16/07/2021 Gage Repeatability and Reproducibility (R&R) | Six Sigma Study Guide

Gage Repeatability and Reproducibility (R&R)

Posted by Ted Hessing

Gage Repeatability and Reproducibility is commonly referred as Gage R&R. It’s a method to assess the measurement system’s repeatability and

reproducibility. In other words, Gage R&R studies are carried out to discover how much of the process variation is due to the measurement

system.

What is a Measurement System Analysis?

Measurement system Analysis (MSA) is a tool for analyzing the variation present in each type of inspection, measurement and test equipment. It

is the system to assess the quality of measurement system.

What is a Gage and Gage R&R?

A gage, in this context, is a tool for measurement. A gage could be simple, like calipers and ruler. Or it could be a complex piece of machinery. It

could even be a piece of software.

Gage R&R focuses on two key aspects of measurement:

Repeatability: Repeatability is the variation between successive measurements of the same part, same characteristic, by the same person

using the same gage. In other words, how much variation do we see in measurements taken by the same person, on the same part, using the

same tool?

Reproducibility: Reproducibility is the difference in the average of the measurements made by different people using the same instrument

when measuring the identical characteristic on the same part. In other words, how much variation do we see in measurements taken

by different people on the same part, using the same tool?

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Looking at these two metrics helps us to understand variation in our measurements. When we understand it, we can combat it.

Why is Gage R&R Important?

Gage R&R measures the amount of variability in measurements caused by the measurement system itself. Then compare this variability with the

total variability to determine the actual variability of the measurement system. Gage R&R is very important when new workers are assigned, new

tools are used, or any significant process change.

For example, imagine a situation where our performance metrics are showing us a serious problem in our manufacturing process. We spend a lot

of time and money trying to fix it and improve the process’s performance. But if we’d spent some time looking at gage repeatability and

reproducibility instead, we’d have noticed serious measurement variations. The problem wasn’t in the process at all; it was in the measurements.

Checking this first would have saved time, money, and stress.

Variation is made up of part and gage variation.

Image from Bo-ci-an under CC-BY-SA 3.0.

Types of Gage R&R study

Based on data availability and data type, there are basically three types of Gage R&R available

Crossed Gage R&R

Select crossed gage R&R when each operator measures each part, must have a balanced design with random factors. It is used for non-destructive

testing.

Nested Gage R&R

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Select nested gage R&R when only one operator measures each part. It is used for destructive testing. Since it is not crossed with other factors, it

is called nested gage R&R. It must have a balanced design with random factors.

Expanded Gage R&R

Select expanded gage R&R when we need to include more factors (maximum of eight) than operator and part. Typically crossed and nested deals

with only two factors (operator and part). Design can be balanced or unbalanced.

Methods to perform Gage R&R study

There are basically three methods existed to perform Gage R&R

Range method

Average and range method

Analysis of variance method

Range Method: The range method will provide a quick approximation of measurement variability, but it does not compute measurement system

repeatability and reproducibility separately.

Average and range method: The average and range method quantifies the measurement system’s variability and provides repeatability,

reproducibility, and part variation. Only crossed Gage R&R can be performed with average and range method.

Analysis of Variance method: It is the most widely used and accurate method for measurement system repeatability and reproducibility. It also

quantifies the variability of the interaction between the operator and the parts. Gage R&R (crossed, nested and expanded) can be performed with

ANOVA method.

How to Measure Gage R&R using ANOVA Method

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To measure the Gage R&R, it is recommended to measure minimum of 10 parts

Select 2 technicians to measure the parts

Have each technician measure each part 2 or 3 times

It is recommended three measurements per part by each technician

Collect the measurements of parts in random order and measure overall average of all measurements (x̿ )

t= number of technicians

r= number of trails or replications

p= number of parts

Step 1: Calculate the technician sum of squares

It provides sum of squares by determining the squared deviations between the technician average and the overall average

Step 2: Compute the parts sum of squares

It provides sum of squares by determining the squared deviations between the parts average and the overall average

Step 3: Calculate the total sum of squares

SSTotal = SSTechnician + SSPart + SSTech*Part + SSEquipment

It is the squared deviation of each individual result from the overall average.

Step 4: Compute Equipment within sum of squares

It uses the deviation of all trials for a given part and given technician from the average for that part and technician. 

