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Future state: the Quality Inspectors will be tested their Repeatability and Reproducibility for their inspection to evaluate
their Repeatability/ Accuracy level for confirming their inspection effectiveness/ capability before certifying them like a SI
or SI Online Inspector and also to evaluate overall effectiveness of shipping inspection system. And Gage R&R
Methodology is used for this test. The R&R stands for Repeatability and Reproducibility.
N E W B A L A N C E A s i a Q u a l i t y
G A G E R & R
However, such measurement systems are seen throughout industries. One example in our foot-ware industry is our SI
Inspectors, by visual check to determine whether a shoe pair is Pass or Fail during their shipping inspection(SI).
Hence, it is important to quantify how well such measurement systems are working. The tool used for this kind of
analysis is called Attribute Gage R&R. The R&R stands for Repeatability and Reproducibility.
Attribute Gage R&R reveals two important findings – percentage of Repeatability and percentage of Reproducibility.
Ideally, both percentages should be 100 percent, but generally, the rule of thumb is anything above 90 percent is quite
adequate.
Obtaining these percentages can be done using simple mathematics by Excel or Minitab has a module called Attribute
Agreement Analysis (in Minitab 13, it was called Attribute Gage R&R) that does the same and much more, and this
makes analysts’ lives easier.
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G A G E R & R
Select between 30 to 40 testing samples that represent the full range of defect types encountered in actual production
runs in our factories. In this study, We decided to have 36 samples (shoe pairs), including 34 Defective pairs
representing for 23 NB Standardized Defect types and 2 A-grade shoe pairs, called “Master Defect samples” or
Standard for Gage R&R and we will also assume that you have already prepared, defined the standard of Defective or
A-grade for each shoe sample of these 36 samples, and they are also reviewed and approved by NB Quality
Authorities-RQM, or QMs/ AQMs or QE- based in the factories.
N E W B A L A N C E A s i a Q u a l i t y
G A G E R & R
-Standard (Level) of master defect per sample: need to define the standard of defect like minor or major which exactly reflect actual defects
of production shoes, but they are not too minor which are too difficult to detect or too majors which are very visible to detect. Refer to
Worksheet “Master defect pictures” for reference.
-For common quality issues/ defects frequently happen in the foot-ware industry like Cleanliness, Bonding or Stitching, they are required to
duplicate per each out of 36prs samples. For example, refer to the master defect samples”, you can see we did prepare 2 samples for
Cleanliness, 4 samples for stitching, 2 samples for Bonding, etc. And you can follow this Master Defect Samples/ or Standard to prepare
the shoe samples for your GRR test.
-For major quality issues/ defects frequently happen or escaped from Quality Inspection in a specific factory, then the factory can prepare
the 36 samples with duplicating samples per that major defect to test the inspector.
-After prepared the 36prs of master defect samples, pls take all their pictures and include it in the Worksheet-Master defect pictures as in
the next slide.
-The Master Defect Samples need to be prepared NEW for each GRR Test and keep it confidential. Mean that after you complete the test
and certify the inspectors and when you need to re-certify them, you need to replace a new set of Master Defect Samples (not re-use it due
to confidentiality and the defects/quality issues should be up-to-date). As appropriate, the Factories can exchange their Master defect
samples each other for GRR Test but it should be decided and coordinated by NB QM/AQM.
