MSA (Measurement Systems Analysis)

MSA (Measurement Systems Analysis)
MSA
(Measurement Systems
Analysis)
PHC Manufacturing Pvt Ltd.

Summary
 Quality System requirements.
 Definition of a Measurement system.
 Elements of Measurement Systems
 Why Measurement System analysis?
 Basic concepts related to a measurement system.
 Flow Diagram - Measurement System analysis.
 Instrument Capability - Cg & Cgk Study.
 Outline procedure for performing a Gage Study (Measurement Systems
Analysis)
 Normal Study r & R .
 Short Study r & R.
 Attribute r & R Study(Long +Short).

Quality System Requirements
4.10.1.1 Acceptance Criteria For Attribute Characteristics:

For Attribute Data Sampling Plans , once a defect if found 100% inspection should
be implemented.
4.10.2 Receiving Inspection And Testing
4.10.2.1
The incoming product is not required to be used or processed until it has been
inspected or other wiser verified as conforming to specified requirements which will
be in accordance to Quality Plan(Control Plan) and / or documented procedures.
4.10.2.2
In determining the amount and nature of receiving inspection consideration shall be
given to amount of control exercised at the subcontractor’ premises and the
recorded evidence of the conformance provided.
4.10.2.3
Incase incoming product is released for urgent production the same is required to be
identified and recorded to permit immediate recall and replacement in case of non-
conformity.

4.10.2.4
Supplier’s Incoming Quality System shall use the following methods:

Receipt evaluation of statistical data by the supplier.
Receiving inspection and/or testing
Second or third party assessments or audits of sub-contractor sites when coupled
with records of acceptable quality performance.
Part evaluation be accredited laboratories.
4.10.3 In Process Inspection And Testing:

Process Inspection is dictated by Procedures and Control Plans.
4.10.4 Final Inspection and Testing:

The final Inspection should verify that all the receiving an din process inspections
have been performed so that no non-conforming product can be shipped.


4.10.6 Laboratory Quality Systems:
The requirements of QS-9000 include some elements form ISO / IEC Guide 25 , plus
other unique additions form the industry.
4.10.6.2 Laboratory Personnel:

The personnel working in the laboratory needs to be appropriately qualified with
include theoretical and recent practical experience.
4.10.6.3 Laboratory Product identification and Testing:

There must be a procedure for traceability of items in the lab which include receipt
,identification , handling , protection and retention or disposal of test samples.
Items shall be retained until final data is complete through the life of the item in
the laboratory enabling traceablity from final data to raw data.
4.10.6.4 Laboratory Process Control:

Requirements for environmental conditions shall be established and maintained as
appropriate to the technical activities concerned.

4.10.6.5 Laboratory Testing And Calibration Methods:

Any testing done in the laboratory must meet the needs of
the customer ad be traceable to a customer standard.
4.10.6.6 Laboratory Statistical to Method:

Appropriate Statistical techniques should be applied to verification
activities whose deliverables are data.
4.10.6 Accredited Laboratories:

Outside Lab used should be accredited and in house lab will be audited by
the registrar.
4.11.4 Measurement Systems Analysis

Appropriate Statistical Studies shall be conducted to analyze the variation
present in the results of each type of measuring and test equipment. This
Requirement shall apply to measurement systems referenced in the Control
Plan. The Analytical methods and acceptance criteria used should conform to
those MSA Manual or be approved by the customer needs.

Definition Of A Measurement System.
It is a collection operations,procedures,measuring
equipments,software ,personnel etc. to assign
numbers to material things to represent the
relations among them w.r.t particular properties.
The process of assigning the numbers is

defined as the measurement process and the
value assigned is defined as measurement value

Elements Of A Measurement
System
 Man
 Machine
 Method
 Job
 Environment

Why is there a need for MSA?

• Provides a criterion to accept new measuring equipment.
•Provides a comparison of one measuring device against

another.
• Provides a basis for gauge suspected of being deficient.
•Provides a criterion for measuring an equipment before and

after repair.
•It is required for calculating process variation in a

component and the acceptability Level for a production
process.

