Training Module

On
Measurement System Analysis-MSA
Refer-MSA AIAG Manual-4th Edition

Neel Auto Private Limited,

Human Resources Department.
Gurgaon
1
Contents
 What is Measurement System
 What is Measurement System Analysis
 Accuracy & Precision
 Objective of Measurement process
 Performing MSA preconditions
 Causes of variations
 Discrimination
 Uncertainty of Measurement
 Statistical properties of Measurement System
 Measurement System Errors
 Measurement System Studies
Bias
Linearity
Stability
R&R
Attribute Measurement Studies
 HMSI Guidelines

2
What is a Measurement System ?
Measurement
Assignment of numbers (values) to material things.
e.g. 2.5 mm, 70 kg.cm, 6 ohm etc.
Measurement System
The complete process used to obtain measurement i.e.
Combination of -
• operations,
• Procedures,
• Gauges and other equipment's , software
• Personnel,
• environment and
• assumption etc.

3
Measurement System
methods/procedures time

personnel
software
gage

fixture

environment

4
What is Measurement system analysis
Study of combined effect of all measurement
contributors.
i.e. Measurement system used in measurement
process,
Assessing their suitability against measurement
objective.

5
 Accuracy & Precision
Accuracy: difference between the observed measurement
and the actual measurement
Precision: variation that occurs when measuring the same
part with the same instrument

Precise but not Accurate but not Not accurate or Accurate and
accurate precise precise precise

6
 Accuracy of Measurement
• Broken down into three components:
1. Stability: the consistency of measurements
over time.
2. Accuracy: a measure of the amount of bias
in the system.
3. Linearity: a measure of the bias values
through the expected range of measurements.

7
 Precision of Measurement
• Precision can be broken down into two
components:
1. Repeatability (Equipment variation): variation in
measurements under exact conditions.
2. Reproducibility (Appraiser variation): variation in
the average of measurements when different
operators measure the same part.

8
 Objective of Measurement Process
• PRODUCT CONTROL :

- Whether the product meets the specification

requirements

• PROCESS CONTROL :

- Is the process variation stable and acceptable

9
Performing MSA: Pre-conditions
• Data to be collected under routine measurement
conditions
• Level- 1 control exists i.e. the controls required to be
used even without MSA.
• Equipment is calibrated
• Adequate discrimination
• Persons are qualified
• Unnecessary causes of variations does not exist etc.

10
 CAUSES OF VARIATION
Common vs Assignable Causes
COMMON CAUSE ASSIGNABLE CAUSE
-Consists of many individual - Consists of just one or few
causes individual causes
-Cannot be economically -Easy to detect and generally
eliminated economical to eliminate
-Process follows a predictable -No specific pattern
pattern

- GOK - HAK
( GOD ONLY KNOWS ) ( HUMAN ALSO KNOWS )

11
Why we shouldn’t have assignable cause
 Process operates at its best when under common
causes alone
 Exhibits minimum variation if no assignable cause
 Predictable process if having only chance cause
 Sampling inspection possible
 True capability of a process can be estimated when
assignable causes have been eliminated

12
 DISCRIMINATION
 The ability of the system to detect and indicate even small changes of the
measured characteristic, also known as resolution
 Measurement system is unacceptable for analysis if it cannot detect
process variation
 Measurement system is unacceptable for controlling process if it cannot
detect special cause variation
Measurement system variation can be characterized as:
• Capability : Variability in readings taken over a short period of
time
• Performance : Variability in readings taken over a long period
of time ( Capability + Stability )
• Uncertainty : An estimated range of values about the measured
value in which the true value is believed to be
contained.
Total Variation = Manufacturing Process Variation ( MPV)
+
Measurement System Variation (MSV )
13
Uncertainty of Measurement
The reference material itself, the calibration process, the environment and personnel
performing calibration actually contribute to the measurement uncertainty

Thus the need for accredited labs

• Dimensional Measurements are referred to 200C
• Measured Dimensions are only estimated, not true values
• Deviation from the true value are attributed:
Quality of Instrument
Human Error
Status of Standard
Environmental Conditions
Dimensions of the product
Errors Which can be statistically Estimated- Random Effect ( UR).These Cannot
be eliminated totally, but can be reduced
Errors which arise from systematic effects ( US )

14
STATISTICAL PROPERTIES OF MEASUREMENT
SYSTEM (MS)

1. ADEQUATE DISCRIMINATION & SENSITIVITY:

• Should be small relative to PROCESS VARIATION or
SPECIFICATION LIMIT.
• Rule of 10’s i.e. 1/10th should be followed as a starting point.
• i.e. least count/ resolution of equipment should be 1/10th of
process Variation (10 data categories).

