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Measurement Systems Analysis

Measure

Analyze

Improve

Champion Training

Control

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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

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Since Measurement systems represent a sub-process within a process...


They are subject to Variation. What could be the source of this variation?

Why do Measurements Vary?


CLASS EXERCISE : Break into teams. Do a cause-effect Diagram to determine the causes of variation in Measurement.
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Sources of Measurement Variation


Measurement System C&E Matrix
Measurements
Mechanical Integrety

Materials
Cleanliness Temperature Dimension Weight Corrosion Hardness Algorithm Instability Conductivity Density

Men
Procedure Fatigue Attention Calibration Error Interpretation Speed Coordination Know ledge Dexterity Vision

Wear Electrical Instability

Measurement System Error


Temp Fluxctuation Line Voltage Variation Vibration Cleanliness Operator Training Humidity Ease of use Operator Technique Standard Procedure Sufficient Work time Maintenance Standard Calibration Frequency Wear Stability Resolution Calibration Precision Design Temperature Cleanliness

Environment

Methods Machines Six Sigma Champion Training

Possible Sources of Process Variation


Observed Process Variation

Actual Process Variation

Measurement Variation

Long-term Process Variation

Short-term Process Variation

Variation w/i sample

Variation due to gage

Variation due to operators

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)

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Effects of Measurement Error


Averages
Measurement System Bias Determined through Accuracy Study

total product measurement


Variability
2 2 2 total product measurement
Measurement System Variability Determined through R&R Study

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Work Around Gage Error


If you want to decrease your gage error take advantage of the standard error square root of the sample:

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

Stability (over time) Variation related terms


Repeatability Reproducibility Linearity
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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

Observed Average 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

Y = 0.934227 + 0.994959X 25 R-Squared = 0.981

Trials

35

35

25

Y = 0.245295 + 0.99505X R-Squared = 0.982

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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Stability (drift) Definition


Stability Is the total variation in
the measurement obtained with a measurement system (test / gage ) on the same master parts when measuring a single characteristic over an extended time period. Magnitude Time-2

Time-1

time Points to the frequency of Mean center Calibration


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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

Repeatability is less than the total variation of the measurement system

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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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The Nature of Process Variation


1 2 3 4 5

Precise but not Accurate

Accurate but not Precise

Rule of thumb: . . . . . .Test equipment MUST be a least 10 times more accurate & precise then whats being tested
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Measurement System Discrimination


Least count should be at most one-tenth of the total process capability or tolerance (6 sigma) Process capability 10 Max Least count 1 Part to Part variation must be greater than the smallest unit of measure Range control chart provides best indication of inadequate discrimination Occurs when only 1,2, or 3 possible values for the range within the control limits exists Number of Distinct Categories equals part sigma/ total gage sigma 1.41.

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Measurement System Capability


Gage Capability

515 . * MS GR& R Tolerance

Usually expressed as percent

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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Measurement Error Effect on Capability Index Cp


We know that Cp
Act

USL LSL 6Act


USL LSL

where Act Obs MS


2 2

Therefore:

CpAct

2 6 2 Obs MS

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R&R Effect on Capability


70%
6.0 5.0 %R&R

60%

50%

Actual Cp

4.0 3.0 2.0 1.0 0.0

40% 30% 10%

0% 10% 20% 30% 40% 50% 60% 70%

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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Types of R&R Studies

Variable Gage R&R


Numbers Units of measure

Attribute Gage R&R


Subjective (cosmetic defects) Scatter of defects feel/visual
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The Inspection Exercise


Task: Count the number of times the 6th letter of the alphabet appears in the following text. The Necessity of Training Farm Hands for First

Class Farms in the Fatherly Handling of Farm Live


Stock is Foremost in the Eyes of Farm Owners. Since the Forefathers of the Farm Owners Trained the Farm Hands for First Class Farms in the Fatherly Handling of Farm Live Stock, the Farm Owners Feel they should carry on with the Family Tradition of Training Farm Hands of First Class Farmers in the Fatherly Handling of Farm Live Stock Because they Believe it is the Basis of Good Fundamental Farm Management.
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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

K1-Trial, K2-Operator, & K3-Part Constants

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Gage R&R study


Generally two or three operators Generally 10 units to measure Each unit is measured 2-3 times by each operator

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Preparation for a Measurement Study


Determine if reproducibility is an issue. If it is, select the number of operators to participate. Operators selected should normally use the measurement system. Select samples that represent the entire operating range. Gage must have graduations that allow at least one-tenth of the expected process variation. Insure defined gaging procedures are followed. Measurements should be made in random order. Study must be observed by someone who recognizes the importance of conducting a reliable study.
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Procedure for Performing R&R Study


Calibrate the gage, or assure that it has been calibrated. Have the first operator measure all the samples once in random order. Have the second operator measure all the samples once in random order. Continue until all operators have measured the samples once (this is Trial 1). Repeat above steps for the required number of trials. Use GR&R form to determine the statistics of the study.
Repeatability, Reproducibility & %GR&R Standard deviations of each of the above % Tolerance analysis

Analyze results and determine action, if any.


