VDA 5 3rd 2021 测量和检验过程Measurement and Inspection Processes

Qualitäts Management Center
im Verband der Automobilindustrie 5

Quality Management in the Automotive Industry
Measurement and
Inspection Processes
Capability, Planning and Management
3rd, revised edition, July 2021

Dokument wurde bereitgestellt vom
VDA-QMC Internetportal am 02.11.2021 um 09:52
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Measurement and
Inspection Processes
Capability, Planning and Management
3rd, revised edition, July 2021
Verband der Automobilindustrie e. V.


Imprint
ISSN 0943-9412
Printed: September 2021
Copyright 2021 by
Verband der Automobilindustrie e. V. (VDA)

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03
Non-binding VDA recommendation

The Association of the German Automotive Industry (VDA) recommends its members
to apply the following guidelines for the implementation and maintenance of quality
management systems.
Exclusion of Liability
This VDA volume is a recommendation that is freely available for general use. Anyone
who implements it is responsible for ensuring that it is used correctly in each case.
This VDA volume takes into account state of the art technology, current at the time of
issue. Implementation of VDA recommendations relieves no one of responsibility for
their own actions. In this respect, everyone acts at their own risk.
The VDA and the people involved in the publication of VDA recommendations shall
bear no liability.
If during the use of VDA recommendations, errors or the possibility of misinterpretation

are found, it is requested that these be reported to the VDA immediately so that any
possible faults can be corrected.
Copyright
This publication is protected by copyright. Any use outside of the strict limits of copy-
right law is not permissible without the consent of VDA and is liable to prosecution. This
applies in particular to copying, translation, microfilming and storage or processing in
electronic systems.
Translations
This publication will also be issued in other languages. The current status must be re-
quested from VDA QMC.


04


Foreword 05
Foreword
After more than a decade, the time has come for a fundamental revision of one of the
standard works on measurement and inspection process capability. The focus when
drawing up this 3rd edition of VDA Volume 5, with its new title “Measurement and In-
spection Processes, Capability, Planning and Management”, was on comprehensibility
of methodology in order to achieve better applicability for the user in practice. The VDA
Volume 5 has been completely revised and updated with all the change notices com-
piled in the VDA QMC since 2011. The revision incorporates the latest changes related
to standards and technical development.
One of the innovations in VDA Volume 5 is the division of topics into a main volume and
a practical handbook. The main volume gives users technical guidance and orientation
in the procedure. The practical handbook shows practical implementation of the topic
from the main volume using examples and use cases. Logic has been implemented in
the inspection planning method so that the contents are taken into account right at the
beginning of the product development process. The measurement and inspection pro-
cess capability thus acts as a systems engineering tool for verification and validation in
the early phase of the project. At the same time, for the first time, a connection and
consistency to the adjacent processes inspection equipment management, inspection
planning and inspection process management (including the defined roles) was ap-
plied. The risk-based approach is appropriately and efficiently embedded in the inspec-
tion process management, offers specific assistance in selecting the procedure to back
up audit decisions and allows a differentiated approach while being mindful of econom-
ic requirements. The idea behind VDA Volume 5 is to provide as complete an overview
as possible of the handling of proof of capability for measurement processes.
The 3rd edition has been amended in the following aspects:
• Clarification of terms and definitions closely following VIM [2] and ISO 3534-1 [11]
• Process transparency from the engineering of the measuring system to the capabil-
ity of the measurement and inspection processes
• Strategies for harmonization with the AIAG Core Tool MSA (4th Edition) [1]
• Recommendations for the procurement of measuring systems (for example, specifi-
cations)
• Transferability of proof of capability
• Handling of unsuitable measuring systems/processes
• Handling of fine tolerancesDokument
(FT or wurde
FT rule)
bereitgestellt vom