15
STATISTICAL PROPERTIES OF MEASUREMENT
SYSTEM (MS)

DATA CATEGORIES:

1,2,3...,9,10.
. got
it!
required
resolution
6

16
STATISTICAL PROPERTIES OF MEASUREMENT
SYSTEM (MS)

DATA CATEGORIES:
• The number of groups in which the measurement data
(results) can be obtained by using the measurement system.
Example:
• Process variation : 3.94 - 4.06 mm
• Measurement equipment : Vernier Caliper L.C. 0.02 mm
• Group of readings : 3.94, 3.96, 3.98, 4.00, 4.02, 4.04,
4.06
• Data categories :7

17
 Statistical Properties of Measurement
System (MS)
2. MS should be in statistical control
- Common cause variations only
- No special cause variation
3. Variability of MS < mfg. Variability process variation

-For process control

measurement variation

4. Variability < specification limits (sl)

- for product control

18
MEASUREMENT SYSTEM ERRORS

-BIAS

-LINEARITY LOCATION ERRORS

-STABILITY

-REPEATABILITY WIDTH ERRORS

-REPRODUCIBILITY

19
CONTRIBUTION OF MEASUREMENT SYSTEM ERROR
IN MEASUREMENT RESULT

1. LOCATION ERROR:

ACTUAL VARIATION OBS. VARIATION

DUE TO MS ERROR

20
CONTRIBUTION OF MEASUREMENT SYSTEM ERROR
IN MEASUREMENT RESULT

2. WIDTH (SPREAD) ERROR:

ACTUAL VARIATION OBS. VARIATION

DUE TO MS ERROR

21
CONTRIBUTION OF MEASUREMENT SYSTEM ERROR
IN MEASUREMENT RESULT

2. WIDTH (SPREAD) ERROR:

ACTUAL VARIATION OBS. VARIATION

DUE TO MS ERROR

22
 EFFECT OF MEASUREMENT SYSTEM ERROR ON
MEASUREMENT DECISION

1. EFFECT ON PRODUCT CONTROL:

1a. CALLING A GOOD PART AS BAD PART (CALLED TYPE -I ERROR)

1b. CALLING A BAD PART AS GOOD PART (CALLED TYPE -II ERROR)

23
 EFFECT OF MEASUREMENT SYSTEM ERROR ON
MEASUREMENT DECISION

2. EFFECT ON PROCESS CONTROL:

2a. CALLING A COMMON CAUSE AS SPECIAL CAUSE

(CALLED TYPE -I ERROR)

2b. CALLING A SPECIAL CAUSE AS COMMON CAUSE

(CALLED TYPE -II ERROR)

24
MEASUREMENT SYSTEM STUDIES
-BIAS

-LINEARITY

-STABILITY

-REPEATABILITY

-REPRODUCIBILITY

-ATRIBUTE MEASUREMENT STUDY

25
Bias
– Difference between the observed
average of measurements and the true
value (reference value) on the same Reference
Value
characteristics on the same part.
– A measure of the systematic error of Bias

the measurement system.

– It is the contribution of the total error
comprised of the combined effects of Observed
all sources of variation, known or Average
Value
unknown.

Bias

26
 DETERMINING BIAS
(INDEPENDENT SAMPLE METHOD)

Bias

Observed
Average
Value

Bias
27
 DETERMINING BIAS
(INDEPENDENT SAMPLE METHOD)
•Selection of reference standard:
• Should be sufficiently stable during study for
the characteristics being evaluated
Priority order
i Sample piece else
i Production part else
i Similar other component else
i Metrology standard
28
 DETERMINING BIAS
(INDEPENDENT SAMPLE METHOD)
•Establish reference value:
i Identify measurement location
i To the extent possible to minimize the effect of
within part variation.
i Measure the part for n10 times
i In standard room/ tool room
i With a measurement equipment of better accuracy.
i Using standard measurement method

29
 DETERMINING BIAS
(INDEPENDENT SAMPLE METHOD)
•Establish reference value:
i Calculate the average.
i Use this average as
“Reference Value” (x).

