MEASUREMENT SYSTEMS ANALYSIS Reference Manual Fourth E Fst Elon, October 1990 + Seoond Eton, February 1885; Second Pring, June 1998 “Tid Eciton, March 2002, Second retin, May 2002; Fourh Eton, Jone 2010 Copyight © 1990, 81895, € 3002, © 2010 Chysar Group LLC, Ford Motor Company, General Motors Carporation Teed ore eosuett SsTABLE OF CONTENTS MSA #* Edition Quick Guide nm ‘TABLE OF CONTENI CHAPTER I General Measurement System Guidelines. Section Inaton, Purpose and Teminology Introduction Purpose. Terminology ono — Section B The Measurement Process. “Meacurement Systems. ‘The Effects of Measurement System Variability Section C Measurement Strategy and Planning. Section D Measurement Source Development. Gage Source Selection Process. Section E Measurement Issues Seotion F Measurement Uncertainty... Section G Measurement Problem Analysis CHAPTER II General Concepts for Assessing Measurement Systems. ‘Section A Background, Section B Selecting/Developing Test Procedures Section C Preparation for a Measurement System Study. Section D Analysis ofthe Results. CHAPTER IIL Recommended Practices for Replicable Measurement Systems Section A Example Test Procedures, Section B Variable Measurement System Study Guidelines Guidelines for Determining Stability Guidelines for Determining Bias . ~ lndependent Sample Method. Guidelines for Determining Bias ~ Control Chart Method. Guidelines for Determining Linearity Guidelines for Determining Repeat Range Meth... Average and Range Method “Analysis of Variance (ANOVA) Method. Section C Attribute Measurement Systems Study. isk Analysis Methods. Signal Detection Approach ‘Analytic Method CHAPTER IV Other Measurement Concepts and Practices sor Section A Practices for Non-Replicable Measurement Systems Destructive measurement systems... ‘Systems where the part changes on uselest Section B Stability Studies Section C Variability Studi Section D Recognizing the Effect of Excessive Within-Part Variation Section E Average and Range Method — Additional Treatment. Seotion F Gage Performance Curve Section G Reducing Variation Through Multiple Readings. Section H Pooled Standard Deviation Approach to GRR APPENDICES... . ty and ReproducibilityAppendix A... ‘Analysis of Variance Concepi.. Appendix B, Impact of Gon te Copii inde oe: Formulas: Analysis: Graphical Analysis. Appendix Cones Appendix D. ‘Gage R Study. . - Appendix B..m Alterate PY Calculation Using Error Corection Term Appendix F. PISMOEA. Error Model Glossary. Reference Lis ‘Sample Forms. IndeList of Tables Table Lt, Contl Posophy and Drving Inlorost, ‘Table ILD 1: GRR Criteria Table ILB 1: Bias Study Dat Table IIFB 2: Bias Study — Anaiysis of Bias Study Table ll-B 3: Bias Study — Analysis of Stability Study for Bias Table II-B 4: Lineaity Study Data. . Table II-B 5: Linearity Study — Intermediate Results Table II-B 6: Gage Study (Range Mathod).. Table II-B 6a: Gage Repeatabilty and Reproducilliy Data Collection Sheet... rns-nnnnnn 108: Table II-B 7: ANOVA Table. oo . Table lB 8: ANOVA Analysis % Variation & Contribution. ‘Table iB 8: Comparison of ANOVA and Average and Range Method Table ILB 10: GRR ANOVA Method Report Table II-C 4: Attribute Study Data Set... Table II-© 2: Cross tabulation Study Results. ‘Table iI-C 3: Kappa Summary... Table Il-C 4: Comparisons of Appraisers to Reference. Table l-C 5: Study Effectiveness Table... Table ll-C 6: Example Effectiveness Criteria Guidelines. Table i-C 7: Study Effectiveness Summary. Table l-C.8: Table II-C 1 sorted by Ref Val. Table 1V-A 4: Methods Based on Type of Measurement System. Table IV-H 1: Pooled Standard Deviation Analysis Data Set Table A 1: Estimate of Variance Components - Table A 2: 6 Sigma Spread, Table A 3: Analysis of Variance (ANOVA). Table A’: Tabulated ANOVA Results Table A 5: Tabulated ANOVA Results ‘Table B 1: Comparison of Observed to Actual Cp. Tobie 1: dy Table . Table +: Exampas ofthe PISMOEA Model aiList of Figures ® Figure tA 1: Example of a Teaceabilty Chain for a Length Measurement... Figure £8 1: Measurement System Variability Cause and Effect Diagram. Figure LE 2: Discrimination. Figure LE 3: Impact of Number of Distinct Categories (nde) ofthe Process Distribution on Control and ‘Analysis Activities ... AT ' Figure IE 4: Process Control Charts 49 50 Figure HE §: Characteristics of the Measurement Process Vatiaion ......snsnssnsnnnnnon Figure LE 6; Relationships between Bat and Repaatabity. a nnn 62 Figure 11-8 4: Contsol Chart Analysis for Stability . 