Calibration Vs MSA
Calibration is the process of validating & adjusting the

Performance of a Gage w.r.t to a National Standard which
inturn is validated & adjusted w.r.t an International Standard.
MSA is the process of evaluating the performance of a

Gage considering all the elements of variation in a measurement
system (viz. Man ,Machine , Method , Job &
Environment).Thus MSA helps us in understanding the Average
Production Process more practically and accordingly set
reasonable process limits to get the desired Process Capability.
Calibration Thus is a prerequisite before MSA !!!

Possible Sources of Process Variation

Observed Process Variation
Actual Process Variation Measurement

Variation
Long-term Short-term Variation Variation due Variation due

Process Variation Process Variation w/i sample to gage to operators
Repeatability Calibration Stability Linearity
To address actual process variability, the variation due to

the measurement system must first be identified and
separated from that of the process
We will look at “repeatability” and “reproducibility” as

primary contributors to measurement error

Basic Model
2 2 2
 Total  Product  Measurement System
The Total Variation is equal to the real product

variation plus the variation due to the
measurement system

Results of Simulations 15
LSL USL
Frequency
10
Actual process
variation - No 5
measurement error
0
30 40 50 60 70 80 90 100 110
Process
15
LSL USL
10
Observed process
Frequency
variation - 5
With measurement
error 0
30 40 50 60 70 80 90 100 110
Observ ed

Sources of Variation
Product Variability
(Actual variability)
Measurement
Variability
Total Variability
(Observed
variability)

Types of Measurement System Variations.
 Bias (Accuracy)
 Repeatability(Precision)
 Reproducibility(Precision)
 Linearity(Accuracy & Precision)
 Stability
Bias(Accuracy)
Instrument accuracy is the difference between the observed
average value of measurements and the master or “true” value
The master value is an accepted, traceable reference standard
(e.g., NIST)
Master
Value
Bias
Mean
Bias
Average of measurements are different by a fixed amount. Bias
effects include:
• Operator bias - different operators get detectable different
averages for the same thing
• Instrument bias - different instruments get detectable
different averages for the same thing, etc.
Instrument 1 Master Instrument 2

Bias Value Bias
Instrument 1 Instrument 2
(More Accurate)
(Less Accurate)
Mean Mean
Precision
 Total variation in the measurement
system
 Measure of natural variation of repeated
measurements.It includes repeatability ,
linearity and reproducibility.
 Repeatability and Reproducibility
 2MS   2rpt   2rpd

Precision: Repeatability
 rpt
 The inherent variability of the measurement
system
 Variation that occurs when repeated

measurements are made of the same variable
under absolutely identical conditions
– Same operator
– Same set-up
– Same units
– Same environmental conditions
– Short-term

Repeatability
The variation between successive measurements of the
same part, same characteristic, by the same person
using the same instrument.
Master
Value
Poor
Good Repeatability
Repeatability
Mean Mean
Precision: Reproducibility
 rpd
 The variation that results when different
conditions are used to make the measurements
– Different operators
– Different set-ups
– Different test units
– Different environmental conditions
 Estimated by the standard deviation of the
averages of measurements from different
measurement conditions
 Here the scope of Reproducibility is limited to
different operators only
Reproducibility
The difference in the average of the measurements made by different
persons using the same instrument when measuring the identical
characteristic on the same part.
Master Poor
Value Reproducibility
Good
Reproducibility
Operator 1 Operator 2 Operator 3 Operator 1 Operator 2 Operator 3

Linearity
A measure of the difference in accuracy or precision
over the operating range of instrument capability
Gage 1: Gage 2:
Linearity is an issue here Linearity is not an issue
here
Accuracy Accuracy
0
0
Measurement Units Measurement Units

Stability
A measure of variation obtained with a
measurement system using
- Same operators
– Single characteristic
– Same test units
– But Different environmental conditions (i.e

over an extended period of time)
Stability
Evaluation of the difference in accuracy or
precision over extended time period
Master Master
Value Value
Good Poor
Stability Stability Time 1
Time 1
Time 2 Time 2
Time 3
Time 3

