Professional Documents
Culture Documents
Measure
Analyze
Improve
Champion Training
Control
Learning Objectives
Understand the language of Measurement Show the importance of Measurement Walk away knowing how to perform a Gage R&R and how to interpret results Share some lessons learned
Materials
Cleanliness Temperature Dimension Weight Corrosion Hardness Algorithm Instability Conductivity Density
Men
Procedure Fatigue Attention Calibration Error Interpretation Speed Coordination Know ledge Dexterity Vision
Environment
Measurement Variation
Repeatability
Accuracy
Stability
Linearity
Reproducibility
We will look at repeatability and reproducibility as these are the primary contributors to measurement error.
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Knowledge to be obtained
How big is the measurement error? What are the sources of measurement error? Is the gage stable over time? Is the gage capable for this process? How do we improve the measurement system?
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Sources of Variation
Product Variability
(Actual variability)
Measurement Variability
Total Variability
(Observed variability)
x
n
n = sample size
Example: Gage error of 50% can be cut in half if your point estimate is a sample of 4 data points.
THIS IS USED AS A SHORT TERM APPROACH TO PERFORM A STUDY, BUT YOU MUST FIX THE GAGE.
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Terminology
Location related terms:
True value Bias Linearity
True value:
Theoretically correct value unknown and unknowable Reference standards NIST standards
Bias
Distance between average value of all measurements and true value Amount gage is consistently off target Systematic error or offset
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BIAS Definition
BIAS Is the difference between the
observed average of the measurement and the reference value. The referencevalue is the value that serves as an agreed-upon reference. The reference value can be determined by averaging several measurements with a higher level (e.g., metrology lab) of measuring equipment. Warning: Dont assume your metrology reference is gospel. ACCURACY IS THE SAME AS BIAS
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Reference Value
Linearity
Difference in the accuracy values of a gage through the expected operating range of the gage Good Linearity
Regression Plot
Bad Linearity
Linearity is Not Good
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Trials
Trials
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15
15
5 10 20 30 40 50
5 10 20 30 40 50
Standard
Standard
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Stability
The distribution of measurements remains constant and predictable over time for both mean and standard deviation Total variation in the measurements obtained with a gage, on the same master or master parts, when measuring a single characteristic over an extended time period. Evaluated using a trend chart or multiple measurement analysis studies over time
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Time-1
Stability
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Total variation in the measurement system Measure of natural variation of repeated measurements Terms: Random Error, Spread, Test/Retest error Repeatability and Reproducibility
2 MS
2 G
2 O
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Repeatability
The inherent variability of the measurement system Variation in measurements obtained with a gage when used several times by one operator while measuring a characteristic on one part. Estimated by the pooled standard deviation of the distribution of repeated measurements R
G
* d2
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Repeatability Definition
Repeatability The variation in measurements obtained with one measurement instrument when used several times by one appraiser while measuring the identical characteristic on same part.
REPEATABILITY
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Reproducibility O
Operator variability of the measurement system Variation in the average of the measurements made by different operators using the same gage when measuring a characteristic on one part Must be adjusted for gage variation R Reproducibility is less than the total variation of O * d2 the measurement system
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Reproducibility Definition
Operator-B
Reproducibility Is 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.
Operator-C
Operator-A Reproducibility
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Rule of thumb: . . . . . .Test equipment MUST be a least 10 times more accurate & precise then whats being tested
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Addresses what percent of the tolerance or process capability is taken up by measurement error. Best case: 10% Acceptable: 30% Includes both repeatability and reproducibility Operator Unit Trial Experiment
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Therefore:
CpAct
2 6 2 Obs MS
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60%
50%
Actual Cp
0.5 0.6 0.7 0.8 0.9 1.0 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 2.0
Observed C p
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Convert Data
Try To Always Convert Attribute To Variables
End Disk Height Likert Scale Leak Rate (go/no go) Mass Spec
Examples:
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Basic Terms
EV= Equipment Variation (Repeatability) AV= Appraiser Variation (Reproducibility) R&R= Repeatability & Reproducibility PV= Part Variation TV= Total Variation of R&R and PV
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Guidelines
% R&R
<5% 10% 10% 30% Over 30%
Results
No issues Gage is OK Maybe acceptable based upon importance of application, and cost factor Gage system needs improvement/corrective action
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Operator*Gasket Interaction
Average
3.0SL=0.8796 X=0.8075 -3.0SL=0.7354 1.1 1.0 0.9 0.8 0.7 0.6 0.5 0.4 1 2 3 4 5 6 7 8 9 10
Operator
1 2 3
Sample Mean
Gasket
R Chart by Operator
0.15
1 2 3
Response by Operator
3.0SL=0.1252 1.1 1.0 0.9 0.8 0.7 0.6 0.5 0.4
Sample Range
R=0.03833 -3.0SL=0.000
Operator
Components of Variation
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Response by Gasket
%Total Var %Study Var %Process %Toler 1.1 1.0 0.9 0.8 0.7 0.6 0.5 0.4
Percent
100
Gasket
10
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Source
%Tol
%Process
Total Gage R&R 6.332 Repeatability 3.509 Reproducibility 2.823 Part-to-Part 93.668 Total Variation 100.000
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Calculation Explanation
5.15 Sigma = 5.15 the factor standard deviation. 5.15 was developed empirically to approximate the gage population distribution variation. % Contribution = Percent contribution of each factor based upon the variance. Repeatability = 100 repeatability variance/ total variation variance. % Study Variation = 5.15 the factor standard deviation divided by 5.15 the total variation standard deviation. Repeatability = 100 5.15 repeatability standard deviation/ 5.15 total variation standard deviation. % Tolerance = 5.15 the factor standard deviation divided by the tolerance. Repeatability = 100 5.15 repeatability standard deviation/tolerance.