06 Foreword
• Procedure for insufficient sample sizes in the “measuring system” and “measure-
ment process” trials.
• Procedure for small pre-series and production lots in development and production
• Consideration and monitoring of the ongoing capability using stability measure-
ments
The measurement uncertainty calculation methods have been largely left unchanged,
down to the index adjustments and linearity calculations. Calculations for fine toleranc-
es, one-sided tolerances and attribute calculation methods have been added.
It is necessary to comply with specified tolerances of individual parts and assemblies

to guarantee the function of technical systems. According to ISO 8015 [34], it is as-
sumed that the tolerance limits correspond to the functional limits when defining the
required tolerances in the design process.
Inspection process capability is more than just the release of the inspection equipment,
it also includes the handling of measurement uncertainty in product and manufacturing
design. A comprehensive measurement result consists of a determined measured val-
ue and a measurement uncertainty in the measurement process. In the area of toler-
ance limits, no reliable statement can be made about compliance or non-compliance
with the tolerances due to the measurement uncertainty. This can lead to incorrect
evaluations of measurement results. Different standards and guidelines contain re-
quirements for estimating and considering the measurement uncertainty. For this rea-
son, both the measuring system and measurement process uncertainty must be taken
into account as early as the planning stage of measurement processes. In this respect,
companies must address various questions in implementing and certifying their quality
management system. This document shows how to meet these many demands. The
procedures described here are based on ISO/IEC Guide 98-3 (2008-09) [31] and DIN
EN ISO 14253-1 [20].
The topic of conformity according to DIN EN ISO 14253-1 [20] cannot be comprehen-
sively represented with conventional methods of measuring system analysis. Some
important reasons for this are that certain influencing quantities such as calibration
uncertainty, quality of the setting standards, error limits and temperature effects were
not sufficiently catered for. Furthermore, known methods of measuring system analysis
are used only to assess individual components separately, but not the entire inspection
process. With the proof of capability method for measurement and inspection process-
es, this latest edition of VDA Volume 5 offers a practical, standard-compliant solution.
Even a comparison of the headings of the old and new requirements of DIN EN ISO
9001 [16] reveals significant differences. To date, the “control of monitoring and meas-
uring equipment” has been sufficient. On the other hand, DIN EN ISO 9001 [16] has
been referring to “resources for monitoring and
Dokument wurde measurement”
bereitgestellt vom since 2015. This clearly

Foreword 07
shows that it is not, as has been in the past, only about the monitoring and measuring
equipment, but about all necessary resources too, from spatial conditions, appropriate-
ly trained personnel, suitable inspection equipment, the measuring equipment including
software, to the necessary auxiliary devices and methods that are involved in the for-
mation of valid and reliable monitoring and measurement results. All of this must serve
the purpose of conformity of products and, more recently, also of services, i.e. it must
be ensured that only assured quality is delivered to the customer.


08


INHALT 09
Table of contents
Foreword 05
1 Standards and guidelines 15
2 Benefits and scope of application 16
3 Terms and definitions 20
3.1 Measuring and inspecting 20
3.2 Evaluation and attributive inspection 21
3.3 Frequently used terms 23
4 Inspection process management 34

4.1 Inspection process management tasks 35
4.1.1 Assurance of inspection results, taking into account measure-
ment uncertainty as per DIN EN ISO 14253-1 [20] 35
4.1.2 Effect of the measurement uncertainty on the manufacturing process 39
4.2 Roles and competencies in inspection process management 40
4.2.1 Roles in inspection process management 40
4.2.2 Competencies in inspection process management 44
4.3 Risk-based assurance 47
4.3.1 Preselection of inspection processes for risk-based assurance 50
4.3.2 Procedure for risk-based assurance 53
4.3.2.1 Criteria, consequences and probability of occurrence of an
incorrect inspection decision 54
4.3.2.2 Derivation of the risk class for the individual inspection process 55
4.3.2.3 Degree of assurance 56
4.3.3 Complaint process of inspection systems, inspection processes
in the application 58
4.4 Inspection process planning 59
4.4.1 Sequence of inspection process planning 59
4.4.2 How inspection process planning contributes to the systems
engineering process 67
4.5 Inspection equipment
Dokument management 71
wurde bereitgestellt vom