30
 DETERMINING BIAS
(INDEPENDENT SAMPLE METHOD)
•Data collection:
•Measure the reference standard at the marked location
•Under routine measurement condition i.e. TRIAL#
1
OBS.(y )
2
2 4 8
• Routine measurement equipment, 3
4
3
5 7
5 4

• Routine operator, 6 2 6
7 5
5

FREQUENCY
8 4

• Routine method, 10
9 3
3
4

11 4 3
12 5

• Routine environmental condition etc.) 13

14
5
4
2

1
15 3

•For n> 10 times

16 4 0
17 4 2 3 4 5
18 6
19 5
20 6

31
 DETERMINING BIAS

Graphical analysis (analysis for normality):

•Plot the data (observations) as a histogram
•Analyse if any special cause present.
•If yes, identify & remove the cause and recollect data & re-
analyse.
•If not, proceed for numerical analysis.
GRAPHICAL ANALYSIS
8

7
FREQ UENCY

4
3

0
2 3 4 5 6

OBSERVED VALUE

32
 DETERMINING BIAS
(INDEPENDENT SAMPLE METHOD)

•Numerical computation: n
– Compute average of n readings as  yi
i=1
y =
n
- Compute bias(b)= y - x
Sum(y) 81

y bar 4.05
Bias (b )= y bar-x = -0.02
33
 DETERMINING BIAS
(INDEPENDENT SAMPLE METHOD)
•Decision making- (checking if bias is significant)
TABLE
•Select max.(xi) and min.(xi) from the data n
2
d2*
1.414
d2
1.128
v
1
t(v,.025)
12.706
3 1.911 1.693 2 4.303
•Compute 4
5
2.239
2.481
2.058
2.326
3
4
3.182
2.776


6 2.673 2.534 5 2.571
7 2.830 2.704 6 2.447
8 2.963 2.847 6 2.447
repeatability = max (xi ) - min (xi) 9
10
3.078
3.179
2.970
3.077
7
8
2.365
2.306
d2* 11
12
3.269
3.350
3.173
3.258
8
9
2.306
2.262
13 3.424 3.336 10 2.228
14 3.491 3.407 10 2.228
15 3.553 3.472 11 2.201
16 3.611 3.532 11 2.201
17 3.664 3.588 12 2.179
18 3.714 3.681 12 2.179
19 3.761 3.689 13 2.160
20 3.805 3.735 13 2.160

max.(y)= 6 min.(y) 2 R=max. (y)- min. (y)= 4 Sigma r =R/d 2 *= 1.051

34
 DETERMINING BIAS
•Statistical analysis :Compute the followings-
– b = r /n
– Lower bound (L) = b – [d2 b / d2* (tv,/2)]

– Upper bound (U) = b + [d2 b / d2* (tv,/2)]

– d2, d2*, v (degree of freedom) can be obtained from appendix- A

– t can be obtained from t table .  (preferably 0.05) is a measure
v,/2
of confidence

Bias is acceptable at 100(1-) level if

L<0<U
Bias (b)= y bar-x= -0.02 Sigma b=Sigma r /Sqrt(n)= 0.2351 M=d 2 .Sigma b/d 2 *= 0.2351 Mt= 0.508
L=LOWER LIMIT= -0.528 U=UPPER LIMIT= 0.488

35
 Linearity
– The difference in the bias values through the expected
operating (measurement) range of the equipment.
– This is change of bias with respect to size.

MEASURMENT 3
POINTS 1 2

36
 Linearity
LINEARITY – NONCONSTANT BIAS

CONSTANT BIAS
1 1 1
BIAS

NE

0 0 0
LI

NE
AS

NE

LI
BI

LI

AS
RO

AS

BI
ZE

BI

RO
OR

ZE
ZE
-1 -1 -1

REFERENCE VALUE

37
 Linearity
LINEARITY – NONCONSTANT BIAS

CONSTANT BIAS
1 1 1

POSITIVE BIAS
BIAS

ZERO BIAS
0 0 0

NEGATIVE BIAS

-1 -1 -1

REFERENCE VALUE

38
 DETERMINING LINEARITY

The difference in the bias values through the expected

operating (measurement) range of the equipment.
This is change of bias with respect to size.

