Define

Control Measure
6

Improve Analyze

MSA
Gage Repeatability and
Reproducability
PROPRIETARY
 Gage R&R Objectives

• Used on measurement
systems with variable
data
• Meters, scales, calipers,
rulers, manager’s ratings,
etc.
• Can the measurement
system can see changes

8.5 10 7 • Can the measurement

system tell good parts
from bad

AUTOLIV-AOA/FW-TR/6-27-03/What is 6 Sigma - 2 PROPRIETARY

 Measurement System Variation

The
Theinstructor
instructorwill
willfire
fireone
oneshot
shotfrom
fromthe
the
catapult.
catapult. Write
Write down
downhowhowmany
many inches
inchesyou
you saw
saw
the
theball
ball go.
go. Try
Tryto
tobe
beaccurate
accurateto
towithin
within¼”.
¼”.

AUTOLIV-AOA/FW-TR/6-27-03/What is 6 Sigma - 3 PROPRIETARY

 Variation of the Catapult Observations

Observed Distance

Anderson-Darling Normality Test

A-Squared: 0.387
P-Value: 0.343

Mean
StDev
StDev
101.062 4.602
4.605
Variance 21.2097
Skewness -3.3E-01
Kurtosis -1.08856
N 15
94 98 102 106
Minimum 93.264
1st Quartile 97.942
Median 100.611
3rd Quartile 104.339
95% Conf idence Interv al f or Mu Maximum 107.569
95% Conf idence Interv al f or Mu
98.512 103.612
98 100 102 104 95% Conf idence Interv al f or Sigma
3.372 7.263
95% Conf idence Interv al f or Median
95% Conf idence Interv al f or Median
98.178 104.317

All
Allobservers
observerssaw
sawthe
thesame
sameevent.
event. Yet
Yetthere
thereisisvariation
variationinin
what
whatthey
theysaw.
saw. What
Whatisisthe
thesmallest
smallestchange
changeininthe
theprocess
process
you
youthink
thinkwewecan
candetect?
detect?
AUTOLIV-AOA/FW-TR/6-27-03/What is 6 Sigma - 4 PROPRIETARY
 Gage Repeatability and
Reproducibility
Repeatability
• How well one person, can repeat the same
measurement
• Sometimes called “test-retest error”
• If repeatability is poor, look at the measurement tool
itself
Reproducibility
• How well multiple persons can get the same answer
as each other
• If reproducibility is poor, look at training, standards,
and definitions

AUTOLIV-AOA/FW-TR/6-27-03/What is 6 Sigma - 5 PROPRIETARY

 Seeing Changes
I Chart for distance
115
3.0SL=113.6
Individual Value

105

X=100.9

95

-3.0SL=88.20
85
0 10 20 30
Observation Number

There
Therereally
reallyisisaashift
shiftin
inthe
thedata!
data!
Where
Whereisisit?it?
AUTOLIV-AOA/FW-TR/6-27-03/What is 6 Sigma - 6 PROPRIETARY
 Seeing Changes

• The total observed I Chart for distance

Standard Deviation is 115
3.0SL=113.6

4.23
• The Measurement

Individual Value
105

X=100.9

System supplies most of 95

the observed variation -3.0SL=88.20

85

• The real process shift is

re
0 10 20 30

he
Observation Number

d
ne
very difficult to extract

pe
ap
h
ift
Sh

AUTOLIV-AOA/FW-TR/6-27-03/What is 6 Sigma - 7 PROPRIETARY

 % Gage R&R

• The ratio of the measurement

system standard deviation to the
observed standard deviation
• Indicates how much of the
 ms
variation comes from the
%Gage R & R 
process and how much from the
gage  observed
• Changes in the process cannot
be seen if the measurement
standard deviation is not much
smaller than the observed
 ms   process
standard deviation 2 2
• The observed variation of a
process is the real process  observed 
variation mixed with the 2
measurement system variation

AUTOLIV-AOA/FW-TR/6-27-03/What is 6 Sigma - 8 PROPRIETARY

 Gage R&R Rule of Thumb
 ms
%Gage R & R 
 observed

Over .30,
Danger

.10 to .30,
Caution

Below .10,
OK

AUTOLIV-AOA/FW-TR/6-27-03/What is 6 Sigma - 9 PROPRIETARY

 A Typical GR&R Setup
10-15 Samples
are ‘Inspected’

By Two or
Three
‘Inspectors’

Each ‘Inspector’
Sees the Samples
Two or Three
Times.