10 INHALT
4.5.1 Inspection equipment management system 72

4.5.2 Calibration of inspection equipment 73
4.5.2.1 Internal calibration 73
4.5.2.2 External calibration 74
4.6 Proof of efficiency for inspection process management 76
4.7 Proof of capability for measurement processes – General 77
4.7.1 Analysis of the measurement process and scope of the proof of
capability 78
4.7.2 Modeling in VDA Volume 5 80
4.7.3 Measuring system capability and measurement process capability 81
4.7.4 Transferability of proof of capability 83
4.7.5 How to proceed if measurement and inspection process capability
is not reached – General overview 85
4.7.5.1 Optimizing the measuring system and measurement process 87
4.7.5.2 Risk analysis with conditional approval 87
4.7.5.3 Improvement/substitution of the manufacturing process 87
4.7.6 Implicit proof of capability 88
5 General procedure for measurement and inspection

process capability 89
5.1 Influences on the measurement uncertainty results 89
5.1.1 Influencing quantities in the measuring system 91
5.1.1.1 Comparison of reference types (standards, samples and
reference parts) 91
5.1.1.2 Measurement errors 93
5.1.1.3 Mounting device 95
5.1.1.4 Measuring method, measuring procedure 95
5.1.2 Influencing quantities in the measurement process 96
5.1.2.1 Mother nature, environment 96
5.1.2.2 Person, examiner, operator 96
5.1.2.3 Measured object, inspected object 97
5.1.2.4 Evaluation methods 97
5.1.2.5 Short-term stability 97
5.1.2.6 Long-term stability (ongoing capability) 97
5.1.2.7 Reproducibility of measuring systems 98
5.2 Phases of measurement and inspection process capability 99
5.3 Standard uncertainties 101
5.3.1 Method A (Experimental
Dokumentdetermination) 101

INHALT 11
5.3.1.1 Consideration of a single influencing quantity 102

5.3.1.2 Consideration of several influencing quantities 102
5.3.2 Method B (use of prior information) 103
5.4 Combined standard uncertainty 104
5.5 Extended measurement uncertainty 105
5.6 Uncertainty budget 106
5.7 Proof of conformity 108
5.8 Proof of capability of the measurement process 109
6 Measurement uncertainty determination in

measurement process 110
6.1 Basic procedure 110
6.2 Practical determination of typical standard uncertainties 111
6.3 Influencing quantities in measuring system 112
6.3.1 MPE Maximum permissible error of the measuring system – uMPE 113
6.3.2 Display resolution – uRE 114
6.3.3 Calibration uncertainty of the standard – uCAL 115
6.3.4 Repeatability on the standard – uEVR 116
6.3.5 Systematic measurement error – uBI 116
6.3.6 Influence on linearity error in the scope of application – uLIN 117
6.3.6.1 Linearity from preliminary information (method B) 118
6.3.6.2 Linearity from test (method A) 119
6.3.6.2.1 Simple linearity analysis 120
6.3.6.2.2 Linearity testing with ANOVA [26] 121
6.3.7 Additional influencing quantities in measuring system – uMS.REST 122
6.3.8 Determination of the uncertainties according to the “measuring
system test” (MS test) 122
6.3.8.1 Test with one standard or reference part 123
6.3.8.2 Test with 2 standards 123
6.3.8.3 Test with 3 and more standards 124
6.4 Measurement process influencing quantities 125
6.4.1 Repeatability on the measured object – uEVO 125
6.4.2 Reproducibility of the operators – uAV 125
6.4.3 Interaction – uIA.i 126
6.4.4 Reproducibility of measuring systems – uGV 127
6.4.5 Stability of the measurement process – uSTAB (short-term stability) 127
6.4.6 Inhomogeneity of the measured object – uOBJ 128
6.4.7 Temperature – Dokument
uTEMP 130