Step 5: Find the interaction sum of squares

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SSTotal = SSTechnician + SSParts + SSTechnician*Part + SSEquipment

SSTechnician*Part = SSTotal – (SSTechnician + SSPart+ SSEquipment)

Step 6: Create ANOVA table

Step 7: Evaluate repeatability, technician, part and interaction variance

σ2 Repeatability = MSEquipment

σ2 TechnicianxPart = (MSTechnicianxPart – σ2 Repeatability)/ number of trails

And , σ2 Part = (MSPart – MSTechnicianxPart)/ (number of trails*number of technician)

σ2 Technician = (MSTechnician – MSTechnicianxPart)/ (number of trails*number of part)

If any of the value is negative, then consider it as zero

Step 8: Compute Gage R&R and interpret the results

Gage R&R = σ2 Repeatability  + σ2 Technician

Equipment Variation (Reliability) = σ2 Repeatability 

Technician Variation (Reproducibility) = σ2 Technician + σ2 TechnicianxPart

Part to Part = σ2 Part

Total Variation = σ2 Repeatability + σ2 Part+ σ2 Technician+ σ2 TechnicianxPart

Calculate % Contribution Variance and interpret the results and below are the criteria for acceptance of Gage R&R

Then, find the standard deviation and % study variance. Interpret the results. According to the Automotive Industry Action Group (AIAG) below

are the guidelines for measurement system assessment using %GRR

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What is the Number of Distinct Categories (NDC)

The number of distinct categories is a metric in gage R&R is to identify measurement system’s ability to detect a difference in the measured

characteristic. It represents the number of non-overlapping confidence intervals that span the range of product variation.

Formula for number of distinct categories

Number of distinct categories =(Standard deviations for parts / standard deviation for gage) * √2

So the number of categories depends on the ratio of the variability in the measuring parts and the variability in the measurement system.

Guidelines for number of distinct categories

According to Automotive Industry Action Group (AIAG), the number of distinct categories should be greater than 5 for an adequate measuring

system

>=5: Adequate measuring system               

=2:    Data can be divided into two say Low and High          

=3:    Data can be divided into three say Low, Medium, and High  

<2:    Measurement system of no value for controlling the system 

Example of Gage R&R using ANOVA method in a Six Sigma

project
Example: A testing engineer selected 10 parts that represent the expected range of process variation. Three technicians measured the ten parts

three times a part in random. Assess the measurement system Gage R&R.

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t= number of technicians =3

r= number of trails or replictions =3

p= number of parts =10

Average of all the measurements = (2.78+1.87+1.87+2.36+2.36+2.21+……….+2.44+1.8+1.72+4.12+3.25+3.69)/90= 3.066

Step 1: Calculate the technician sum of squares

Calculate the average measurement of each technician

For technician A: Average of 10 parts , 3 trails value = ((2.78+1.87+1.87+2.36+2.36+2.21+……….+4.1+3.88+3.56)/30 = 3.05

Calculate the squared deviation of each technician: squared deviations between the technician average and the overall average

For technician A: (3.05-3.066)2 =0.003

Similarly, calculate for technician B and C

Add all squared deviation for technicians = 0.003+0.0022+0.0008=0.0033

For 10 parts and 3 trails sum of deviations = 3*10*0.0033 =0.0999

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Step 2: Calculate the parts sum of squares

Calculate the average of measurement for each part for all trails

for part 1: (2.78+1.87+1.87+2.56+2.22+2.14+2.56+2.22+2.15)/9=2.263

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Calculate the squared deviation of each part: squared deviations of each part and the overall average

For part 1: (2.263-3.066)2 =0.644

Similarly calculate values for 10 parts

Add all squared deviation for 10 parts = 0.644+0.577+0.537+1.542+0.357+0.833+0.677+5.914+1.165+0.703=12.9477

For 3 trails and 3 technicians sum of deviations = 3*3*12.9477 =116.5294

Step 3: Calculate the total sum of squares

Squared deviation of each individual result from the overall average.

for first part trail 1: (2.78-3.066)2 = 0.082

Similarly, conduct for all the 90 trails and sum of Squared deviation of 3 trails = 0.082+1.430+1.430+……..+1.111+0.034+0.389 =120.682

Step 4: Compute Equipment within sum of squares

It uses the deviation of all trials for a given part and given technician from the average for that part and technician.