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Variable Gage R&R

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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Gasket Thickness Study


PT1 PT2 PT3 PT4 PT5 PT6 PT7 PT8 PT9 PT10 OP/TRIAL 0.65 1.00 0.85 0.85 0.55 1.00 0.95 0.85 1.00 0.60 A1 0.60 1.00 0.80 0.95 0.45 1.00 0.95 0.80 1.00 0.70 A2 0.55 1.05 0.80 0.80 0.40 1.00 0.95 0.75 1.00 0.55 B1 0.55 0.95 0.75 0.75 0.40 1.05 0.90 0.70 0.95 0.50 B2 0.50 1.05 0.80 0.80 0.45 1.00 0.95 0.80 1.05 0.85 C1 0.55 1.00 0.80 0.80 0.50 1.05 0.95 0.80 1.05 0.80 C2 Xbar & R Minitab Example Using Aiag49:mtw Data File Specification: 0.6 - 1.0 mm Process Variation: 1.6 mm Reference QS Measurement System Analysis Manual
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Gage R&R (Xbar/R) for Thickness

Gage name: Date of study : Reported by : Tolerance: Misc:

Xbar Chart by Operator


1.1 1.0 0.9 0.8 0.7 0.6 0.5 0.4 0.3
1 2 3

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

0.10 0.05 0.00

R=0.03833 -3.0SL=0.000

Operator

Components of Variation
200

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

0 Gage R&R Repeat Reprod Part-to-Part

Gasket

10

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Gage R&R Study for Thickness XBar/R Method


Source Total Gage R&R Repeatability Reproducibility Part-to-Part Total Variation Variance 2.08E-03 1.15E-03 9.29E-04 3.08E-02 3.29E-02 StdDev 0.045650 0.033983 0.030481 0.175577 0.181414 5.15*Sigma 0.235099 0.175015 0.156975 0.904219 0.934282

Source

%Contribution %Study Var

%Tol

%Process

Total Gage R&R 6.332 Repeatability 3.509 Reproducibility 2.823 Part-to-Part 93.668 Total Variation 100.000

25.164 18.733 16.802 96.782 100.000

58.77 43.75 39.24 226.05 233.57

14.69 10.94 9.81 56.51 58.39

Number of distinct categories = 5

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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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Attribute Data Example


Using A_grr.xls file

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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Attribute Gage R & R Effectiveness


Instructions:
1)
2)

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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Attribute Gage R & R Effectiveness


SCORING REPORT
Attribute Legend 1 pass 2 fail

DATE: NAME: PRODUCT: SBU: TEST CONDITIONS:


Operator #1 Try #1 Try #2

3/10/96 Allied Employee 3313 Spark Plug F&SP

Known Population Sample # Attribute 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30

Operator #2 Try #1 Try #2

Operator #3 Try #1 Try #2

Y/N Agree

Y/N Agree

% APPRAISER SCORE(1) -> % SCORE VS. ATTRIBUTE(2) ->

#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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Attribute Gage R & R Effectiveness


SCORING REPORT
Attribute Legend
1 pass 2 fail

DATE: NAME: PRODUCT: SBU: TEST CONDITIONS:

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 -

Operator #1 Try #1 Try #2


pass pass fail fail fail pass fail pass pass pass pass pass fail fail pass pass fail fail fail pass fail pass pass pass pass pass fail fail -

Operator #2 Try #1 Try #2


pass pass fail fail pass pass fail pass pass fail pass pass fail pass pass pass pass fail fail pass fail pass pass fail pass pass fail fail -

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

% APPRAISER SCORE(1) -> % SCORE VS. ATTRIBUTE(2) ->

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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Attribute Gage R&R Workshop


Perform attribute Gage R&R study using M&M's. Determine the defects by looking for consistent color in the M&M's, clear markings (M's), and roundness. Use 3 operators/inspectors Complete attribute GR&R analysis and report results (30 minutes). Improve inspection criteria, rerun attribute Gage R&R study/analysis and report results (30 minutes).

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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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