Measurement System Analysis - Gauge R&R

[Repeatability & Reproducibility]

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Gauge R&R

What is MSA & why it is required?

- Everyday we are impacted by more & more data
- We have become an data driven society
- In industries we are using data in more ways than before and we gather massive information by
measurement & Inspection
- Vital decisions are made based on measurement result and if it is incorrect, we also make
incorrect decision
- MSA can help for decision making based on data
 Measurement System Analysis is a mathematical method of determining the amount of variation
that exists within a measurement process
 [Way of evaluating how well measurement system works]

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 Gauge R&R

1) Process Variation:
Process fail to follow a precise pattern

2) Precision:
Repeated Measurements show same
result in unchanged conditions

3) Accurate: 
Measured value has a little deviation
from the actual value

4) Repeatability: 
How much variation do we see in
measurements taken by the same
person, on the same part, using the
same tool
5) Reproducibility: 
How much variation do we see in
measurements taken by different people
on the same part, using the same tool

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 Gauge R&R

1) Process Variation:
Precise
Process fail toand Accurate
follow a precise pattern

2) Precision:
Repeated Measurements show same
result in unchanged conditions

3) Repeatability: 
How much variation do we see in
measurements taken by the same
person,Not
on the same part,
Accurate & using the Accurate & not Precise but not Precise but accurate
same tool
Precise Precise accurate
Error % [AIAG – Automotive Industry Action Group]
S.No Error % Condition
1 <10% Accepted & Satisfactory
2 10% ~ 30% Acceptable [Based on application & Cost]
3 >30% Unacceptable
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 Gauge R&R

HowVariation:
1) Process to Process:
Process fail to follow a precise pattern
- Type of Data collection [Continuous or Discrete]
2) Precision:
- No of Samples, No of Appraisers & No of repeat readings
Repeated Measurements show same
- Large
result no of parts
in unchanged & readings will have high confidence level
conditions
- Use appraiser who is familiar with measurement, equipment & Procedure
- If Applicable mark the exact location to be measured
- Ensure instrument or equipment is calibrated
- Sample parts should have number and measurement should be taken in random order
- Appraiser should not know about the details of sample parts
- Third party should record measurement result, Appraiser Name & Trial Number

Methods to perform Gage Repeatability and Reproducibility study

Range method
Average and range method
Analysis of variance method 5
 Gauge R&R

Step 1: Need to calibrate the gage

Step 2: Record the result of measurements

Trial
Operator Part Remarks
1st 2nd 3rd 4th

A x 0.29 0.31 0.33 0.32

A Y 0.28 0.29 0.31 0.27
A Z 0.27 0.29 0.31 0.28
B x 0.3 0.31 0.3 0.32
B Y 0.29 0.28 0.3 0.29
B Z 0.29 0.3 0.31 0.3
C x 0.3 0.3 0.31 0.3
C Y 0.29 0.28 0.29 0.28
C Z 0.31 0.3 0.31 0.3
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 Gauge R&R

Trial
Mean of Mean of Total Mean Range of
Operator Part Range Mean
1st 2nd 3rd 4th Range Mean Range Means

A x 0.29 0.31 0.33 0.32 0.04 0.3125

A Y 0.28 0.29 0.31 0.27 0.04 0.2875 0.04 0.295833
A Z 0.27 0.29 0.31 0.28 0.04 0.2875
B x 0.3 0.31 0.3 0.32 0.02 0.3075
B Y 0.29 0.28 0.3 0.29 0.02 0.29 0.02 0.299167 0.023333 0.003333
B Z 0.29 0.3 0.31 0.3 0.02 0.3
C x 0.3 0.3 0.31 0.3 0.01 0.3025
C Y 0.29 0.28 0.29 0.28 0.01 0.285 0.01 0.2975
C Z 0.31 0.3 0.31 0.3 0.01 0.305

Range (R) = Max-Min

Mean (M) = Sum of all trial/4 [Consider for this case]

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 Gauge R&R

Repeatability: Equipment Variation [EV]

EV= R *k1
- R = Total Mean Range [0.0233]
- k1 = 1/D2
How to find D2
=Subgroup size [No of Trials]
=4
= No of combinations of trials
= 3 Operators & 3 Parts
= 3*3
=9
D2 = Please refer 4 & 9
D2=2.080
K1=1/2.080 = 0.480

EV= 0.0233*0.480
= 0.0112 8
 Gauge R&R

Reproducibility: Appraiser Variation [EV]

AV = (Xdiff *k2)2 – (EV)2/n*r

Xdiff is the range of means = 0.0033

n=number of parts (3) & r = number of trials = 4

To find D2 we need K2
Number of Parts = 3
Number of parts and operators = 3*3 = 9
D2=1.718
K2= 1/1.718 = 0.580

AV = (0.0033*0.580)2 – (0.0112/12)2

= 0.001914 – 0.1344
= - 0.132486 [If AV is negative, set AV=0]

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 Gauge R&R - Variable

Gage R&R : (EV)2 + (AV)2

= (0.0112)2 + (0)2

= 0.0112 *100

R&R = 1.12 %

= Acceptable & Satisfactory

Attribute R&R

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Gauge R&R - Variable

Thank You

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