Professional Documents
Culture Documents
1
Topics
Case Study
2
Measurements Systems Analysis
Purpose:
Determine how much variability is due to the gage
or instrument
Isolate the components of variability of the
measurement system
Assess whether the instrument or gage is capable
3
Components of a Measurement System
Equipment or Gage
Type of Gage:
Attribute: go-no go, vision systems (part present or not present)
Variable: calipers, probe, tape measure, coordinate measurement machines, checking
fixture with inspection device
Discrimination of Measurement – General Rules:
At least 1/10 of tolerance (tol = 1 mm, measure to at least 0.1)
Or, at least 1/10 of 6*process standard deviation (6)
Operator & Operating Instructions
Part locating or orientation scheme
gage must be able to consistently locate the part being measured.
4
Gage R&R
6
Gage Capability Criteria
R
ˆ gage
d2
1
1
25
can discriminate
U C L=24.06
_
_
X=22.28
20
1
1 1
1
LC L=20.49
between units of
products
1 1
1 3 5 7 9 11 13 15 17 19
Sample
3 U C L=3.104
2
1
_
R=0.95 that operators are
0 LC L=0 consistent.
1 3 5 7 9 11 13 15 17 19
Sample
9
7
11
Gage and Measurement System Capability
Variation Decomposition
r m n
( x
k 1 i 1 j 1
kij x )2
total
2
rmn 1
r m n
x kij RX
x
k 1 i 1 j 1 ˆ reproducibility
rmn R d2
ˆ repeatability
d2
r R X x max x min ;
Use R chart for estimation
r: # of operators R k x max max(x1 , x 2, , x r )
R k 1
m: # of samples r x min min( x1 , x 2, , x r )
n: # of repeated measurements m
xkij :
R ki m m n
Rk i 1
m x ki x xij
i: sample index xk i 1
i 1 j1
R ki max j ( x kij ) min j ( x kij ) m mn
j: repeated measurement index
k: operator index
Gage and Measurement System Capability (Cont’s)
2total
2product 2total gage
2
2repeatability gage
2
2repeatability 2reproducibility 2product
gage
2
2reproducibility
Gage R&R for Attribute Variables
Delamination (printing)
14
Gage R&R for Attribute Variables
15
Gage R&R for Attribute Variables
Then:
Operator Repeatability n
Overall System Repeatability i 1
n
Next steps:
Identify best measurement system procedure
17
Gage R&R for Attribute Variables: Example
18
Gage R&R for Attribute Variables: Example
1 No cancer
2 Benign cancer
3 Possible malignancy
4 Malignancy
19
Gage R&R for Attribute Variables: Example
Results
Individual
Repeatability
Effectiveness
Doctor 1 93.3% 93.3%
Doctor 2 80.0% 93.3%
Doctor 3 40.0% 80.0%
Bore diameter
21
Problem Definition
22
Current State: Gage R&R results
23
Current State: Gage R&R results
Appraiser variation takes up 58% of tolerance width
Equipment variation takes up 69% of total variation
24
Current State: Cause and Effect Diagram
Cause-and-Effect Diagram
Measurements Material Personnel
Lack of training
25
Improvement alternatives
Internal calipers
26
Self centering bore gauge: Gage R&R results
27
Self centering bore gauge: Gage R&R results
Appraiser variation takes up 2.7% of tolerance width
Equipment variation takes up 5.2% of total variation
28
Results
Switch from Dial Caliper to Self Centering Bore Gage
29