final measurement variation.

 No. of distinct data categories NDC > 5

GAGE REPEATABILITY AND REPRODUCIBILITY DATA SHEET

VARIABLE DATA RESULTS
Part Number : Guage Name : Appraiser A :

Part Name : Guage Number : Appraiser B :

Characteristic Range Guage Type Appraiser C :

Characteristic Classification Trials Parts Appraisers Date Performed

APPRAISER/ PART AVERAGE

TRIAL # 1 2 3 4 5 6 7 8 9 10
1. A 1
2. 2
3. 3
4. AVE X-bar a =
5. R R-bar a =
6. B 1
7. 2
8. 3
9. AVE X-bar b =
10. R R-bar b =
11. C 1
12. 2
13. 3

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MSA 4th Edition Case Studies & Guidelines

14. AVE X-bar c =

15. R R-bar c =
16. PART X double bar =
AVE ( Xp ) Rp=
17. (R-bara + R-barb + R-barc) / (# OF APPRAISERS) = R d-bar=
(Max X-bar – Min X-bar) =
18. X barDIFF=
R d-bar x D4*
19. = UCLR=

* D4 =3.27 for 2 trials and 2.58 for 3 trials; UCLR represents the 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 dis-
card values and re-average and recompute R-dbar and the limiting value from the remaining observations.
Notes:

GAGE REPEATABILITY AND REPRODUCIBILITY DATA SHEET

VARIABLE DATA RESULTS
Part Number Gage Name Appraiser A

Part Name Gage Number Appraiser B

Characteristic Gage Type Appraiser C

Characteristic Classification Trials Parts Appraisers Date Performed

Measurement Unit Analysis % TV

Repeatability – Equipment Variation (EV)
EV =R d-bar x K1 Trials K1 % EV =100 (EV/ TV)
= 2 0.8862 =
= 3 0.5908 =
Reproducibility – Appraiser Variation (AV)

AV ={(x barDIFF x K2)2 – (EV2/nr)}1/2 % AV =100 (AV/ TV)

= =
= Appraisers 2 3 =
n = number of
parts, r = number of trials K2 0.70710.5231
Repeatability & Reproducibility (GRR)
GRR ={(EV2 + AV2)}1/2 Parts K3 % GRR =100 (GRR/ TV )
= 2 0.7071 =
= 3 0.5231 =
Part Variation (PV) 4 0.4467

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PV =RP x K3 5 0.4030
= 6 0.3742 % PV =100 (PV/ TV )
= 7 0.3534 =
Total Variation 8 0.3375 =
TV ={(GRR2 + PV2)}1/2 9 0.3249 ndc =1.41(PV/GRR)
= 10 0.3146 =
= =

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 MSA 4th Edition Case Studies & Guidelines

CONTROL PLAN
Prototype Pre-launch Production Key Contact / Phone Date (Org.) Date (Rev.)
Control Plan Number S. Specs 555-8888
Part Number / Latest Change Level Core Team Customer Engg. Approval/Date (if Reqd.)

Part Name / Description Supplier / Plant Approval Date Customer Quality Approval / Date (if reqd.)

Supplier / Plant Supplier Code Other Approval Date (if reqd.) Other Approval Date (if reqd.)

Part/ Process Name / Machine, Characteristics Special Methods Reaction

Process Operation Description Device, No. Product Process Char. Product/Process Evaluation Sample Control Plan
Number Jig. Tools specification / Measurement Size Freq Method
For Mfg. Tolerance Technique .
20 Turning CNC 1 O.D 275 +/- 0.1 H – GAGE 1 hr Self SOP
Inspn VE/SOP/
2 THICK 47 +/- 0.1 E – GAGE 1 hr Self 08
inspn.
3 BORE * 50 +0.05 BORE DIAL 5 hr X bar &
( 0.001) R chart

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MSA 4th Edition Case Studies & Guidelines

t-Distribution Table
Α 0..6 0.75 0.90 0.95 0.975 0.99 0.995 0.9975 0.999 0.9995

1 0.325 1.000 3.078 6.314 12.706 31.821 63.657 127.320 318.310 636.620
2 0.289 0.816 1.886 2.920 4.303 6.965 9.925 14.089 23.326 31.598
3 0.277 0.765 1.638 2.353 3.182 4.541 5.841 7.453 10.213 12.924
4 0.271 0.741 1.533 2.132 2.776 3.747 4.604 5.598 7.173 8.610
5 0.267 0.727 1.476 2.015 2.571 3.365 4.032 4.773 5.893 6.869
6 0.265 0.718 1.440 1.943 2.447 3.143 3.707 4.317 5.208 5.959
7 0.263 0.711 1.415 1.895 2.365 2.998 3.499 4.029 4.785 5.408
8 0.262 0.706 1.397 1.860 2.306 2.896 3.355 3.833 4.501 5.041
9 0.261 0.703 1.383 1.833 2.262 2.821 3.250 3.690 4.297 4.781
10 0.260 0.700 1.372 1.812 2.228 2.764 3.169 3.581 4.144 4.587
11 0.260 0.697 1.363 1.796 2.201 2.718 3.106 3.497 4.025 4.437
12 0.259 0.695 1.356 1.782 2.179 2.681 3.055 3.428 3.930 4.318
13 0.259 0.694 1.350 1.771 2.160 2.650 3.012 3.372 3.852 4.221
14 0.258 0.692 1.345 1.761 2.145 2.624 2.977 3.326 3.787 4.140
15 0.258 0.691 1.341 1.753 2.131 2.602 2.947 3.286 3.733 4.073
16 0.258 0.690 1.337 1.746 2.120 2.583 2.921 3.252 3.686 4.015
17 0.257 0.689 1.333 1.740 2.110 2.567 2.898 3.222 3.646 3.965
18 0.257 0.688 1.330 1.734 2.101 2.552 2.878 3.197 3.610 3.922
19 0.257 0.688 1.328 1.729 2.093 2.539 2.861 3.174 3.579 3.883
20 0.257 0.687 1.325 1.725 2.086 2.528 2.845 3.153 3.552 3.850
21 0.257 0.686 1.323 1.721 2.080 2.518 2.831 3.135 3.527 3.819
22 0.256 0.686 1.321 1.717 2.074 2.508 2.819 3.119 3.505 3.792
23 0.256 0.685 1.319 1.714 2.069 2.500 2.807 3.104 3.485 3.767
24 0.256 0.685 1.318 1.711 2.064 2.492 2.797 3.091 3.467 3.745
25 0.256 0.684 1.316 1.708 2.060 2.485 2.787 3.078 3.450 3.725
26 0.256 0.684 1.315 1.706 2.056 2.479 2.779 3.067 3.435 3.707
27 0.256 0.684 1.314 1.703 2.052 2.473 2.771 3.057 3.421 3.690
28 0.256 0.683 1.313 1.701 2.048 2.467 2.763 3.047 3.408 3.674
29 0.256 0.683 1.311 1.699 2.045 2.462 2.756 3.038 3.396 3.659
30 0.256 0.683 1.310 1.697 2.042 2.457 2.750 3.030 3.385 3.646
40 0.255 0.681 1.303 1.684 2.021 2.423 2.704 2.971 3.307 3.551
60 0.254 0.679 1.296 1.671 2.000 2.390 2.660 2.915 3.232 3.460
120 0.254 0.677 1.289 1.658 1.980 2.358 2.617 2.860 3.160 3.373
0.253 0.674 1.282 1.645 1.960 2.326 2.576 2.807 3.090 3.291
ν - degrees of freedom

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