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Calculation Explanation
% Process Variation = 5.15 x the factor standard deviation divided by the process variation. Repeatability = 100 x 5.15 repeatability standard deviation/ process variation. Number of Distinct Categories = part standard deviation divided by the total gage R&R standard deviation times 1.41.
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Metric is the % error against known population deemed good by local experts Attribute legend can be the defect codes If appraiser % is less than 100% training is required, focus on area of weakness 100% is the target for screen effectiveness Use this to prove measurement system capability prior to task assignment Select the 5 vital few (80-20 rule) to conduct GR&R
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The following spreadsheet is used to calculate an Attribute GR&R Effectiveness, in which up to 30 samples can be evaluated, using 2 or 3 operators.
In the worksheet fill in the appropriate information in the Scoring Report section and enter the type of Attributes you are evaluating in the Attribute Legend section. YOU MUST ENTER THE INFORMATION IN THE ATTRIBUTE LEGEND SECTION OR THE SPREADSHEET WILL NOT WORK . The attributes can be either alpha or numeric, e.g. Yes, No; pass, fail; go, stop; or 1, 2. You must be consistent throughout the form and spell properly, anything will work as the spreadsheet compares what is in each cell. If you or an expert has selected samples to be evaluated and you know what attributes these samples are, enter this information in the Attribute sample column. This will enable you to determine how well each operator can evaluate a set of samples against a known standard. You do not need to enter information in this column for the spreadsheet to work. You do not have to specify how many operators or the # of samples that you will be evaluating during the test. Simply enter the data into the spreadsheet under the specific operator. Remember the attributes must be spelled properly or the spreadsheet will not analyze the data correctly. To print a copy of the report click on the Print Report icon. To delete the data in the spreadsheet, click on the Delete Data icon. To delete all and begin a new test, click on the Delete All icon To see a Demo of the Attribute GR&R Effectiveness spreadsheet, click on the Demo icon. Move around the spread sheet to see the data. When you are finished click the Delete All icon to delete all data to begin entering your own data.
3)
4)
5) 6) 7) 8)
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Y/N Agree
Y/N Agree
#DIV/0! Known
#DIV/0! Known
0% Known
SCREEN % EFFECTIVE SCORE(3) -> #DIV/0! SCREEN % EFFECTIVE SCORE vs. ATTRIBUTE (4) ->
#DIV/0!
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3/10/96 Allied Employee 3313 Spark Plug 3313 Spark Plug F&SP Operator #3 Try #1 Try #2
fail fail fail fail fail pass fail pass pass fail pass pass fail fail fail fail fail fail fail pass fail pass pass fail pass pass fail fail -
Known Population Sample # Attribute 1 pass 2 pass 3 fail 4 fail 5 fail 6 pass 7 pass 8 pass 9 fail 10 fail 11 pass 12 pass 13 fail 14 fail 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 -
Y/N Agree N N N Y N Y Y Y Y N Y Y Y N
Y/N Agree N N N Y N Y N Y N N Y Y Y N
100.00% 78.57%
78.57% 64.29%
100.00% 71.43%
SCREEN % EFFECTIVE SCORE(3) -> 57.14% SCREEN % EFFECTIVE SCORE vs. ATTRIBUTE(4) -> 42.86%
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Calculation
Known Population Sample # Attribute 1 1 2 1 3 2 4 2 5 2 6 1 7 1 8 1 9 2 10 2 11 1 12 1 13 2 14 2 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 % Appraiser Score Agreements Total Sample Operator #1 Try #1 Try #2 1 1 1 1 2 2 2 2 2 2 1 1 2 2 1 1 1 1 1 1 2 1 2 1 2 2 2 2 Operator #2 Try #1 Try #2 1 1 1 1 2 1 2 2 1 2 1 1 2 2 1 1 1 1 2 2 1 1 1 1 2 2 1 2 Operator #3 Try #1 Try #2 2 2 2 2 2 2 2 2 2 2 1 1 2 2 1 1 1 1 2 2 1 1 1 1 2 2 2 2 Y/N Agree FALSE FALSE FALSE TRUE FALSE TRUE TRUE TRUE TRUE FALSE FALSE FALSE TRUE FALSE Y/N Agree FALSE FALSE FALSE TRUE FALSE TRUE FALSE TRUE FALSE FALSE FALSE FALSE TRUE FALSE
85.71% 12 14
78.57% 11 14
100.00% 14 14
42.9% 6 14
28.6% 4 14
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Do You Understand?
The language of Measurement ? The importance of Measurement? How to perform a Gage R&R Study and how to interpret results ? Use Minitab to analyze GR&R results?
ANY QUESTIONS OR COMMENTS
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