Format no : HYAQF/ QAD/20

MEASUREMENT SYSTEM ANALYSIS (MSA) Rev No : 00

GAUGE REPEATABILITY & REPRODUCIBILITY REPORT Date :

Customer: TEPL Part Name: REC Slider Part No: SJ2501-RECSPK-1001-032 Date: 24-07-2024

Instument Name: Micrometer Range: 0-25 mm Gauge No: HYA/DMM/01 Characteristics: Distance

No. of Appraisers : 3 No fo Trail: 3 Parts qty 10 Specification: 16 ( -0.02 / -0.03)

Appraisers:- A - Vediyappan B - Sathis kumar C - Anandhalakshmi
Appraiser Parts # / Observation
Sl # Avearage
Trial# 1 2 3 4 5 6 7 8 9 10
1 A 1 15.990 15.980 15.990 15.980 15.970 15.980 15.970 15.990 15.970 15.990 15.98100
2 2 15.960 15.970 15.980 15.960 15.960 15.970 15.970 15.980 15.980 15.990 15.97200
3 3 15.990 15.980 15.960 15.990 15.970 15.960 15.970 15.980 15.970 15.980 15.97500
4 Average 15.98000 15.97667 15.97667 15.97667 15.96667 15.97000 15.97000 15.98333 15.97333 15.98667 Xa= 15.97600
5 Range 0.03000 0.01000 0.03000 0.03000 0.01000 0.02000 0.00000 0.01000 0.01000 0.01000 Ra = 0.01600
6 B 1 15.970 15.980 15.960 15.970 15.970 15.980 15.960 15.980 15.970 15.970 15.97100
7 2 15.960 15.970 15.970 15.980 15.960 15.970 15.980 15.970 15.980 15.960 15.97000
8 3 15.970 15.980 15.970 15.970 15.980 15.970 15.960 15.970 15.980 15.970 15.97200
9 Average 15.96667 15.97667 15.96667 15.97333 15.97000 15.97333 15.96667 15.97333 15.97667 15.96667 Xb= 15.97100
10 Range 0.01000 0.01000 0.01000 0.01000 0.02000 0.01000 0.02000 0.01000 0.01000 0.01000 Rb = 0.01200
11 C 1 15.980 15.970 15.970 15.960 15.980 15.990 15.970 15.980 15.970 15.980 15.97500
12 2 15.960 15.980 15.970 15.980 15.970 15.960 15.980 15.970 15.990 15.960 15.97200
13 3 15.970 15.960 15.980 15.980 15.980 15.970 15.990 15.980 15.990 15.990 15.97900
14 Average 15.97000 15.97000 15.97333 15.97333 15.97667 15.97333 15.98000 15.97667 15.98333 15.97667 Xc= 15.97533
15 Range 0.02000 0.02000 0.01000 0.02000 0.01000 0.03000 0.02000 0.01000 0.02000 0.03000 Rc = 0.01900
16 Part Avearge 15.97222 15.97444 15.97222 15.97444 15.97111 15.97222 15.97222 15.97778 15.97778 15.97667 X = 15.97411
17 Xp Rp = 0.00667

18 R = [ (Ra +Rb + Rc) / 3 (No. of Appraiser) ] = 0.0156667 UCLR = ( R x D4 ) = 0.0403417 UCLx = X + A2 R = 15.9901

19 X diff = ( Xmax - Xmin) = 0.00500 LCLR = ( R x D3 ) = 0 LCLx = X - A2 R 15.95808411

Measurment Unit Analysis % Total variation ( Tv ) Acceptance Criteria:
REPEATABILITY = EQUIPMENT VARIATION = (Ev) %Ev = 100 [ Ev / Tv ] %R&R < 10% = Acceptable
21
Ev = R x K1 Ev = 0.0093 95.44 %R&R < 30% & >10% = May be Acceptable
REPRODUCIBILITY = APPRAISER VARIATION = (Av) %Av = 100 [ Av / Tv ] %R&R > 30% = Not Acceptable
22 Av = { ( X diff x K2 )2 - ( Ev2 / n r ) }1/2 Av = 0.00200 20.58 ndc >= 5
Where, n= No. of Parts & r = No. of Trials %GRR = 100 [ R & R / Tv ]
REPEATABILITY & REPRODUCIBILITY = GRR 97.63 CONLUSION
23 GRR = (Ev2 + Av2 )1/2 GRR = 0.00947 %Pv = 100 [ Pv / Tv ] Gauge not Acceptable
PART VARIATION = Pv. Pv = Rp x K3 Pv = 0.00210 21.63
TOTAL VARIATION = Tv ndc = 1.41 (Pv / GRR)
24
Tv = [ ( GRR )2 + ( Pv )2 ] 1/2 Tv = 0.00970 0
Table of Constants K1 = 0.5908 K2 = 0.5231 K3 = 0.3146 A2 = 1.0230 D4 = 2.575 D3 = 0.000
 Appariser A - Average Chart Appariser A - Range Chart

16.000 0.045
0.040
15.990
0.035
15.980 Average 0.030
Average

Range
0.025 Range
15.970 UCL
0.020 UCL
15.960 LCL 0.015
0.010
15.950
0.005
15.940 0.000
1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10
Part No Part No

