MASTERCRAFT ENGINEERS PVT. LTD.

MOULDING DIVISION
BANGALORE- 560008.

Procedure for MSA (Measurement System Analysis)

Purpose
Guidelines for assessing the quality of measurement system.

Quality of measurement data.

This is defined as the statistical properties of the measurements obtained
from a measurement system operating under stable conditions.
The statistical properties connected with the data are Bias & Variance.
 Bias refers location & Variance refers to spread of data.

Statistical Properties of Measurement system.

The statistical properties of the system is bias and variance.
Quality of the system is determined by these statistical properties.
However small the bias and variance of the measuring equipment is, it may
be unable to do a good job of discriminating good and bad products
because of the additional sources of variation introduced by other elements
of the system.
Hence acceptable method of measuring them are required.

Sources of variation
System is impacted due to random and systematic sources of variation.
The sources of variation are due to common and special causes. To control
the system variation, identify the potential sources of variation and
eliminate or monitor these sources of variation.

The six essential elements of a measuring system that effect the

system are
S Standard.
W Work piece
I Instrument
P Person / Procedure.
E Environment.

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 MASTERCRAFT ENGINEERS PVT. LTD.
MOULDING DIVISION
BANGALORE- 560008.

Cause for variation

Standard : Calibration, Thermal expansion, Elasticity,
Work piece: Mass, Cleanliness, Burr, Geometry,
Instrument: Calibration, Bias, Linearity, Stability, Repeatability,
reproducibility, Robust, Contact geometry,
Person: Training, Skill, Experience, attitude, Understanding,
Physical / Educational limitation,
Environment: Light, Temperature, Air pollution, Noise pollution,
Vibration

Effect of above variations: Measurement system Variability.

Measurement system errors can be classified into 5 categories.

 BIAS,
 Repeatability,
 Reproducibility,
 Stability &
 Linearity
MSA should be carried out for BIAS, Repeatability, Reproducibility, Stability
& Linearity.

Number of Distinct Categories : If the measuring equipment can have /

make either 5 or above distinct categories within the tolerance of the item /
characteristic being measured, such equipment is suitable for
measurement.

The AIAG’s MSA manual is referred to for all the MSA studies.

Procedure followed for Bias Study

Obtain sample and establish the reference value.

Measure the sample n > 10 times.
Plot histogram & Compute the average of the n readings.
Bias = observed average measurement – reference value
For acceptance of Bias, use the mathematical method shown in reference
manual on MSA.

Procedure for Stability Study.

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 MASTERCRAFT ENGINEERS PVT. LTD.
MOULDING DIVISION
BANGALORE- 560008.

Select the reference value.

Measure the master sample 3 to 5 times on periodic basis.
Plot the X & R chart.
Establish the control limits and evaluate the out of control situation using
control chart analysis.
Procedure followed for Repeatability and Reproducibility Study
Repeatability is within system variation. Reproducibility is between
appraiser variation.
The Average and Range method is a mathematical method, which will
determine both repeatability and reproducibility for a measurement system.
This method will allow the measurement system to be decomposed in to
two separate components, repeatability and reproducibility.
If repeatability is large compared to reproducibility the reason may be:
 The gauge instrument needs maintenance.
 The gauge should be redesigned to be more rigid.
 The clamping or location for gauging needs to be improved.
 There is excessive with in part variation
If reproducibility is large compared to repeatability, then possible causes
could be:
 The operator needs to be better trained in how to use and read the
gauge instrument.
 Calibration on the gauge dial are not clear
 A fixture of some sort may be needed to help operator use the
gauge more consistently.

1) Refer the operators as A, B, C and number the parts as 1 through 10

so that the numbers are not visible to the operator.
(Note: The ten parts should be randomly selected across a full range
of the process. It is important that the parts, as much as possible, be
representative of the total process (variation))
2) Use a calibrated gauge.

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 MASTERCRAFT ENGINEERS PVT. LTD.
MOULDING DIVISION
BANGALORE- 560008.

3) Let operator A measure 10 parts in a random order and have another

observer enter the result in the format. Let operators B and C
measure the same 10 parts without seeing each other’s readings,
and then enter the results in respectively in the rows identified for
them in the format.
4) Repeat the cycle using a different random order of measurement.
And enter data in respective rows. If three trials needed, repeat the
cycle.
5) An alternative method may be used if the operators are on different
shifts. Let operator A measure all 10 parts and enter the readings in
row 1.Thenhave operator A repeat the reading in a different order and
enter the results in row 2 and 3. Do the same with operator B and C
on the other shifts.
6) Use the MSA manual and calculate the different values.

Analysis of Results:

If the analysis based on percent of tolerance is preferred instead of

percent of process variation, then the gauge repeatability and
reproducibility report form can be modified so that the various ratios
in the form represents % of tolerance instead of % of process
variation.

Guidelines for acceptance of gauge repeatability and reproducibility

(%R&R) using both approaches described above are:
 Under 10% error ---- Gauge system O.K.
 10% to 30% error ---- May be acceptable based upon importance of
application, cost of gauge, cost of repairs, etc.
Justification has to be given.
 Over 30 % error ---- Gauge system needs improvement, Make
every effort to identify the problems and have
them corrected.