Take the average of first part , first technician three trails = (2.78+1.87+1.87)/3 =2.173

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Calculate the Squared Deviation Trial 1 for first part = (2.78-2.173)2 = 0.368

Similarly calculate squared deviation for all trails for each part

Sum of 90 values = 0.368+0.092+0.092+…………………+0.188+0.191+0.000=3.606

Step 5: Find the interaction sum of squares

SSTechnician*Part = SSTotal – (SSTechnician + SSPart+ SSEquipment)

SSTechnician*Part = 120.682 – (0.0999 + 116.5294+ 3.606) =0.447

Step 6 : Create ANOVA table

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Since p value for interaction is more than 0.05 we need to consider the repeatability without interaction values

Step 7: Evaluate repeatability, technician, part and interaction variance

σ2 Repeatability = MSEquipment =0.05196

Then, σ2 TechnicianxPart = (MSTechnicianxPart – σ2 Repeatability)/ number of trails = (0.02482-0.05196)/3 = -0.00904 =0

σ2 Part = (MSPart – MSTechnicianxPart)/ (number of trails*number of technician) = (12.9477-0.05196)/(3*3) = 1.4328

σ2 Technician = (MSTechnician – MSTechnicianxPart)/ (number of trails*number of part) =(0.04996-0.05196)/(10*3) = -0.00006667 =0

Step 8: Compute Gage R&R and interpret the results

Gage R&R = σ2 Repeatability  + σ2 Technician =0.05196+0 = 0.05196

Equipment Variation (Reliability) = σ2 Repeatability  =0.05196

Technician Variation (Reproducibility) = σ2 Technician + σ2 TechnicianxPart = 0+0 =0

Part to Part = σ2 Part=1.4328

Total Variation = σ2 Repeatability + σ2 Part+ σ2 Technician+ σ2 TechnicianxPart = 0.05196+1.4328+0+0 = 1.4848

From the above values, compute the % contribution variance

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Since the Total Gage R&R is 3.5%, it is in the yellow zone. So it may be acceptable depending on application and cost factors, but the team needs to

improve it further.

Find the standard deviation and % study variance

According to the Automotive Industry Action Group (AIAG) measurement system assessment using %GRR

Since the Total Gage R&R is 18.71%, it is in the yellow zone. So it may be acceptable depending on application and cost factors, but the team needs

to improve it further.

Calculate the number of distinct categories (NDC)

According to Automotive Industry Action Group (AIAG), the number of distinct categories should be greater than 5 for an adequate measuring

system

Number of distinct categories =(Standard deviations for parts / standard deviation for gage) * √2 =(1.9702/0.2279) * √2 =7

Gage R&R ANOVA Excel Template

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Gage Repeatability and Reproducibility using Minitab

Step 1: Copy the data in Minitab sheet

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Step2: Select Stat –> Quality Tools –> Gage Study –> Gage R&R (Crossed)

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Select Part numbers, Operator and Measurement data and select ANOVA method

Under options: Enter process tolerance, the default alpha to remove interaction term would be 0.25. click on ok

Step 3 : Interpretation of results (session window)

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The p-value for the operator (0.163) is greater than 0.05

The p-value for Parts * Operator (0.98) is greater than 0.05. Hence Minitab ignores the values and considers the values in the without

interaction table.

Part to part variation is 96.5. which is much great than the Total Gage R&R (3.5%). So it tells that much variation is between the parts.

Total Gage R&R is 3.5%. So it may be acceptable depending on application and cost factors, but there is a scope for improvement .

Similarly, in the % study variance, the total Gage R&R is 18.71%. According to AIAG it may be acceptable depending on application and cost

factors, but the team needs to improve it further.

The number of distinct categories is 7 which is greater than acceptable number of 5.

Step 4: Interpretation of results (graphs window)

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First Graph- Components of Variation: It clearly shows the much variation is between the part to part, but not due to Gage R&R

Second Graph- Measurement values by parts: Clearly indicate the variation between the parts

Third Graph- R chart by operator: All the values are within control limits

Fourth Graph – Measurement value by operator: The difference between operators is small.

Fifth Graph – X bar chart by operator: Most of the points are outside of control limits. Hence it indicates that variation is basically due to

the parts.

Sixth Graph – Operator * Parts Interaction: There is no much difference between the operators and also there is no interaction between

parts and operator.

Videos of Gage R&R Charts

5-31: MSA: Gage R&R Test

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How to Setup a Gage R&R Study

Video: How to set up a Gage R&R study

Gage R&R Definitions

Precision

Getting consistent results repeatedly.

The repeatability of the gage.

Accuracy

Unbiased true values are obtained.

Must be assured before an R&R can be performed.

This is why we calibrate.

Sensitivity

Ability to detect differences in measurement.

Reproducibility

We compare the results of different operators at different times.

We examine variation between the averages of each operator.

Repeatability

We look at the variation between individual operators.

We look at the variation within their readings.

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