Gage R&R Values Gage R&R Percentages

Gage R&R Part Number

Average & Range Method 1 2 3 4 5 6 7 8 9 10 Sum
Operator 1 Trial 1 161.2688 ### ### ### ### ###
Enter your data here-> Trial2 161.7198 ### ### ### ### ###
Trial3 161.8170 ### ### ### ### ###
Trial4 161.2204 ### ### ### ### ### Xbar1 Reference
Trial 5 161.1537 ### ### ### ### ### 161.2148 12.500 <-Insert Reference
Total 807.17963 812.515 786.99 806.408 817.28 Bias
Average-Apprais161.43593 162.503 157.4 161.282 163.46 Rbar1 148.715
Range1 0.6632802 0.39334 0.8444 0.47635 0.3194 0.539355
Operator 2 Trial 1 161.8133 ### ### ### ### ###
Enter your data here-> Trial2 161.1449 ### ### ### ### ###
Trial3 161.6479 ### ### ### ### ###
Trial4 161.5174 ### ### ### ### ### Xbar2 Reference
Trial 5 161.7718 ### ### ### ### ### 161.3229 12.500
Total 807.89538 811.588 787.87 808.007 817.71 Bias
Average-Apprais161.57908 162.318 157.57 161.601 163.54 Rbar2 148.823
Range2 0.6684535 0.85553 0.4838 0.78469 0.4473 0.647954
Operator 3 Trial 1 161.5751 ### ### ### ### ###
Enter your data here-> Trial2 161.5083 ### ### ### ### ###
Trial3 161.1165 ### ### ### ### ###
Trial4 161.3013 ### ### ### ### ### Xbar3 Reference
Trial 5 161.5095 ### ### ### ### ### 161.2812 12.500
Total 807.01068 812.372 787.17 808.542 816.94 Bias
Average-Apprais161.40214 162.474 157.43 161.708 163.39 Rbar3 148.781
Range3 0.4586247 0.77113 0.561 0.38309 0.6765 0.570072

Range Average 0.5858 Constants

XDiff 0.1081 5 Trials 4 Trials 3 Trials 2 Trials # Trials 5
UCL 1.2360 2.11 2.28 2.58 3.27 D4 2.11 UCL represents the limit of the individual R's
LCL 0.0000 0 0 0 0 D3 0 Circle those beyond the limit.
Repeatability(EV) 0.2518 0.577 0.729 1.023 1.88 A2 0.577 Identify and correct causes
Reproducibility(AV) 0.0257 0.4299 0.4857 0.5908 0.8862 K1 0.4299 LCL = 0 D3=0 for up to 7 trials
Gage Capability(R&R) 0.2531 0.7071 0.5231 K2 0.5231
Spec Tolerance 0.0100 2 Ops 3 Operators
Acceptability(%) 25.31

% Using % Using
AIAG - Automotive Industry Action Gro TV Tolerance
Equipment Variation (Repeatability) 0.2518
%EV 10.4% 15110%
Appraiser Variation (Reproducibility) 0.02571
%AV 1.1% 1543%
R&R (Gage Capability) 0.2531
%R&R 10.4% 15189%
PV (Part Variation) 2.4152
%PV 99.5% 144910%
TV (Total Variation) 2.4284
Conclusions / Recommendations
Gage system may be acceptable based on importance of application and cost
Gage may need maintenance, redesign, or better clamping

# Parts #Trials #Ops

5 5 3

Calculate GageR&R using Anova With Interaction Without Interaction

Anova Source df SS MS F P F P
Appraiser 2 ### ### -4 Err:502 -34 Err:502
Parts 4 310.6739 77.6685 0.00033 1.00000 0.00282 0.99998
Appraiser x Part 8 ### 234080 4E+06 0.00000
Gage w AP Interaction 60 3.8410 0.0640
Gage w/o AP Interaction 68 ### ###
Total 74 315.34283
%
Estimate of 5.15* % Study Contribut
Variance Std. Dev Stdev Variation ion
Repeatability 0.06402 0.2530151 EV 1.303 0% 0%
Appraiser 46815.9625741 216.36997 AV 1114.3 65% 43%
AppraiserxPart 46815.9663287 216.36998 INT 1114.3 65% 43%
R&R 93631.99292 305.99345 R&R 1575.9 93% 86%
Part 15600.14848 124.90055 PV 643.24 38% 14%
TV 1702.1

Part by Appraiser Plot (Stacked)

166

164
Averagge

162
Average-
Appraiser 1
160 Average-
Appraiser 2

158

156

154
1 2 3 4 5 6 7 8 9 10
Part

Part by Appraiser Plot

166

164
Averagge

162

160

158
Averagg
162

160

158

156

154
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

Appraiser 1 Appraiser 2 Appraiser 3

Range of Parts by Appraiser (Stacked)

0.9

0.8

0.7
Range

0.6

0.5 Ra
ng
0.4 e1

0.3

0.2

0.1

0
1 2 3 4 5 6 7 8 9 10
Parts

Range of Parts by Appraiser

0.9

0.8

0.7
Range

0.6

0.5

0.4

0.3
 0.9

0.8

0.7
Range

0.6

0.5

0.4

0.3

0.2

0.1

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

Appraiser 1 Appraiser 2 Appraiser 3

Instructions 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% Gage System Okay (Most variation caused by parts, not people or equipment)
%R&R<30% May be acceptable based on importance of application and cost of gage or repair
%R&R>30% Gage system needs improvement (people and equipment cause over 1/3 of variation)

Verified using AIAG Measurement Systems Analysis 3rd Edition

<-Insert Reference Value Here
 Range Method

Range Method Insert Your Data Here

Part 1 2 3 4 5 Average
Appraiser 1 12 22 12 10 11 13.4
Appraiser 2 11 23 13 12 21 16 d2
Range 1 1 1 2 10 3 1.19