MEASURMENT 3
POINTS 1 2

39
 DETERMINING LINEARITY
• Determine operating range of gage
• Select Reference standard (refer bias)
– Select g > 5 parts covering the operating range of the gage
– Determine their reference values
· Collect data (refer bias)
– Measure each part m > 10 times on the subject gage by one
of the operators who normally use the gage
– select the parts in random order

40
 DETERMINING LINEARITY
ref. ref. ref. ref. ref.
value value value value value
2 4 6 8 10
T r i aml s) (
Obs. Obs. Obs. Obs. Obs.
value value value value value
1 2.700 5.100 5 .800 7.600 9.100
2 2.500 3.900 5 .700 7.700 9.300
3 2.400 4.200 5 .900 7.800 9.500
4 2.500 5.000 5 .900 7.700 9.300
5 2.700 3.800 6 .000 7.800 9.400
6 2.300 3.900 6 .100 7.800 9.500
7 2.500 3.900 6 .000 7.800 9.500
8 2.500 3.900 6 .100 7.700 9.500
9 2.400 3.900 6 .400 7.800 9.600
10 2.400 4.000 6 .300 7.500 9.200
11 2.600 4.100 6 .000 7.600 9.300
12 2.400 3.800 6 .100 7.700 9.400

41
 DETERMINING LINEARITY
• Graphical analysis Ref. 2 4 6 8 10
Value
– Calculate the part bias (b) for all
Avg 2.492 4.125 6.025 7.708 9.383
reference values
Bias 0.492 0.125 0.025 -0.292 -0.617
b i,j = yi.j – (reference value)i
– Calculate bias average (yi) for each part
m

 Biasi,j
yi= Biasji =
=1
m
– Plot the individual biases and the bias averages with respect to the
reference values on a linear graph x bar y bar
6 -0.053
– Calculate total bias average ( )= ( yi)/n
42
 DETERMINING LINEARITY
– Calculate and plot the best fit line and the confidence band of
the line using the following equations LINEARITY CHART

For the best fit line, use: yi = axi + b 0.6

0.4
Where
0.2

xi = reference value 0

BIAS
2 4 6 8 10

yi = bias average -0.2

-0.4

-0.6

xy – 1gm x  y -0.8

a = slope REFERENCE VALUE

=
x2 – gm
1 ( x)2

b = y – ax = intercept
43
 DETERMINING LINEARITY
xy – 1  x  y
g
a =
LINEARITY CHART
= -0.132
x – 1 ( x)
2 2 0.6

g 0.4

b = y – ax = 0.737 0.2

0
R e f. v a lu e ( x )

BIAS
2 4 6 8 10
-0.2
B ia s ( y )

S q r(x )

S q r(y )

-0.4
xy

2 0.492 0.983 4 0.242

-0.6
4 0.125 0.5 16 0.016
6 0.025 0.15 36 6E-04
8 -0.292 -2.333 64 0.085 -0.8
10 -0.617 -6.167 100 0.38 REFERENCE VALUE

30 -0.267 -6.867 220 0.723

E = S u m (S q r (x))=

F = S u m (S q r (y))=
S (xy)= S u m (xy)=
S (x)= S u m (x)=

S (y)= S u m (y)=

44
 DETERMINING LINEARITY
For a given x0, the  level confidence bands are

Where s = y2i – b yi – a xiyi

gm – 2
1/2
1 (x0 – x)2
Lower: b + ax0 – tgm-2,/2 +
gm s
(x1 – x)2

1/2
1 (x0 – x)2

Upper: b + ax0 tgm-2,/2 + s

gm (x1 – x)2
+

45
 DETERMINING LINEARITY
For a given x0, the  level confidence bands are
y2i – b yi – a xiyi
s= =0.063

B ia s ( y )
gm – 2

S q r( y )
xy
0.492 0.983 0.242
0.125 0.5 0.016
0.025 0.15 6E-04
-0.292 -2.333 0.085
-0.617 -6.167 0.38

F = S u m ( S q r(y ) ) =
S(xy)= Sum(xy)=
S(y)= Sum(y)=
-0.267 -6.867 0.723

46
 0.6

DETERMINING LINEARITY
0.4

0.2 1/2

BIAS
1 (x0 – x)2
Lower: b + ax0 –
0 tgm-2,/2 +
2 4 gm6 8 10
s
-0.2 (x1 – x)2
-0.4
H =S q r(d )/S u m (S q r(d ))
-0.6
t TABLE
-0.8 v t(v,.025)
R ef. va lu e (x)

J=(1 /g m )+H
40 2.021
REFERENCE VALUE
d =x-x b a r

K=S q rt(J) 60 2.000

B =b +a x

U =B +Q
L=B -Q
S q r(d )

Q =Kst
120 1.980

2 -4 16 0.4 0.417 0.645 0.081 0.473 0.393 0.554

4 -2 4 0.1 0.117 0.342 0.043 0.21 0.167 0.253
6 0 0 0 0.017 0.129 0.016 -0.053 -0.069 -0.04
8 2 4 0.1 0.117 0.342 0.043 -0.317 -0.359 -0.27
10 4 16 0.4 0.417 0.645 0.081 -0.58 -0.661 -0.5