Flow – Diagram MSA
Take the printout of the word file

Instrument Capability(Cg &Cgk Study)
• When to Use
 All new measuring Equipments
 All measuring Equipments after repair
 All Modified measuring equipments

Procedure For Inst. Capability Study

 The repeated sample should be a calibration std.,an
appropriate part with best qlty.
 The part should be removed and replaced between
each measurement.
 The part should have a consistent orientation
throughout the study.
 Take min. 50 measurements using the same part ,cal
X Bar And Std . Deviation(S inst)
 Then calculate Cg and Cgk.
 The minimum acceptable criterion is Cg and Cgk =1.33

Instrument Capability & Process Capability.
Cg is
Process variation
compared
with20%
Cp
6-Sigma Process
Instrument variation
6 Sigma
Inst
Calculations Cg & Cgk
• Cg=0.2 X Std. Dev(Process)/ Std. Dev (Inst)

And
Instrument Capability Index ,Cgk
• Cgk= (0.1 X 6 Std. Dev(Proc) – Bias)/3 Std. Dev(Inst)
Note: If the measurement system is used for other

purposes than process control or Cp is unknown or
Cpk<1 then the replace 6 Sigma (Proc)with Total Spec Tol

Normal Study – r & R

Guidelines for A Measurement System study
• The sample parts must be selected from the process and

should represent its entire operating range
• There should be clear identification on the sample parts
• All measurements must be performed in one sequence which
means no delays.
• The operators taking the readings should measure the samples
without seeing each others records and (if possible)an observer
should record the readings.
• The instrument must have a discrimination that allows at least
one – tenth of the expected process variation.

Calculations – r &R
Take the printout of the X-Cel Sheet

Gauge Acceptance Criteria :
• r&R% <10 :Very Good
• r&R% betn 10-30 :May be acceptable based

on Application,Cost of
Repair,Cost of device
etc.
•r&R% <30 :Not Acceptable

(Improvement needed)

Measurement System Evaluation
If repeatability is large compared to reproducibility, the reason

may be:
The gage instrument needs maintenance.
The gage should be redesigned to be more rigid.
The clamping or location for gauging needs to be improved.
There is excessive within part variation.
If reproducibility is large compared to repeatability then possible
cause could be:
The operator needs to be better trained in how to use and read
the gage instrument.
Calibration on the gage dial are not clear.
A fixture of some sort may be needed to help operator use the
gage more consistently.

Short Study – r & R
•Two operators measuring a same set of samples which are selected at

random and have different values
•The absolute difference in the measurements of the two operators is
calculated and summated and averaged.
This gives the RBAR.
•Therefore r &R=5.15 (RBAR)/d2 * . Calculate the r & R% and it is
should be <10.
•Otherwise there is a need for Normal Study – r & R
•Thus the short study as a quicker method for determining
acceptance of a measurement system.
•Also it enables us to determine the frequency of
Normal Study – r & R.

Attribute Gage-Short Study

Features
•An attribute Gage compares each part to a specific set

of limits and accepts or rejects the part.Thus such gages
cannot indicate how good or bad part is but only that the
part is accepted or rejected.
•The Gage is acceptable if all the measurement decisions

agree.If any of the decisions are not agreeing in that case
we need to improve and re-valuate the gage.

Attribute Gage - Long Study
Concept Of the Study:
The concept of the Gage Performance Curve is used for Developing a

Gage Study, which is used to assess the amount of Repeatability and
the bias of the Attribute Gage.
Application:
1. The Study can be done for both Single and Double Limit Gages.
2. For Double Limit Gages only one limit needs to be examined (Here
lets assume the Lower side ).


Procedure:
I) Sample Selection:
1. It is required that the reference value is known for each part used in
the study.
2. Eight parts are selected from nearly equidistant intervals as practical
3. These eight parts must be run through the Gage , m=20 times and
the number of accepts(a)recorded.
4. For the total study , the smallest part must have a value a=0 and the
six other parts , 1<=a<=19 and the largest part must have a valve a=20.
5. If these Criteria are not satisfied more parts with known reference
valves(Xp) must be run through the Gage and the conditions met.
[Contd.]