Appariser B - Average Chart Appariser B - Range Chart

16.000 0.045
0.040
15.990
0.035
15.980 Average 0.030
Average

Range
0.025 Range
15.970 UCL
0.020 UCL
15.960 LCL 0.015
0.010
15.950
0.005
15.940 0.000
1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10
Part No Part No

Appariser C - Average Chart Appariser C - Range Chart

16.000 0.045
0.040
15.990
0.035
15.980 Average 0.030
Average

Range

0.025 Range
15.970 UCL
0.020 UCL
15.960 LCL 0.015
0.010
15.950
0.005
15.940 0.000
1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10
Part No Part No
 Average Chart - Stacked Range Chart - Stacked

16.000 0.045

0.040
15.990
0.035

15.980 Ap A 0.030
Ap A
Ap B
Average

Average
0.025 Ap B
15.970 Ap C
Ap C
UCL 0.020
UCL
LCL
15.960 0.015

0.010
15.950
0.005

15.940 0.000
1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10
Part No Part No

Analysis of GRR Study

If repeatability is larger compared to reproducibility, the reason may be:
1. The instrument needs maintenance
2. The gage may need to be redesigned to be more rigid.
3. The clamping or location for gaging needs to be improved
4. There is excessive within part variation.

If reproducibility is large as compared to repeatability, then possible causes could be:

1. The appraiser needs to be better trained in how to use and read the gage instrument
2. Calibration of the gauge is not clear.

CHECKED BY: APPROVED BY:

Restricted Area
Ntote: For work instruction for R& R Ref. Work instruction file
Calculations:

Av = { ( X diff * K2 )2 - ( Ev2 / n r ) }1/2 GRR = (Ev2 + Av2 )1/2 Tv = [ ( R&R )2 + ( Pv )2 ] 1/2

2
( X diff * K2 ) = 0.00000684084 Ev2 = 0.0000857 (GRR)2 = 0.00008966
Ev2 = 0.00008567107 Av2 = 0.0000040 ( Pv )2 = 0.0000044
nr = 30.000 Ev2 + Av2 = 0.000089656 Tv = 0.009698
Ev2 / n r = 0.00000285570 (Ev2 + Av2 )1/2 = 0.009469
2 2
( X diff * K2 ) - ( Ev / n r ) = 0.00000398514
Av = { ( X diff x K2 )2 - ( Ev2 / n r ) }1/2 = 0.0019963
If a negative value is calculated under the square root sign, the appraiser
variation(AV) defaults to zero
Table of Constants: Control Limits
Trial K1 Appraiser K2 Parts K3 No. of UCLx LCLx UCLR
2 0.8862 2 0.7071 2 0.7071 Observatons in A2 D3 D4 15.990 15.958 0.04034
3 0.5908 3 0.5231 3 0.5231 Sub group 15.990 15.958 0.04034
4 0.4467 2 1.880 0.000 3.267 15.990 15.958 0.04034
5 0.4030 3 1.023 0.000 2.575 15.990 15.958 0.04034
6 0.3742 4 0.729 0.000 2.282 15.990 15.958 0.04034
7 0.3534 5 0.577 0.000 2.115 15.990 15.958 0.04034
8 0.3375 6 0.483 0.000 2.004 15.990 15.958 0.04034
9 0.3249 7 0.419 0.000 1.924 15.990 15.958 0.04034
10 0.3146 8 0.373 0.136 1.864 15.990 15.958 0.04034
9 0.337 0.184 1.816 15.990 15.958 0.04034
10 0.308 0.223 1.777
11 0.285 0.256 1.744
12 0.266 0.284 1.716
13 0.249 0.308 1.692
14 0.235 0.329 1.671
15 0.233 0.348 1.652
 ANALYSIS OF GRR STUDY REPORT
1. Repeatability : The variation in measurement obtained by an appraiser while
measuring the identical characteristic on the same part when used several times
If repeatability is higher than reproducibility then:
1) Gauge need maintenance
2) Fixture clamping require modification
3) There is excessive variation with in part
2. Reproducibility : Variation in measurement when the same characteristics is
measured by different appraiser using the same gauge
If reproducibility is higher than repeatability then:.
1) Then appraiser needs training
2) Calibration on the gauge not o.k.

ANALYSIS OF GRR AVRAGE & RANGE CHARTS

The primary purpose of graphical approach is to determine if the measurement process is
adequate to measure the manufacturing process variation and / or evaluate the product
conformance.
Range Chart:
P If all the range are in control, all the appraiser are doing the same job
P If one appraiser is out of control, his method differs from the others.
P If all appraisers have some out of control range, the measurement system is
sensitive to appraiser technique and needs improvement to obtain useful data.
Average Chart
P If all average falls with in control limits, the measurement system variation is higher
than the manufacturing process variation and measurement system is not controlling
that process.
P If less than half of the averages are outside the limits, the measurement system is
inadequate for process control.
P If majority of the averages falls outside the control limits , the manufacturing
process variation is greater than the measurement variation. This measurement
system can provide useful data for controlling the process.