N E W B A L A N C E A s i a Q u a l i t y
G A G E R & R
1. Leather-cutting marks (L) 2. Leather-veins/ scars on toebox (L) 3-Leather-suede hair mismatching 4. Textile-damaged at heel (L) 5. A-Grade
6. Component- N Logo scratches 7. Soleunit-Midsole web chipped off 8. Color Variation- at vamp(L&R) 9. Cutting-N logo cut edge(L) 10. Trimming- top edge eyesrow(L)
11-Embossing-NB logo is not clear on heel(R) 12. Printing-peeling off at heel(R) 13-Stitching-tension loose (L) 14-Stitching-broken thread(L) 15-Stitching Skipped stitches(R)
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16-Stitching-margin failure (L) 17. Punching-a blind hole 18-Upper-eyestay off(L) 19. Tongue length-mismatching 20. Hardware-BOA broken/ wire twisted(L)
26. A-Grade 27-Bonding gap(L) 28-Outsole Delamination(L) 29-Insert-wrong size (R) 30. Lace-damged lace tip(L)
31. Lace- scratch/ frayed(L) 32. Cleanliness-Lace dirty(L) 33. Cleanliness-Glue on toebox(L) 34-Label-wrong Width on size label (R) 35. Label-tongue size label peeling off (R)
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Table 1
Step 1: Inspector#1 inspects the 36 selected shoe pairs and write down Defect name in Inspection Form .
Step 2 : Inspector#2 inspects the 36 selected shoe pairs and write down Defect name in Inspection Form .
Step 3 : Inspector#3 inspects the 36 selected shoe pairs and write down Defect name in Inspection Form .
The inspectors must strictly follow NB 60sec+ Inspection Method for this inspection. Let’s say 60sec + 20sec max to
complete inspecting a shoe pair. So, it takes Max 48 minutes to complete this 1st round of 36-shoes inspection per Inspector.
We can accept for Inspector to write down max 3 defect names per shoe pair into the Inspection Form if they found more than
1 defect per shoe pair.
Notes: To shorten the 1st inspection round, we can divide the 36 samples into 3 sections of samples (12 prs per section), then
the 3 inspectors can inspect their assigned 12prs-section at the same time.
For example:
- The inspector#1 inspects from sample #1-12,
- The inspector#2 inspects from sample #13-24,
-The inspector#3 inspects from sample #25-36 and each Inspector will continue to complete 36 prs inspection for the 1st
round.
N E W B A L A N C E A s i a Q u a l i t y
G A G E R & R
- Disorder sequence of testing samples for the 2nd inspection and the 3rd inspection to increase difficult level of test.
- Repeat step 1 to 3 with the same testing samples and same inspectors for 2nd Inspection and 3rd Inspection. Ensure that you
do not let the Inspectors see each others results as well as their own 1st Inspection results while doing this exercise as it may
influence their decisions. So you need to re-print a new Inspection form for the 2nd inspection, and 3rd inspection.
Step 5 : Now you have the results of 3 times of Inspection for each Inspector for all 36 samples, including the Master Defect
standard.
The reporter will report the inspection result and compare the Defect Name found by Inspectors vs Master Defect of sample
to decide if it’s Pass (matching) or Fail (mismatching) then records Inspector assessment on Acceptability (Pass or Fail ) of
test samples in the column – Inspector#1 – 1st INSP, 2nd INSP, 3rd INSP. Similarly, to report the inspection results for
Inspector#2 and Inspector#3 to Inspection Report Template.
Refer to Table 2 in the slide#14.
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G A G E R & R
Tested by:
inspection result
_______________________________
25
26
27
28
29
30
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INSPECTOR#1 :_____AN__________________
2 Leather-veins/scars on toe box(L) Leather-veins/scars on toe box(L) Pass Cleanliness(L) Fail Leather-veins/scars on toe box(L) Pass
3 Leather-suede hair mismatching Glue stain(L) Fail Glue stain(L) Fail Glue stain(L) Fail
4 Textile-damaged at heel (L) Textile-damaged at heel (L) Pass Textile-damaged at heel (L) Pass Textile-damaged at heel (L) Pass
5 A-GRADE SHOE A-GRADE SHOE Pass Glue(L) Pass A-GRADE SHOE Pass
6 Component-N logo scratch(L) Component-N logo scratch(L) Pass Component-N logo scratch(L) Pass Component-N logo scratch(L) Pass
7 Soleunit-Midsole web chipped off (L) Soleunit-Midsole web chipped off (L) Pass Soleunit-Midsole web chipped off (L) Pass Soleunit-Midsole web chipped off (L) Pass
8 Color Variation- at vamp (L&R) Color Variation- at vamp (L&R) Pass Color Variation- at vamp (L&R) Pass Dirty Fail
9 Cutti ing- N Logo cutti ng edge (L) Cuttiing- N Logo cutting edge (L) Pass Cuttiing- N Logo cutting edge (L) Pass Cuttiing- N Logo cutting edge (L) Pass
10 Trimming-top edge eyesrow Trimming-top edge eyesrow Pass Trimming-top edge eyesrow Pass Trimming-top edge eyesrow Pass
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G A G E R & R
You can use any statistical analysis software(Minitab), or an Excel with macro enabled template
to do the test.