II)Actual Study:
1.Reference values for each of the selected samples should be known.
2.Evaluate the samples a number of times(m) by running through
the Gage and record the total number of accepts(a)for each part
3.Statisfy the data collection criteria, and calculate the
probablities of acceptance for each part using the following
Equations.
P'a = (a+0.5)/m if a/m<0.5,a0
P'a=(a-0.5)/m if a/m>0.5,a20
P'a=0.5 if a/m=0.5
4.Once the P'a has been calculated for each Xt, Develop the
gage Performance Curve by generating aline of best fit.

5. The Bias is equal to the lower limit minus the reference value
measurement that corresponds to P'a =0.5
Bias +Lower Limit - Xt( at P'a=0.5)
Determine if the bias is significantly different from zero by usinf the

following statistical formula.
T=31.3*Bias /Repeatability
If this calculated value is greater than 2.093 , then the bias is
significantly different from zero.
6. Determine Repeatability by finding the differences of the

refernece value measurements corresponding P'a =0.995 and P'a
=0.005 and dividing by an adjustment factor of 1.08.
Repeatability =[Xt(at P'a =0.995) - Xt(at P'a = 0.005)]/1.08

Measurement Error
Effect on Capability Indices
The higher the measurement error

the more dramatic the impact on
your ability to understand the true
process capability!

MSA (Measurement Systems Analysis)

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MSA (Measurement Systems Analysis)

PHC Manufacturing Pvt Ltd.

PHC Manufacturing Pvt Ltd.

Quality System Requirements

4.10.1.1 Acceptance Criteria For Attribute Characteristics:

PHC Manufacturing Pvt Ltd.

Quality System Requirements

Supplier’s Incoming Quality System shall use the following methods:

4.10.3 In Process Inspection And Testing:

4.10.4 Final Inspection and Testing:

PHC Manufacturing Pvt Ltd.

Quality System Requirements

4.10.6.2 Laboratory Personnel:

4.10.6.3 Laboratory Product identification and Testing:

4.10.6.4 Laboratory Process Control:

PHC Manufacturing Pvt Ltd.

Quality System Requirements

4.10.6.5 Laboratory Testing And Calibration Methods:

4.10.6.6 Laboratory Statistical to Method:

4.10.6 Accredited Laboratories:

4.11.4 Measurement Systems Analysis

PHC Manufacturing Pvt Ltd.

Definition Of A Measurement System.

The process of assigning the numbers is

PHC Manufacturing Pvt Ltd.

PHC Manufacturing Pvt Ltd.

Why is there a need for MSA?

•Provides a comparison of one measuring device against

• Provides a basis for gauge suspected of being deficient.

•Provides a criterion for measuring an equipment before and

•It is required for calculating process variation in a

PHC Manufacturing Pvt Ltd.

Calibration is the process of validating & adjusting the

MSA is the process of evaluating the performance of a

Calibration Thus is a prerequisite before MSA !!!

PHC Manufacturing Pvt Ltd.

Possible Sources of Process Variation

Actual Process Variation Measurement

Long-term Short-term Variation Variation due Variation due

Repeatability Calibration Stability Linearity

To address actual process variability, the variation due to

We will look at “repeatability” and “reproducibility” as

PHC Manufacturing Pvt Ltd.

The Total Variation is equal to the real product

PHC Manufacturing Pvt Ltd.

PHC Manufacturing Pvt Ltd.

PHC Manufacturing Pvt Ltd.

Types of Measurement System Variations.

 Linearity(Accuracy & Precision)

Instrument 1 Master Instrument 2

 2MS   2rpt   2rpd

PHC Manufacturing Pvt Ltd.

 Variation that occurs when repeated

PHC Manufacturing Pvt Ltd.

Operator 1 Operator 2 Operator 3 Operator 1 Operator 2 Operator 3

PHC Manufacturing Pvt Ltd.

Measurement Units Measurement Units

PHC Manufacturing Pvt Ltd.

– Same test units

– But Different environmental conditions (i.e

PHC Manufacturing Pvt Ltd.

Flow – Diagram MSA

Take the printout of the word file