40

47
 DETERMINING LINEARITY

Plot Lower & Upper band and the “bias = 0”

line LINEARITY CHART

0.8

0.6

0.4

0.2
BIAS

0
2 4 6 8 10
-0.2

-0.4

-0.6

-0.8
REFERENCE VALUE

48
 DETERMINING LINEARITY
Linearity acceptable if,
“bias = 0” lie
entirely within the confidence bands of the fitted
line.
LINEARITY CHART

0.432
BIAS

0.000
13.900 34.200 68.700 92.300 130.900

-0.432
REFERENCE VALUE
49
 DETERMINING LINEARITY
Linearity acceptable if,
“bias = 0” lie
entirely within the confidence bands of the fitted line.

LINEARITY CHART

0.432

Regression
BIAS

0.000
13.9 34.2 68.7 92.3 130.9
90% CI

-0.432
REFERENCE VALUE

50
 DETERMINING LINEARITY
NUMERICAL ANALYSIS
If the graphical analysis indicates that the measurement system
linearity is acceptable then the following hypothesis should be true:
H0: a = 0 slope = 0
do not reject if

a
t = < t gm-2,/2
s
(xj – X)2

51
Stability (Drift)
The total variation in the measurements obtained with a
measurement system-
•on the same master or parts,
•when measuring a single characteristic,
•over an extended time period.
i.e. Stability is the change of bias over time

52
DETERMINING STABILITY

53
 DETERMINING STABILITY
iSelection of reference standard: Refer bias study.
iEstablish reference value :Refer bias study.
iData collection:
i Decide subgroup size
i Decide subgroup frequency
i Collect data for 20-25 subgroups

54
 DETERMINING STABILITY
iAnalysis
iCalculate control limits for X-R chart.
iPlot data on chart
iAnalyse for any out of control situation.

iDecision
Measurement system is stable & acceptable if no
out of control condition is observed other wise not
stable and needs improvement .

55
 Repeatability (Within system variation)

The variation in measurements obtained

•with one measurement instrument
•when used several times
•by one appraiser
•while measuring the identical
characteristic
•on the same part.
repeatability= Rtrial/d2=K1R, where K1=1/d2
Repeatability

Note:Repeatability is commonly referred to as equipment variation(EV),

although this is misleading. In fact repeatability is within system variation

56
 Reproducibility (Between system variation)
The variation in the average of the measurements
• made by different appraisers
• using the same measuring instrument
• when measuring the identical characteristic
• on the same part.
reproducibility= Rappraiser/d2=K2R, where K2=1/ d2

APPRAISER
A C B
REPRODUCIBILITY

57
 Gage Repeatability & Reproducibility(GRR)
An estimate of the combined variation of repeatability and
reproducibility.
GRR is the variance equal to the sum of within system &
between system variances.
2GRR = 2EV + 2AV

A C B
APPRAISER

58
 Gage Repeatability & Reproducibility
2 = 2 + 2
GRR reproducibility repeatability

APPRAISER B
A C

59
 R&R-AVERAGE AND RANGE METHOD

AN APPROACH WHICH WILL PROVIDE

ESTIMATE OF BOTH REPEATABILITY AND
REPRODUCIBILITY FOR A MEASUREMENT
SYSTEM.

60
 R&R-AVERAGE AND RANGE METHOD
– CONDUCTING THE STUDY
1) Selection of sample: n > 5 parts depending on size, measurement
time/ cost etc (representing process variation).
2) Identification: 1 through n (not visible to the appraisers).
– Location Marking (easily visible & identifiable by the appraisers).
– Selection of appraiser: 2-3 routine appraisers
– Selection of Measuring equipment: Calibrated routine equipment
– Deciding number of trials: 2-3
– Data collection:
– Using data collection sheet
– Under normal measurement condition
– in random order
– using blind measurement process

61
 R&R-AVERAGE AND RANGE METHOD
Data collection
1) Enter appraiser A result
2) Enter appraisers B and C results
3) Repeat the cycle (2nd trial) & enter data If three trials are
needed, repeat the cycle and enter data