12 INHALT
6.4.7.1 Considerations on the influence of temperature on the measure-

ment process 130
6.4.7.2 Evaluation of the situation 133
6.4.7.3 Methods to determine measurement uncertainty by temperature 134
6.4.8 Additional Measurement process influencing quantities – uMP.REST 135
6.4.9 Determining the uncertainties according to the “Test Measure-
ment Process” (Test MP) 136
6.5 Typical measurement uncertainty budget 137
6.6 Overview of typical measurement process models 139
6.7 Preselection of measuring systems 141
6.7.1 Motivation, requirements 141
6.7.2 Sources of information for determining important specifications of
measuring equipment 142
6.7.2.1 National and/or international standards 142
6.7.2.2 Guidelines 142
6.7.2.3 Manufacturer specifications 143
6.7.3 Characteristic values for the evaluation of the selection of
measuring/inspection equipment and auxiliary devices 143
6.7.4 Categories of measuring equipment and sources of information
of the specifications/characteristic values 145
7 Proof of capability of the measurement process

– in detail 146
7.1 Calculation of capability ratios 146
7.1.1 Capability ratio QMS for the measuring system 146
7.1.2 Capability ratio QMP for the measurement process 147
7.1.3 Capability ratios QMS and QMP with one-sided specification limits 148
7.1.3.1 Calculation of capability indices for one-sided specifications 149
7.1.3.2 Calculation of capability indices for one-sided specifications with
defined operating point 153
7.1.4 Minimum possible tolerance for measuring systems/measure-
ment processes 154
7.1.5 Capability of measurement processes and capability of
manufacturing processes 154
7.2 Evaluation of capability ratios 157
7.3 Documentation and reporting of proof of capability 159
7.3.1 Test report of the proof of capability 159
7.3.2 Documentation of Dokument
measurement and inspection
wurde bereitgestellt vom process capability 161

INHALT 13
7.4 Handling of unsuitable measuring systems/processes 162

7.4.1 Procedures for process optimization 163
7.4.2 Risk analysis and conditional approval 164
7.4.3 Reflection and, if necessary, extension of the limit values 165
7.4.4 Extension of the characteristic tolerances 165
7.4.5 Special strategies 165
7.4.5.1 Fine tolerance rule for measurement processes with small
tolerances 165
7.4.5.2 Reduction of the measurement uncertainty through multiple
measurement 168
8 Special measurement processes 170

8.1 Grading and pairing 170
8.2 Validation of measurement software 173
8.3 Insufficient sample sizes for MS and MP test 174
8.4 Consideration of the measurement uncertainty in the development 176
9 Proof of capability of attributive inspection processes 179

9.1 Risks of attributive inspection 180
9.2 Proof of capability for attributive inspection processes 181
9.2.1 Attributive inspection processes with discretized results 182
9.2.2 Attributive inspection processes with purely discrete results 183
9.3 Notes on the composition of a representative inspection lot 185
9.4 Notes on the composition of the inspection lot on the basis of
conditional probabilities 185
9.5 Possible methods for the evaluation of attributive inspection
processes 187
9.5.1 Methods for discretized characteristics 187
9.5.1.1 Method of signal detection 187
9.5.1.2 Analytical methods 191
9.5.2 Methods for discrete characteristics 193
9.5.2.1 Short method 193
9.5.2.2 Effectiveness 194
9.5.2.3 Bowker Test 196
9.5.2.4 Kappa method according to Cohen and Fleiss [28] 199
9.5.2.5 Concordance coefficient W according to Kendall [39; 40] 201


14 INHALT
10 Monitoring of ongoing capability 204

10.1 Methods for ongoing capability 205
10.2 General notes on planning, implementation and documentation 206
10.3 Application of a stability chart (control chart) 207
10.4 Consideration in the uncertainty budget 212
11 Index of formula symbols 213

12 Index of abbreviations 216
13 Downloads 217
14 References 218
15 Index 224
16 List of illustrations 229
17 List of tables 232