86 Figure II-B 2: Bias Study — Histogram of Bias Study 31 "100 Figure III-B 3: Linearity Study ~ Graphical Analysis, Figure Il-8 4: Average Chart — “Stacked” Figure ll-8 5: Average Chart — “Unstacked" Figure ll-8 6: Renge Chart ~ “Stacked" Figur II-B 7: Range Chart — "Unstacked Figure iI-B 8: Run Chart by Part : Figure lll-B 8: Scatter Plot. Figure II-B 10: Whiskers Chart. Figure IB 11: Error Charts. Figure II-B 12: Normalized Histogram, Figure II-B 13: X-Y Plot of Averages by Size Figure 11-8 14: Comparison X-Y Plots... Figure II-B 15: Completed GR&R Data Colection Sheet. Figure 8 18: Gape Repeatabity end Feproducblty opr, Figure II-B 18: Residual Plot Figure IIl-C 1: Example Process with Pp = Ppk = 0.50. Figure ll-G 2: The “Gray” Areas Associated with the Measurement System. Figure li-C 3: Example Process with Fp = Ppk = 4.33. Figure lI-C 4: Attribute Gage Performance Curve Plotted on Normal Probability Paper Figure IIL 5, Altibute Gage Performance Curve Figure 1V-E 4: Measurement Evaluation Control Chart (X & R)- 1 Figure 1V-E 2: Measurement Evaluation Control Chart (X & R)-2. Figure IV-E 3: Altemate Computations for Evaluating a Measurement Process (Part 1 of 2) Figure IV-E 4: Altemate Computations for Evaluating a Measurement Process (Part 2 of 2). Figure IVF 1: Gage Performance Curve Without Errer.. Figure IV-F 2: Gage Performance Curve Example. Figure 1V-F 3: Gage Performance Curve Piotied on Normal Probability Paper Figure v4 1: Pooled Standard Daviaton Study Graphical Anahi Figure 1V-H 2: Dot diagram of h values. . Figure IV-H 3: Dot diagram of k values. Figure B 1: Observed vs. Actual Cp (process based).. Figure B 2: Observed vs. Actual Cp (tolerance based)Chaptert General Messurement System Guidelines CHAPTER I General Measurement System Guidelines(Chapter {Section A Totrodaction, Purpose and Terminology e(Chapter I~ Section A Introduction, Purpose and Terminology , SectionA Introduction, Purpose and Terminology Introduction : Measurement data are used more often and in more ways than ever before. For instance, the decision to adjust a manufacturing process is now commonly based on measurement data. The data, or some statistic calculated from them, are compared with statistical control limits for the process, and if the comparison indicates that the process is out of statistical control, then an adjustment of some kind is made. Otherwise, the process is allowed to run without adjustment, Another use of measurement data is to determine if a significant relationship exists between two or more variables. For example, it may be suspected that a critical dimension on a molded plastic partis elated to the temperature of the feed material. That possible relationship could be studied by using a statistical procedure called regression analysis to compare ‘measurements of the critical dimension with measurements of the temperature of the feed material. Studies that explore such relationships are examples of what Dr. W. E. Deming called analytic studies. In general, an analytic study is one that increases knowledge about the system of causes that affect the process. Analytic studies are among the most important uses of measurement data because they lead ultimately to better understanding of processes. ) ‘The benefit of using a data-based procedure is largely determined by the cuality ofthe measurement data used. Ifthe data quality i low, the Benefit of the procedure i likely tobe low. Similarly, ifthe quality of the datas high, the benefit key fo be high also To ensure that the benefit derived from using measurement data is great enough to warrant the cost of obtaining it, atention needs to be focused on the quality of the data ———————_ The quality of measurement data is defined by the statistical properties of Quality of multiple measurements obtained from a measurement system operating under stable conditions. For instance, suppose that a measurement system, ata a certain characteristic. If the measurements are all “close” to the master value for the characteristic, then the quality of the data is said to be “high”. Sithilariy, if some, or all, of the measurements are “Yar avvay” from the ‘master value, then the quality of the data is said to be “low”. ‘The statistical properties most commonly used to characterize the quality of data are the bias and variance of the measurement system. The property called bias refers to the location of the data relative to a reference (master) value, and the property called variance refers to the spread of the data, ‘One of the most common reasons for fow-quality data is too much variation Much of the variation in a set of measurements may be due to the interaction between the measurement system and its environment. For instance, aChapter ~ Section A Tatroduction, Pupose and Terminology Purpose Terminology ‘measurement system used to measure the volume of liquid in a tank may be sensitive to the ambient temperature of the environment in which it is used. In that case, variation in the data may be due either to changes in the volume or to changes in the ambient temperature. That makes interpreting the data ‘more difficult and the measurement system, therefore, less desirable. If the interaction generates too much variation, then the quality of the data ‘may be so low that the data are not useful. For example, a measurement system with a large amount of variation may not be appropriate for use in analyzing a manufacturing process because the measurement system's variation may mask the variation in the manufacturing process. Much of the work of managing a measurement system is directed at monitoring and