62
 R&R- GRAPHICAL ANALYSIS
1) For appraiser A, calculate Average (X) & Range(R) for each part and
enter results
2) Do the same for appraisers B & C and enter results
3) For appraiser A, calculate average (X) of all the averages and average
(Ra) of all the ranges and enter in data sheet.
4) Calculate Xb, Rb & Xc, Rc for appraisers B & C also and enter the results
in data sheet.
5) Calculate average of all the observations (rows 4, 9 &14) of each part
and enter result.
6) Calculate Part range (Rp)= Difference of Max. and Min. of row 16 and
enter in data sheet
7) Calculate X =(Xa + Xb + Xc )/3 and enter in data sheet

63
 R&R- GRAPHICAL ANALYSIS
1) Calculate R = (Ra+ Rb + Rc )/3 and enter result
2) Calculate Xdiff = Difference of Max and Min of (Xa , Xb & Xc) and enter
result
3) Calculate UCL R =D4 R and enter in row 19 (D4=3.27 for 2 trials & 2.58
for 3)
4) Calculate LCL R =D3 R and enter in row 20 (D3= 0 for trials<7)
5) Calculate UCL X= X+A2 R (A2=1.88 for 2 trials & 1.02 for 3 trials).
6) Calculate LCL R= X-A2R

64
 R&R- GRAPHICAL ANALYSIS
RANGE CHARTS
– Used to determine whether the process is in statistical control.
– The special causes need to be identified and removed
– Plot all the ranges for each part & each appraiser on range chart
– If all ranges are under control, all appraisers are doing the same job.
– If one appraiser is out of control, the method used differs from the others.
– Repeat any readings that produced a range greater than the calculated uclr
using the same appraiser and part as originally used.
– Or, discard those values and re-average and recompute X and the limiting
value UCLR based upon the revised sample size.
– Correct the special cause that produced the out of control condition.

65
 R&R- AVERAGE CHART
– Plot the averages of the multiple readings by each appraiser on each part
on X chart.
– The X chart provides an indication of “usability” of the measurement
system.
– The area within the control limits represents the measurement sensitivity
(“noise”).
– Approximately one half or more the averages should fall outside the
control limits.
– If the data show this pattern, then the measurement system should be
adequate to detect part-to-part variation and can be used for
analyzing and controlling the process.
– If less than half fall outside the control limits then either the
measurement system lacks adequate effective resolution or the sample
does not represent the expected process variation.

66
 R&R- ANALYSIS OF RESULTS -- NUMERICAL
Calculate the following and record in report sheet
– Repeatability or equipment variation (EV) = X x K1 (K1 =1/ d2* )
K1 = .8862 for 2 trials & .5908 for 3 trials

– Reproducibility or appraiser variation (AV)= (XDIFF x K2)2 - (EV)2

(K2= .7071 for 2 appraisers & .5231 for 3) nr

– GRR= (EV)2 + (AV)2

– Part to part variation (PV)= RP x K3 n 2 3 4 5 6 7 8 9 10

K3 .7071 .5231 .4467 .4030 .3742 .3534 .3375 .3249 .3146

Total variation (TV) = (GRR) (PV)

2+ 2
–
67
 NUMERICAL ANALYSIS
– Calculate % variation and ndc as follows
%EV = 100 [EV/TV]
%AV = 100 [AV/TV]
%GRR = 100 [GRR/TV]
%PV = 100 [PV/TV]
No. of distinct categories (ndc)= 1.41(PV/GRR)

Note:
– In case measurement system is to be used for product control instead of process
control, TV should be replaced with specification tolerance.
– The sum of the percent consumed by each factor will not equal 100%.

68
 NUMERICAL ANALYSIS
– Decision making:
– For % R & R
Error < 10% - MS is acceptable
10% > Error < 30%- May be acceptable with justification
Error > 30% - MS needs improvement

– ndc >= 5

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 GAGE R & R ANALYSIS REPORT
CUS TOMER: BEHRAN MEHBAR GAGE NAME: MICROMETER NOMINAL: 48.05 DATE: 16.04.2002
PART NO.: 003 GAGE NO.: A29464 TOL(+): 0.02 PERFORMED BY: NAMENE
CHARACTERIS TIC: DIAMETER GAGE TYPE: 25-50MM .001 LC TOL(-): 0

APPRAISER A NAME: AMIRI PART

1 2 3 4 5 6 7 8 9 10 AVERAGE
1 48.06 48.055 48.054 48.065 48.064 48.056 48.063 48.064 48.065 48.066 48.061
TRIAL 2 48.061 48.056 48.055 48.065 48.063 48.055 48.06 48.066 48.062 48.063 48.061
3 N/ A

