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UNCLASSIFIED / FOUO
National Guard
Black Belt Training
Module 24
Measurement
System Analysis (MSA)
Continuous Data
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TOOLS
•Process Mapping
ACTIVITIES
• Map Current Process / Go & See •Process Cycle Efficiency/TOC
• Identify Key Input, Process, Output Metrics •Little’s Law
• Develop Operational Definitions •Operational Definitions
• Develop Data Collection Plan •Data Collection Plan
• Validate Measurement System •Statistical Sampling
• Collect Baseline Data •Measurement System Analysis
• Identify Performance Gaps •TPM
• Estimate Financial/Operational Benefits •Generic Pull
• Determine Process Stability/Capability •Setup Reduction
• Complete Measure Tollgate •Control Charts
•Histograms
•Constraint Identification
•Process Capability
Note: Activities and tools vary by project. Lists provided here are not necessarily all-inclusive. UNCLASSIFIED / FOUO
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Learning Objective
Understand how to conduct and interpret a
measurement system analysis using Continuous Data
Note: Gage R&R Study (Crossed) is the most commonly used method for Variables
(Continuous Data). It is used when the same parts can be tested multiple times, i.e. NON
DESTRUCTIVE TESTS. GR&R (Nested) MSA is for DESTRUCTIVE TESTING. .
Enter the variables (circled fields) in the above dialogue box and keep
the ANOVA method of analysis checked. The main difference between
ANOVA and Xbar and R is that ANOVA will estimate an operator by
part interaction. The ANOVA method is the preferred method.
After entering
the variables
in this dialog box,
click on Options
to view the
options dialog box
Options
dialog box
Interpreting Acceptability
If Process Tolerance and Historical Sigma values are not
used in Minitab, a critical assumption is then made that
the sample parts chosen for the study, truthfully exhibit
the true process variation. In this case, the acceptability
of the measurement system is based upon comparison
only to the part variation seen in the study. This can be
a valid assumption if care is taken in selecting the study
sample parts.
One element of criteria whether a measurement system
is acceptable to analyze a process is the percentage of
the part tolerance or the operational process variation
that is consumed by measurement system variation.
% Process
% Tolerance 9.75
50
9.50
0
Gage R&R Repeat Reprod Part-to-Part 1 2 3 4 5 6 7 8 9 10
Part
R Chart by Operator
1 2 3
Response by Operator
UCL=0.1073
0.10 10.00
Sample Range
_ 9.75
0.05
R=0.0417
9.50
0.00 LCL=0
1 2 3
Operator
Xbar Chart by Operator
1 2 3 Operator * Part Interaction
10.00 10.00 O perator
Sample Mean
1
_
_
Average
UCL=9.8422 2
X=9.7996 9.75
9.75 LCL=9.7569 3
9.50
9.50
1 2 3 4 5 6 7 8 9 10
Part
An estimate of Process
Within the Gage
(or Part) Variation
Or one Inspector
unless the Historical
Equipment/Gage Sigma is entered Parts
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It is desirable to see plots that consistently go outside the UCL and LCL
because limits are determined by gage variance and these plots should show
that gage variance is much smaller than variability within the parts
If the samples chosen do not represent the total variability of the process,
the gage (repeatability) variance may be larger than the part variance and
invalidate the distinct categories calculation
If the patterns of the operators are not comparable, there may be significant
operator and part interactions (discussed on another slide)
On this chart you want At Least 50% of the
points to be Outside the Control Limits
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This graph shows the data for all ten parts for all operators plotted
together. It should show plots that vary from the smallest dimensions
for the parts made by the process to the largest dimensions for the
same parts. Parts should be both in tolerance and out of tolerance if
the process makes them.
If a part shows a large spread, it might be a poor candidate for the test
because the feature may not be clear on that part.
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This graph shows the data for all ten parts for plotted by each
operator. The red line connecting the averages of all 10 parts
measured by each operator should be horizontal.
Any significant slope is an indication that this operator has a general
bias to measure large or small when compared to the other operators
% Process
% Tolerance 9.75
50
9.50
0
Gage R&R Repeat Reprod Part-to-Part 1 2 3 4 5 6 7 8 9 10
Part
R Chart by Operator
1 2 3
Response by Operator
UCL=0.1073
0.10 10.00
Sample Range
_ 9.75
0.05
R=0.0417
9.50
0.00 LCL=0
1 2 3
Operator
Xbar Chart by Operator
1 2 3 Operator * Part Interaction
10.00 10.00 O perator
Sample Mean
1
_
_
Average
UCL=9.8422 2
X=9.7996 9.75
9.75 LCL=9.7569 3
9.50
9.50
1 2 3 4 5 6 7 8 9 10
Part
This should be
4 or More
This tabulation from Minitab builds the % of Study Variation that each source contributes to a
calculated potential Total Variation seen in the study. The 6.0 * SD is how statistically 99.73% of the
Total Variation is calculated and this is assumed to equal 99.73% of the true process variation unless
the Historical Sigma is input into Minitab.