Standards and guidelines 15
1 Standards and guidelines

Relevant standards and guidelines for quality management require knowledge of the
measurement uncertainty or proof of the capability of the measuring system or meas-
urement process, often also called capability. Requirements for measurement and in-
spection processes are contained in the documents listed in Table 1-1 as examples.
Table 1-1: Objectives of selected technical standards, recommendations and guidelines for the evaluation of
inspection equipment
Objective International/national standards Industry Standards

and documents
Structure of QM • DIN EN ISO 9000 ff • VDA Volume 6.1
systems/inspection • DIN EN ISO 10012 • VDI/VDE 2600-1
process manage- • DIN EN ISO/IEC 17025 • VDA Volume ‘Special
ment • DIN 32937 Characteristics’
• IATF 16949 • VDA Volume 1
Determination of Measuring technology, general: • Industry association
measurement un- • DIN 1319 standards
certainty • ISO/IEC Guide 98-3 (GUM) • VDMA 8720
• DIN ISO 22514-7 • EA-4/02 M: 2013
Dimension metrology:
• Supplement 1 to
DIN EN ISO 14253-1
Determination of • DIN ISO 22514-7 • AIAG MSA
measuring system • Company standards
capability/measure-
ment process capa-
bility
Consideration of • DIN EN ISO 14253-1 • AIAG MSA
measurement un- • Company standards
certainty
VDA Volume 5 aims to combine the requirements and procedures of the existing stand-
ards and guidelines to gain a standardized and practical procedure for determining and
consideration of the extended measurement uncertainty. If necessary, the methods of
capability analysis (see MSA [1] and company standards) established in practice are inte-
grated. Appropriate answers are given to typical problems regarding the determination of
standard uncertainties as well as the extended measurement uncertainty Table 6-1.

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Qualitäts Management Center

im Verband der Automobilindustrie 5

3rd, revised edition, July 2021

Nur zur internen Verwendung für ZF Friedrichshafen AG bestimmt.

3rd, revised edition, July 2021

Verband der Automobilindustrie e. V.

Dokument wurde bereitgestellt vom

Nur zur internen Verwendung für ZF Friedrichshafen AG bestimmt.

Verband der Automobilindustrie e. V. (VDA)

Layout and printing:

Printed on chlorine-free bleachedDokument

Nur zur internen Verwendung für ZF Friedrichshafen AG bestimmt.

Non-binding VDA recommendation

If during the use of VDA recommendations, errors or the possibility of misinterpretation

Dokument wurde bereitgestellt vom

Nur zur internen Verwendung für ZF Friedrichshafen AG bestimmt.

Dokument wurde bereitgestellt vom

Nur zur internen Verwendung für ZF Friedrichshafen AG bestimmt.

The 3rd edition has been amended in the following aspects:

Nur zur internen Verwendung für ZF Friedrichshafen AG bestimmt.

It is necessary to comply with specified tolerances of individual parts and assemblies

Nur zur internen Verwendung für ZF Friedrichshafen AG bestimmt.

Dokument wurde bereitgestellt vom

Nur zur internen Verwendung für ZF Friedrichshafen AG bestimmt.

Dokument wurde bereitgestellt vom

Nur zur internen Verwendung für ZF Friedrichshafen AG bestimmt.

4 Inspection process management 34

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4.5.1 Inspection equipment management system 72

5 General procedure for measurement and inspection

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5.3.1.1 Consideration of a single influencing quantity 102

6 Measurement uncertainty determination in

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6.4.7.1 Considerations on the influence of temperature on the measure-

7 Proof of capability of the measurement process

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7.4 Handling of unsuitable measuring systems/processes 162

8 Special measurement processes 170

9 Proof of capability of attributive inspection processes 179

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Nur zur internen Verwendung für ZF Friedrichshafen AG bestimmt.

10 Monitoring of ongoing capability 204

11 Index of formula symbols  213

Dokument wurde bereitgestellt vom

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1 Standards and guidelines

Objective International/national standards Industry Standards

Nur zur internen Verwendung für ZF Friedrichshafen AG bestimmt.

Nur zur internen Verwendung für ZF Friedrichshafen AG bestimmt.

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4 Inspection process management 34

4.5.1 Inspection equipment management system 72

5.3.1.1 Consideration of a single influencing quantity 102

7.4 Handling of unsuitable measuring systems/processes 162

8 Special measurement processes 170

9 Proof of capability of attributive inspection processes 179

10 Monitoring of ongoing capability 204

11 Index of formula symbols 213