Propose to use Minitab, one of the preferred statistical analysis software for Lean Six
Sigma practitioners. However, the results and the takeaways will stay the same irrespective of
what software or excel template you use.
In this Guideline, the author uses an excel template to calculate the Agreement Percentage(%) of
all 4 test parameters. Please refer to the embedded object in this slide for the GRR test template.
Microsoft Excel
Worksheet
N E W B A L A N C E A s i a Q u a l i t y
G A G E R & R
Simply put, for you to accept your measurement system, the Within Appraiser, Each
Appraiser vs standard, Between Appraisers, All Appraisers vs standard and the agreements
have to be 90% or above. In such cases you conclude that you have the right measurement
system in place and proceed to confirm and certify the inspectors. Now, look at each of these
parameters in the following slides.
N E W B A L A N C E A s i a Q u a l i t y
G A G E R & R
This is a comparison of the results of each inspection of a single Inspector and shows if the Inspector
is able to repeat her own results across 3 inspection times. This is called Repeatability.
Refer to the column “Repeatability” in GRR Test file, you can see in the results of Within Inspector #1
or #2 or #3 on their assessment agreement(%).
Overall, all Inspectors’ assessment agreement stands at 90% or more and hence is acceptable. This
means, your measurement system or Inspectors do not have Repeatability issues.
If anyone or more percentages drop below 90%, we will conclude that our measurement system has
Repeatability issues and the MSA will be rejected. In such cases, we will need to further coach the
Inspector on correctly assessing the samples for Acceptability and redo GRR.
N E W B A L A N C E A s i a Q u a l i t y
G A G E R & R
In this section, the inspection results for each Inspector across 3 inspections are compared with the
Standard response and agreement percentage is displayed. This is Accuracy of Individual Inspector or
measurement system.
Refer to the column “Accuracy” in GRR Test file, you can see in the results of Each Inspector #1 or #2
or #3 vs Standard on their assessment agreement(%).
If the Agreement percentage drops below 90% for any inspector, we will reject this measurement
system or can say the Inspector is failed this GRR test, correct any disconnects that Inspector #1, #2
and #3 have and redo GRR till the percentage reach above 90%.
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G A G E R & R
Refer to the column “Reproducibility” in GRR Test file, you can see in the results of Between
Inspectors on their assessment agreement(%).
You need to see, out of 36prs, all the Inspectors were able to match how many pairs in all their 3
inspections. If this is below 90% and hence is an issue. We have Reproducibility problem in our
Measurement System or our shoe inspection process. This needs to be corrected before we can use
this measurement system to collect data or confirm/ certify our inspectors.
N E W B A L A N C E A s i a Q u a l i t y
G A G E R & R
The previous comparison was between each Inspector for all inspections for each sample item, whereas this test
compares the result of all Inspectors collectively with the standard. That means, it will show a particular sample as
matched only when all Inspectors across all Inspections give the same result for the sample as the standard.
Refer to the column “Overall Effectiveness of Measurement System” in GRR Test file, you can see in the results
of all Inspector #1 or #2 or #3 vs Standard on their assessment agreement(%).