GR&R 2.521008
Insert Process
Standard
Deviation 5.121849
%GR&R 49%

Page 7
 Bias

t-
Reference Average/ Stdev(r) Statistic/
Value Value Bias n Mean Stdev Stdev(b) critical d2*/d2 df g
5.8 6.0 -0.2 15 6.006667 0.21202 0.2251409 0.114683 3.55333 10.8 d2*
5.7 -0.3 Bias 0.0067 0.0581311 2.2064 3.47193 df
5.9 -0.1 d2
5.9 -0.1 95% Confidence t crit 95%
6.0 0.0 Lower Upper
6.1 0.1 -0.118656 0.131989
6.0 0.0 Bias Acceptable
6.1 0.1
6.4 0.4 Reference: AIAG MSA Version 3 pgs 85-88
6.3 0.3
6.0 0.0
6.1 0.1
6.2 0.2
5.6 -0.4
6.0 0.0

Page 8
 Bias

2 3 4 5 6 7 8 9 10 11 12
1.41421 1.91155 2.23887 2.48124 2.67253 2.82981 2.96288 3.07794 3.17905 3.26909 3.35016
1 2 2.9 3.8 4.7 5.5 6.3 7 7.7 8.3 9
1.12838 1.69257 2.05875 2.3593 2.53441 2.70436 2.8472 2.97003 3.07751 3.17287 3.25846
4.303 3.182 2.776 2.571 2.447 2.365 2.306 2.262 2.228 2.201 2.179

Page 9
 Bias

13 14 15 16 17 18 19 20
3.42378 3.49116 3.55333 3.61071 3.66422 3.71424 3.76118 3.80537
9.6 10.2 10.8 11.3 11.9 12.4 12.9 13.4
3.33598 3.40676 3.47193 3.53198 3.58788 3.64006 3.68896 3.735
2.16 2.145 2.131 2.12 2.11 2.101 2.093 2.086

Page 10
 Linearity

Part
Trials 1 2 3 4 5
1 2.7 <- Insert Your Data Here
2
3 Linearity evaluates a gauge's ability
4 to measure accurately across a wide range
5 Imagine measuring a baseball bat:
6 1. at the grip
7 2. in the middle
8 3. and at the widest part
9
10
11
12
Average 2.70
Reference
Values 2.00 <- Insert Known Reference Values Here
Bias 0.70
Range 0.00 0.00 0.00 0.00 0.00
bias=
slope*ref+b
Slope= Err:502
b= Err:502
Goodness of fit Err:502
Insert Process
Variation
Linearity Err:502
%Linearity Err:502

Linearity Plot

0.80

0.70

0.60
Bias

0.50

0.40

0.30

0.20

0.10

0.00
1.50 2.00 2.50 3.00 3.50 4.00
Reference Value

Page 11
 Linearity

s a gauge's ability
ely across a wide range
g a baseball bat:

Page 12
 Appraiser A Appraiser B Appraiser C Reference Results A-B B-C
Part # Trial 1 Trial 2 Trial 3 Trial 1 Trial 2 Trial 3 Trial 1 Trial 2 Trial 3 ReferenceRef Value Code LSL USL %R&R Gray zone 1 2 3 1 2 3
1 1 1 1 1 1 1 1 1 1 1 0.476901 + 0.45 0.55 25% 0.02500 1 1 1 1 1 1
2 0 0 0 0 0 0 0 0 0 0 0.576459 - 1. Enter Spec Limits Above 0 0 0 0 0 0
3 1 1 0 1 1 0 1 0 0 1 0.544951 X 2. Have 3 appraisers accept/reject 10+ 1 1 0 1 -1 0
4 0 - 3. Enter pass/fail in columns B-J
5 0 - 4. Enter Reference value in column L
6 0 - 5. Evaluate effectiveness columns AJ
7 0 -
8 0 -
9 0 -
10 0 -
11 0 -
12 0 -
13 0 -
14 0 -
15 0 -
16 0 -
17 0 -
18 0 -
19 0 -
20 0 -
21 0 -
22 0 -
23 0 -
24 0 -
25 0 -
26 0 -
27 0 -
28 0 -
29 0 -
30 0 -
31 0 -
32 0 -
33 0 -
34 0 -
35 0 -
36 0 -
37 0 -
38 0 -
39 0 -
40 0 -
41 0 -
42 0 -
43 0 -
44 0 -
45 0 -
46 0 -
47 0 -
48 0 -
49 0 -
50 0 -
0 = Fail + = within spec limits
1 = Pass - = outside spec limits
x = gray area around spec limits
 C-A A-REF B-REF C-REF
1 2 3 1 2 3 1 2 3 1 2 3
1 1 1 1 1 1 1 1 1 1 1 1
0 0 0 0 0 0 0 0 0 0 0 0
1 -2 0 1 1 -2 1 1 -2 1 -2 -2 Crosstabulation Crosstabulation Miss
B Total REF Total Effectiveness Rate
A 0 1 A 0 1 A 89% 11%
0 4 0 4 0 3 0 3 B 89% 11%
1 0 5 5 1 1 5 5 C 78% 22%
Tota 4 5 9 Tota 4 5 9 System 85% 15%
85%
C Total REF Total Effectiveness
B 0 1 B 0 1 Acceptable >= 90%
0 4 1 5 0 3 0 3 Marginal >=80%
1 0 4 4 1 1 5 6 Unacceptable <80%
Tota 4 5 9 Tota 4 5 9

A Total REF Total

C 0 1 C 0 1
0 4 0 4 0 3 0 3
1 1 4 5 1 2 4 6
Tota 5 4 9 Tota 5 4 9