AVERAGE 48.061 48.056 48.055 48.065 48.064 48.056 48.062 48.065 48.064 48.065 XBARA 48.061
RANGE 0.001 0.001 0.001 0.000 0.001 0.001 0.003 0.002 0.003 0.003 RBARA 0.002

APPRAISER B NAME: SHARIFI PART

1 2 3 4 5 6 7 8 9 10 AVERAGE
1 48.06 48.057 48.053 48.065 48.052 48.055 48.063 48.064 48.065 48.063 48.060
TRIAL
2 48.06 48.056 48.056 48.065 48.053 48.054 48.06 48.065 48.065 48.063 48.060
3 N/ A

AVERAGE 48.060 48.057 48.055 48.065 48.053 48.055 48.062 48.065 48.065 48.063 XBARB 48.060
RANGE 0.000 0.001 0.003 0.000 0.001 0.001 0.003 0.001 0.000 0.000 RBARB 0.001

70
 GAGE R & R ANALYSIS REPORT
REPEATABILITY RANGE CONTROL CHART

APPRAIS
XB AR p 48.060 48.056 48.055 ER A 48.058 R48.055
48.065 - OP1 48.062 48.065 48.064 48.064 APPRAIS
# P AR TSER 10
B M (F OR E V( K1 ) = # O F TR IA LS )
0.005 U CL-R 0.004 0.004 0.004 0.004 0.004 UCL-R
0.004 0.004 0.004 0.0050.004 0.004 OP 1 ? 1 d2 2 0.005
0.004 LCL-R 0.000 0.000 0.000 0.000 0.000 0.000
LCL-R 0.000 0.000 0.000
0.004 0.000 OP 2 ? 1 1 1.410
R - OP2 0.004
R BAR BAR 0.001 0.001 0.001 0.001 0.001 0.001 0.001 0.001 0.001 0.001 OP 3 ? 0 2
UCL-R 1.280
0.003 RBARBAR
XB AR BAR 48.060 48.060 48.060 48.060 48.060 48.060 48.060 48.060 0.003 48.060 48.060 # OP ER 2 3 1.230 0.003
0.002 LCL-R
U CL-XBAR 48.0645 48.0645 48.0645 48.0645 48.0645 48.0645 48.0645 48.0645 0.002
48.0645 48.0645 # T R IALS (M) 2 4 1.210 0.002
LCL-XBAR 48.0561 48.0561 48.0561 48.0561 48.0561 48.0561 48.0561 48.0561 48.0561 48.0561 (G) 20.000 G RBARBAR
5 1.190
0.001 0.001 0.001
d 2 A(EV)= 1.128 d 2 (EV)= 1.128 6 1.180
0.000 d0.000
2 (P V)= 3.180 d 2 (AV)= 1.410 0.000
1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 1
PART APPRAIS ER AVERAGE CHART
Xavg - OP1 7 1.170
COUNT D4 D3 APPRAIS
A2 3/d 2 ER SAIZE A2 D3 D4 3/d 2 TOLERANCE APPRAISXD
ERiff (R
B o ): 0.001 8 1.170
UCL-XBAR 60.000
2 3.268 0 3.268 2.659 2 1.88 0 3.268 48.070
2.659 0.02 R p : 0.010 9 1.160
48.070 50.000
3 1.023 LCL-XBAR
0 2.574 1.772 16.02 AV1 : 0.000 10 Xavg - OP2
1.160
48.065 48.065
4 0.729 XBARBAR
0 2.282 1.457 AV2 : 0.000 1 1UCL-XBAR
1.160 40.000
48.060 5 0.577 0 2.114 48.060
1.29 1 2LCL-XBAR
1.150 30.000
48.055 48.055 G 13 1.150 20.000
48.050 XBARBAR
48.050 14 1.150 10.000
48.045 48.045 15 1.150 0.000
1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 >1 5 1.128

71
 GAGE R & R ANALYSIS REPORT
GAGE R & R SUMMARY
ME AS U R E ME N T U N IT AN ALYS IS
R EP E AT ABILITY (EV)
(EQUIP MENT VARIATION): 0.006
R E P R ODUCIBILIT Y (AV)
(AP PRAISER VARIATION): 0.004
R &R
(REP EATABILITY & REP RODUCIBILITY): 0.007

P AR T VAR IATION (P V): 0.017

T OT AL VAR IAT ION (T V): 0.018

% P R OCE S S % T OLE R AN CE
VAR IAT ION (T V) VAR IAT IO N (T OL)