AUTOLIV-AOA/FW-TR/6-27-03/What is 6 Sigma - 10 PROPRIETARY

 GR&R Applied to Call Center Tech
Ratings
‘Samples’ are recordings of call center Open
Open
technicians helping customers. CALLGRR.MTW.
CALLGRR.MTW.
Check the ratings for Operators 4 and 7.

Do the ratings
seem to be
consistent
between the first
and second ‘trial’?
Do the ratings
seem to be
consistent from
supervisor to
supervisor?

AUTOLIV-AOA/FW-TR/6-27-03/What is 6 Sigma - 11 PROPRIETARY

 GR&R Applied to Call Center
Tech Ratings msmt sys
observed
If we ‘improve’ our phone tech
response, can we detect it?

R&R has two components:

Repeatability is how
consistent a single
‘inspector’ is. If this factor
is big, YOU MAY NEED
NEW GAGES.
Reproducibility is
consistency between
various ‘inspectors’. If
this is big, BETTER
DEFINITIONS AND
TRAINING MAY HELP.
AUTOLIV-AOA/FW-TR/6-27-03/What is 6 Sigma - 12 PROPRIETARY
 GR&R Applied to Call
Center Tech Ratings
Another check:
How many times will
my measurement
system variation fit
within my process
variation? If less
than 4, measurement
system is inadequate.

AUTOLIV-AOA/FW-TR/6-27-03/What is 6 Sigma - 13 PROPRIETARY

 GR&R Applied to Call
Center Tech Ratings
Gage name:
Date of study:
Gage R&R (ANOVA) for rating Reported by:
Tolerance:
Upper and lower limits are
Misc:

Xbar Chart by superv isor set by measurement

superv isor*sample Interaction
supervis
10
9
1 2 3 10
9
repeatability.
repeatability
1
Sample Mean

8 8 2

Average
7 3.0SL=7.100 7
X=6.442 3
6 -3.0SL=5.783 6
5 5
4
3
4
3
Graph is variation of parts.
2 2
0 sample 1 2 3 4 5 6 7 8 9 10

1.5
R Chart by superv isor
1 2 3
We want the upper andisorlower
By superv
10

limits close together, and the

9
Sample Range

3.0SL=1.144 8
1.0 7

0.5
actual data to vary far beyond the
6
5
R=0.3500 4

0.0 measurement system limits.

-3.0SL=0.00E+00
3
2
0 supervisor 1 2 3

Components of Variation By sample

10
100
%Total Var 9
%Study Var 8
AUTOLIV-AOA/FW-TR/6-27-03/What is 6 Sigma - 14 PROPRIETARY 7
nt
 GR&R Applied to Call
Center Tech Ratings

Total R&R is made up of

Repeatability and
Reproducibility. These terms
should be much smaller than
Part-to-Part variation.

AUTOLIV-AOA/FW-TR/6-27-03/What is 6 Sigma - 15 PROPRIETARY

 GR&R Applied to Call
Center Tech Ratings Gage name:
Date of study:
Gage R&R (ANOVA) for rating Reported by:
Tolerance:
Misc:

Xbar Chart by superv isor superv isor*sample Interaction

10 1 2 3 10 supervisor
9 9 1
Sample Mean

8 8
2

Average
7 3.0SL=7.100 7
X=6.442 3
6 -3.0SL=5.783 6
5 5
4 4
3 3
2 2
0 sample 1 2 3 4 5 6 7 8 9 10

R Chart by superv isor By superv isor

1 2 3 10
1.5 9
Sample Range

3.0SL=1.144 8
1.0 7
6
0.5 5
R=0.3500 4
3
0.0 -3.0SL=0.00E+00 2
0 supervisor 1 2 3

Components of Variation By sample

100 10
%Total Var 9
%Study Var 8
7
Percent

6
50
5
4
3
0 2
Gage R&R Repeat Reprod Part-to-Part sample 1 2 3 4 5 6 7 8 9 10

AUTOLIV-AOA/FW-TR/6-27-03/What is 6 Sigma - 16 PROPRIETARY

 Fooling Mother Nature

 Gather process samples that

represent only part of your natural
process variation.
 Tweak your samples to create
additional variation.