The percentages are used to grade the validity of the measurement system to perform measurement
analysis using percentages already taught. If the process is performing well, the %Tolerance is then
important. The sum of the percentages might add to more than 100% due to the math.
The Number of Distinct Categories represents the number of non-overlapping confidence intervals
that this measurement system can reliably distinguish in the product variation. We would like that
number to be 5 or higher. Four is marginal. Fewer than 4 implies that the measurement system can
only work with attribute data. DC= (s parts/s GRR total)* 2
Measurement System Analysis (MSA) - Continuous UNCLASSIFIED / FOUO 30
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% Process
% Tolerance 9.75
50
9.50
0
Gage R&R Repeat Reprod Part-to-Part 1 2 3 4 5 6 7 8 9 10
Part
R Chart by Operator
1 2 3
Response by Operator
UCL=0.1073
0.10 10.00
Sample Range
_ 9.75
0.05
R=0.0417
9.50
0.00 LCL=0
1 2 3
Operator
Xbar Chart by Operator
1 2 3 Operator * Part Interaction
10.00 10.00 Operator
Sample Mean
1
_
_
Average
UCL=9.8422 2
X=9.7996 9.75
9.75 LCL=9.7569 3
9.50
9.50
1 2 3 4 5 6 7 8 9 10
Part
Let’s Do It Again
Three parts were selected that represent the expected range of the
process variation. Three operators measured the three parts, three
times per part, in a random order.
No History of the process is available and Tolerances are not
established
Go to exercise set: Gage2.mtw
This data set is used to illustrate Gage R&R Study and Gage Run Chart
400
50
200
0
Gage R&R Repeat Reprod Part-to-Part 1 2 3
Part
R Chart by Operator
1 2 3
Response by Operator
400 UCL=376.5 600
Sample Range
400
200 _
R=146.3
200
0 LCL=0
1 2 3
Operator
Xbar Chart by Operator
1 2 3 Operator * Part Interaction
UCL=555.8
O perator
500
Sample Mean
1
450
Average
_
_ 2
3
400 X=406.2 400
300 350
LCL=256.5
1 2 3
Part
Gage2.mtw - Results
This should be
less than 30%
for process
improvement
efforts
What does
this tell
you?
Remember this?
What does this mean ?
Measurement System Analysis (MSA) - Continuous UNCLASSIFIED / FOUO 37
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Gage2.mtw – Conclusions
What needs to be addressed first? Where do we begin
improving this measurement system?
400
50
200
0
Gage R&R Repeat Reprod Part-to-Part 1 2 3
Part
R Chart by Operator
1 2 3
Response by Operator
400 UCL=376.5 600
Sample Range
400
200 _
R=146.3
200
0 LCL=0
1 2 3
Operator
Xbar Chart by Operator
1 2 3 Operator * Part Interaction
UCL=555.8
O perator
500
Sample Mean
1
450
Average
_
_ 2
3
400 X=406.2 400
300 350
LCL=256.5
1 2 3
Part
One-Sided Specifications
Typically, in the transactions environment, customer specifications are
only one-sided. For example, most of the time an upper specification
alone given on cycle time… faster is always better.
How does Minitab analyze and report findings for a GR&R for a one-sided
specification?
So, if for example, the USL was 10 and the mean for response was 5,
then the OST equals 10-5 or 5
Takeaways
It is important to be able to rely on the accuracy of the
measurement system to make good decisions
Understand the various types of measurement system variation
Eliminate as much of the variation in the measurement system
as possible to focus on and improve the true cause of variation
in process performance
Conduct a Gage R&R analysis to assess the measurement
system for continuous data
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National Guard
Black Belt Training
APPENDIX
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. * s MS
515 Usually
P/T expressed as a
Tolerance percent
s MS
% R& R = ´ 100 Usually expressed
s Total as a percent
sP
D. I. = ´ 2 The D.I. Is similar to the “Number of Distinct
Categories” on the Gage R&R Statistics output
s MS
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Note: The Discrimination Index is entirely different from the Measurement Unit
Discrimination discussed earlier
The measurement UNIT discrimination, evaluated in the range chart,
determines if the units being used are sufficiently small enough to detect variation
(are we using a unit of time such as “days” when we need to be using “minutes”
The Discrimination Index looks at Measurement Variation vs. Product Variation to
determine if the measurement system is capable of discriminating from item to item
USL LSL
CpAct where s Act s2Obs s2MS
6s Act
Therefore:
USL LSL
CpAct
6 s2Obs s2MS
Where and
Therefore:
USL X Obs X MS
X Obs X MS LSL
CpkAct Min or
3 s2
s2
3 s2
s2
Obs MS Obs MS
References
Automotive Industry Action Group, Measurement
Systems Analysis, 3rd Edition, 2nd Printing, 2003,
AIAG, Southfield, MI. (248) 358-3003, www.aig.org
Minitab, StatsGuide