This percentage gives the Overall effectiveness of the measurement system. It is the percent of time all inspectors
agreed and their agreement matches with the standard. If this is below 90%, the measurement system is not good to
proceed and needs to be corrected.
1 1. Materials - Leathers / Synthetics Leather-cutting mark at heel (L) Pass Pass Pass 1 1 Pass Pass Pass 1 1 Pass Pass Pass 1 1 1 1
2 Leather-veins/scars on toe box(L) Pass Fail Pass 0 0 Pass Pass Pass 1 1 Pass Pass Pass 1 1 0 0
3 Leather-suede hair mismatching Fail Fail Fail 1 0 Pass Pass Pass 1 1 Pass Pass Pass 1 1 0 0
4 2. Materials - Textiles Textile-damaged at heel (L) Pass Pass Pass 1 1 Pass Pass Pass 1 1 Fail Fail Fail 1 0 0 0
5 A-GRADE A-GRADE SHOE Pass Pass Pass 1 1 Pass Fail Pass 0 0 Pass Pass Pass 1 1 0 0
31 Lace-scratches Fail Pass Pass 0 0 Pass Pass Pass 1 1 Pass Pass Pass 1 1 0 0
32 21. Cleanliness Cleanliness-lace dirty (L) Pass Pass Pass 1 1 Pass Pass Pass 1 1 Pass Pass Pass 1 1 1 1
33 Cleanliness- Glue on toebox (R) Pass Pass Pass 1 1 Pass Pass Pass 1 1 Pass Pass Pass 1 1 1 1
34 22. Labeling / Packing Labeling-wrong Width on size label (R) Pass Pass Pass 1 1 Pass Pass Pass 1 1 Pass Pass Pass 1 1 1 1
35 Labeling-tongue size label peeling of (R) Pass Pass Pass 1 1 Pass Pass Pass 1 1 Pass Pass Pass 1 1 1 1
36 23. Evenness Eveness- HF Component position uneven Pass Pass Pass 1 1 Pass Pass Pass 1 1 Pass Pass Pass 1 1 1 1
What Gage R&R test parameters are used to evaluate for certifying the Quality Inspectors
We need to assess Individual Quality Inspector capability through her Agreement Percentage of
Repeatability and Accuracy, called as Individual Inspection effectiveness, which are to be
greater than 90% for certifying them.
What Gage R&R test parameters are used to evaluate for Overall Effectiveness of Quality
Inspection system(or measurement system)
For Attribute Gage R&R, the issue mostly lies with the Inspectors not able to evaluate the required attributes(Defective or OK)
correctly. What you need to do is further refine the Inspector definition of the said attribute (in this case, Acceptability of the
testing samples including Defective and OK) and make is more robust for everyone to understand. Master defect samples should
be crystal clear leaving no doubt in the Inspectors mind.
Next, coach and train the Inspectors who are failed GRR(below 90%) for the 3 key contents: Global NB Standard, NB 60sec+
Inspection Method, Common defects escaped from the quality inspections(like EOL QC, SI/SI Online, the 3rd party inspection,
NB WH IQC or QIRs) and more other contents if needed. Ensure that they all are on the same page with regards to the attribute
of defective samples, what is acceptable, what is not.
Once this is done, repeat the whole GRR again and check the agreement percentage. You will need to keep repeating this process
till the agreement percentage for all assessments above reach 90% or more.
While repeating the GRR test for the failed Inspectors, these inspectors are not allowed to inspect a NB PO independently but
under/ being supervised and confirmed the PO inspection result by Factory SI Leader/ or Supervisor. As appropriate, NB QA/QE
needs to follow up and randomly re-inspect the POs done by them until the inspectors will have been re-tested GRR with “PASS”
result.
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G A G E R & R
However, for new starting-up Factories making NB products within 2 years or quality concerning factories
appointed by QD or RQM, this Gage R&R test is required to proceed each 6 months to re-certify the
inspectors.
N E W B A L A N C E A s i a Q u a l i t y
G A G E R & R