AUTOLIV-AOA/FW-TR/6-27-03/What is 6 Sigma - 17 PROPRIETARY

 Precision to Tolerance
Tolerance = Upper Spec Limit – Lower Spec Limit

P/T Ratio
=
5.15*msys
Tolerance

Precision = 5.15 x  of Can we tell good

Measurement System parts from bad?
(99% of Total MS Variation)
AUTOLIV-AOA/FW-TR/6-27-03/What is 6 Sigma - 18 PROPRIETARY
 Ratio Rules: Telling Good from Bad
 Measurement System
P/T Ratio =
Tolerance

Over .30,
Danger

.10 to .30,
Caution

Below .10,
OK
AUTOLIV-AOA/FW-TR/6-27-03/What is 6 Sigma - 19 PROPRIETARY
 Precision to Tolerance
Go to CALLGRR.MTW, click
OPTIONS, and enter 6 in We get a new column, our
TOLERANCE. Call center P/T ratio.
operators cannot be better than
10, and those below 4 are
retrained or replaced, so 6 is our
process tolerance.

Can we
reliably tell
good
operators
from bad?

AUTOLIV-AOA/FW-TR/6-27-03/What is 6 Sigma - 20 PROPRIETARY

 Crimp Depth GR&R Example

A crimping process that crimps

the end of a generator housing
around an end disk needed to be
verified on the machine.
The drawing calls out a depth of
1.5 mm +/- .25mm.
The currant process uses a DVT
camera, rotates the part, and
Crimp
measures each crimp depth.
Depth
$3,000 in generators were
scrapped every week due to bad
crimp depths!

AUTOLIV-AOA/FW-TR/6-27-03/What is 6 Sigma - 21 PROPRIETARY

 Gage R&R on DVT System

Gage R&R
StdDev Study Var %Study Var %Tolerance
Source (SD) (5.15*SD) (%SV) (SV/Toler)

Total Gage R&R 3.86E-02 0.198774 50.65 39.75

Repeatability 2.06E-02 0.106311 27.09 21.26
Reproducibility 3.26E-02 0.167955 42.80 33.59
Appraiser 0.00E+00 0.000000 0.00 0.00
Appraiser*Part 3.26E-02 0.167955 42.80 33.59
Part-To-Part 6.57E-02 0.338339 86.22 67.67
Total Variation 7.62E-02 0.392408 100.00 78.48

Number of Distinct Categories = 2

AUTOLIV-AOA/FW-TR/6-27-03/What is 6 Sigma - 22 PROPRIETARY

 Improvement #1

Replaced the 100% DVT

measurement of crimps
with 100% LDT stroke
measurement.
Added Correlation Data
Collection to correlate
machine values with
actual values using Depth
Gage.

AUTOLIV-AOA/FW-TR/6-27-03/What is 6 Sigma - 23 PROPRIETARY

 Gage R&R on Depth Gage

Gage R&R
StdDev Study Var %Study Var %Tolerance
Source (SD) (5.15*SD) (%SV) (SV/Toler)

Total Gage R&R 1.89E-02 0.097463 24.74 19.49

Repeatability 1.04E-02 0.053465 13.57 10.69
Reproducibility 1.58E-02 0.081489 20.69 16.30
Appraiser 8.53E-03 0.043928 11.15 8.79
Appraiser*Part 1.33E-02 0.068635 17.42 13.73
Part-To-Part 7.41E-02 0.381668 96.89 76.33
Total Variation 7.65E-02 0.393916 100.00 78.78

Number of Distinct Categories = 6

AUTOLIV-AOA/FW-TR/6-27-03/What is 6 Sigma - 24 PROPRIETARY

 Improvement #2

A large amount of within part

variation is still being caused
from measuring off
deformed OD as a datum.
Replaced Depth Gage with
Snap Gage.