% E QUIP ME NT VAR IAT ION: 32.10 29.68

% AP P R AIS E R VAR IAT ION: 22.59 20.89
% R & R: 39.26 36.29
% P AR T VAR IAT ION: 91.97 85.02

72
 ATTRIBUTE MEASUREMENT
SYSTEMS STUDY
– Attribute measurement systems are the class of measurement systems where
the measurement value is one of a finite number of categories.
– This is contrasted to the variables measurement system which can result in a
continuum of values.
– The most common of these is a go/no-go gage which has only two possible
results.
– There is a quantifiable risk when using any attribute measurement systems in
making decisions.
– The largest risk is at the category boundaries
LSL USL

MEASUREMENT SYSTEM GRAY AREAS

73
 ATTRIBUTE MEASUREMENT
SYSTEMS STUDY

METHODOLOGY:

–Select n>12 parts as follows:

– Approximately one third conforming,

– One third non conforming & one third marginal (marginal conforming &
marginal non conforming)

– Note down the correct measurement attribute (true status).

– Decide the no. Of appraiser & no. Of trials to be conducted.

– Record the measurement result in data sheet

74
 ATTRIBUTE MEASUREMENT
SYSTEMS STUDY

Possible outcome by the appraiser:

–Correct decisions
– Calling good part as good (good-correct)
– Calling bad part as bad (bad-correct)
–Wrong decisions
– Calling good part as bad (false alarm)
– Calling bad part as good (miss)
–For each appraiser count the data as follows
– Number good-correct (GN)
– Number bad -correct (NB)
– Number total correct (CN): total (BN+NB)
– Number false alarm(NF): that is rejecting ok part
– Number miss(NM): that is accepting rejected part
– Number total (TN): total of (GN+NB+NF+NM)
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 ATTRIBUTE MEASUREMENT
SYSTEMS STUDY

Methodology:
–For each appraiser calculate the following
– Effectiveness (E)= CN/Total opportunity for correct decision
– Probability of false alarm(Pfa)=NF/ Total opportunity for false alarm
– Probability of miss(PM)=NM/ Total opportunity for miss
–Decision
Parameter acceptable marginal unacceptable
E >.90 .80 to .90 <.80
Pfa <.05 .05 to .10 >.10
Pm <.02 .02 to .05 >.05

76
 MSA Guidelines
Criteria for doing MSA

•All measurement systems involves in measuring defined critical characteristics e.g. characteristic
that defines (HS, HA, HB) parts & all critical stations identified by Supplier.

•Problems (Specific to a Supplier) reported from customer in previous model for similar
part/dimension.
• For Variable data:

• Select the instrument for which R&R study is to be conducted. The Least Count of instrument
shall be at least 1/10th of the total tolerance or process spread which ever is lower.

• Select operators and train them.

• Minimum three operators to be selected for study.

• Minimum 10 parts to be selected for study.

• Take samples in such a manner so that the variation of all parts will approximately cover the
total tolerance range or process spread of product and input identification no. on the same.
Ensure that operator don’t have knowledge of identification numbers during the study.

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 MSA Guidelines

• Criteria for acceptance of measurement system :

• Compare the %R&R value as below

• Less than 10 % - OK
• Between 10% & 30 % - Marginal (not to be used for critical
characteristics and have an action to plan to improve to <= 10 %)
• Above 30% - NG

• If R&R value is not OK suitable corrective measure to be taken e.g. training of

selection of instrument.

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 MSA Guidelines
•For Attribute data:

• Define measurement method.

• Select gauge/ visual inspection parameter for which MSA to be conducted.

• Minimum two operators to be selected.

• Minimum 20 samples to be taken for study & in such a manner that they
approximately cover entire range of OK & not OK result.

• Calculate Effectiveness.

• Criteria for acceptance

Effectiveness > 0.9 - OK
Effectiveness > 0.8~0.9 - marginal
Effectiveness < 0.9 - NG
If effectiveness is not OK, suitable counter measure to be taken.

79
 MSA Guidelines
Analysis of External Calibration Certificate:

Purpose :
To describe in detail the method for analysis of externally calibrated
measuring and test equipment.

Scope :
Applicable to all measuring and testing equipment and masters calibrated by
external calibration sources including newly purchased.

Verify calibration certificate as:

• Identification number
• Lab is certified by NABL for this calibration
• Details of equipment used for calibration
• Reference standard used for calibration
• Traceability of equipment used for calibration
• Validity certificate NABL certification
• Acceptance criteria

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