AUTOLIV-AOA/FW-TR/6-27-03/What is 6 Sigma - 25 PROPRIETARY

 Gage R&R on Snap Gage

Gage R&R
StdDev Study Var %Study Var %Tolerance
Source (SD) (5.15*SD) (%SV) (SV/Toler)

Total Gage R&R 8.93E-03 0.045982 19.37 9.20

Repeatability 8.29E-03 0.042686 17.98 8.54
Reproducibility 3.32E-03 0.017096 7.20 3.42
Appraiser 3.32E-03 0.017096 7.20 3.42
Part-To-Part 4.52E-02 0.232913 98.11 46.58
Total Variation 4.61E-02 0.237408 100.00 47.48

Number of Distinct Categories = 7

AUTOLIV-AOA/FW-TR/6-27-03/What is 6 Sigma - 26 PROPRIETARY

 Gage R&R Comparisons

DVT

Depth Gage

Snap Gage

AUTOLIV-AOA/FW-TR/6-27-03/What is 6 Sigma - 27 PROPRIETARY

 Run a Gage R&R on
CALLGRR.MTW, columns C7-C10.

 Given this measurement system, can the Production

Manager detect changes in the resistor making
process?
 Given this measurement system, can they reliably
tell good parts from bad ones?
 Bonus question: Is the resistor production process
capable?

AUTOLIV-AOA/FW-TR/6-27-03/What is 6 Sigma - 28 PROPRIETARY

 Licorice
Minitab GRR form is
Exercise
Each team has received the following: in GRRFORM.MTW
2 Process Ropes (Red Licorice)10 straws,Scissors, Marker, Ruler, Calipers,

Procedure:
1. Cut licorice rope into (30) approximately 2” sections (3 operators/ 10 pieces each) without using any
measurement method. Select 10 pieces and number them 1-10.
2. Cut straws into (30) 2.5CM sections (3 operators/ 10 pieces each) use the ruler to mark straws for cutting.
Select 10 pieces and number them 1-10 (Use masking tape to secure number).
3. Perform a Gage R&R Study on the cut length (10 pieces, 3 operators & 3 repetitions) for each of the
following parts (Record values in mm):
 Licorice Rope Parts measured with 0.1CM Graduated Ruler
 Straw Parts measured with Calipers
4. Data Entry for Licorice Rope
 Enter the data into MINITAB (Parts/ Operators/ Rope Measurements) Enter the number of the part in
C1. Enter the inspector’s name in C2. Enter the rope measurements in C3.
5. Data Entry for Straw
 Enter the number of the part in C4. Enter the inspector’s name in C5. Enter the straw measurements
in C6.
6. Analyze Results and prepare to discuss.
Note: Parts should be measured in random order and the operator measuring the part should not record the
measurement or know the part number.

Exercise: If your Gage R&R levels are not all satisfactory, develop a list of
suggestions to improve them.
AUTOLIV-AOA/FW-TR/6-27-03/What is 6 Sigma - 29 PROPRIETARY
 Summary
 IoKappa tests the agreement of judges in assigning
things to categories.
 Gage Repeatability and Reproducibility Studies
apply to things that are measured.
 Gage R&R tells whether we can detect changes in
the process. Less than 10% is good, 10-30% is
marginal. Does not test calibration.
 P/T ratio tells whether we can tell good items from
bad. Less than 10% is good, 10-30% is marginal.
 No measurements have meaning apart from their
measurement systems.

AUTOLIV-AOA/FW-TR/6-27-03/What is 6 Sigma - 30 PROPRIETARY

 Appendix

AUTOLIV-AOA/FW-TR/6-27-03/What is 6 Sigma - 31 PROPRIETARY

 How to Make Your Own GRR Form

Use the “Simple Set of

Numbers” generator to
make ID tags for for
PARTS, OPERATORS,
TRIALS, and RESULTS.

AUTOLIV-AOA/FW-TR/6-27-03/What is 6 Sigma - 32 PROPRIETARY