Measurement System Analysis

Gage R&R Study

 Types of MSA’s

MSA’s fall into two categories:

• Variable
• Attribute

Variable Attribute
• Continuous scale • Pass/Fail
• Discrete scale • Go/No Go
• Critical dimensions • Document Preparation
• Pull strength • Surface imperfections
• Warp • Customer Service Response

• Transactional projects typically have Attribute based measurement

systems.
• Manufacturing projects generally use Variable studies more often,
but do use Attribute studies to a lesser degree.
 Variable MSA’s

MINITAB™ calculates a column of variance components (VarComp) which are used

to calculate % Gage R&R using the ANOVA Method.

Measured Value True Value

Estimates for a Gage R&R study are obtained by calculating the variance
components for each term and for error. Repeatability, Operator and Operator*Part
components are summed to obtain a total Variability due to the measuring system.
We use variance components to assess the Variation contributed by each source of
measurement error relative to the total Variation.
 Design Types

Crossed Design
• A Crossed Design is used only in non-destructive testing and assumes that all the parts can be
measured multiple times by either operators or multiple machines.
• Gives the ability to separate part-to-part Variation from measurement system Variation.
• Assesses Repeatability and Reproducibility.
• Assesses the interaction between the operator and the part.

Nested Design
• A Nested Design is used for destructive testing (we will learn about this in MBB training) and
also situations where it is not possible to have all operators or machines measure all the
parts multiple times.
• Destructive testing assumes that all the parts within a single batch are identical enough
to claim they are the same.
• Nested designs are used to test measurement systems where it is not possible (or
desirable) to send operators with parts to different locations.
• Do not include all possible combinations of factors.
 Gage R & R Study

Gage R&R Study

• Is a set of trials conducted to assess the Repeatability and Reproducibility of
the measurement system.
• Multiple people measure the same characteristic of the same set of multiple
units multiple times (a crossed study)
• Example: 10 units are measured by 3 people. These units are then randomized
and a second measure on each unit is taken.

A Blind Study is extremely desirable.

• Best scenario: operator does not know the measurement is a part of a test
• At minimum: operators should not know which of the test parts they are
currently measuring.
 Gage R & R Study

• Select 10 parts throughout the range of interest

10 x 3 x 2 Crossed Design is shown

A minimum of two measurements/part/operator
is required. Three is better!

Trial 1
Operator 1
P Trial 2
a
r Trial 1
t 1 2 3 4 5 6 7 8 9 10 Operator 2
s Trial 2

Trial 1
Operator 3
Trial 2
 Changes in AIAG MSA Manual 4th Edition

• Although reproducibility is usually interpreted as appraiser (operator)

variation, there are situations when this variation is due to other sources of
variation.

• For example, with some in-process measurement systems there are no

human appraisers. If all the parts are handled, fixtured and measured by the
same equipment, then reproducibility is zero: i.e., only a repeatability study
is needed.

• If however, multiple fixtures are used, then the reproducibility is the

between-fixture variation.
 Changes in AIAG MSA Manual 4th Edition

When multiple fixtures are used, then the reproducibility

is the between-fixture variation.
 Variable Gage R & R Steps

Step 1: Call a team meeting and introduce the concepts of the Gage R&R
Step 2: Select parts for the study across the range of interest
• If the intent is to evaluate the measurement system throughout the process
range, select parts throughout the range
• If only a small improvement is being made to the process, the range of interest is
now the improvement range
Step 3: Identify the inspectors or equipment you plan to use for the analysis
• In the case of inspectors, explain the purpose of the analysis and that the
inspection system is being evaluated not the people
Step 4: Calibrate the gage or gages for the study
• Remember Linearity, Stability and Bias
Step 5: Have the first inspector measure all the samples once in random order
Step 6: Have the second inspector measure all the samples in random order
• Continue this process until all the operators have measured all the parts one time
• This completes the first replicate
Step 7: Repeat steps 5 and 6 for the required number of replicates
• Ensure there is always a delay between the first and second inspection
Step 8: Enter the data into MINITAB and analyze your results
Step 9: Draw conclusions and make changes if necessary
 Gage R & R Example

Open Minitab Worksheet “Gage_RR.MTW” :

Variables:
• Part
• Operator
• Response
 Gage R & R Example

Gage R&R Study:

Stat > Quality Tools > Gage Study > Gage R&S Study (Crossed)…
 Gage R & R Example

Click « Options… »
 Gage R & R Example

• Click « Options… »
• Enter the process specification limits

A 99.73% spread is
represented by a
multiplier of 6.0
which corresponds
to 3.
 Gage R & R Example

Graphical Output:
Looking at the “Components of Variation” chart, the Part to Part Variation needs to be
larger than Gage Variation. If in the “Components of Variation” chart the “Gage R&R” bars
are larger than the “Part-to-Part” bars, then all your measurement Variation is in the
measuring tool i.e.… “maybe the gage needs to be replaced”. The same concept applies
to the “Response by Operator” chart. If there is extreme Variation within operators, then
the training of the operators is suspect.

Part to Part
Variation needs to
be larger than Gage
Variation
 Gage R & R Example

Session Window Output:

I can see clearly now!

 Gage Evaluation

There are three different ways to evaluate gage variability:

1. Using process variation from GRR Study:
6 ∙ 𝜎𝑔𝑎𝑔𝑒 𝜎𝑔𝑎𝑔𝑒
%Study Var = 100 ∙ = 100 ∙
6 ∙ 𝜎𝑇𝑜𝑡𝑎𝑙 𝜎𝑇𝑜𝑡𝑎𝑙

2. Using historical process variation:

𝜎𝑔𝑎𝑔𝑒
%Process = 100 ∙
𝜎𝐻𝑖𝑠𝑡𝑜𝑟𝑖𝑐𝑎𝑙

3. Using Specification Tolerance:

𝜎𝑔𝑎𝑔𝑒
%Tolerance = 100 ∙
(𝑈𝑆𝐿 − 𝐿𝑆𝐿) 6
 AIAG Standards for Gage Acceptance

Here are the Automotive Industry Action Group’s definitions for Gage
acceptance.

%Contribution (of %Study Variance,

System is…
VarComp) %Tolerance or
%Process

Under 1% Under 10% Excellent

Between 1% and Between 10% and

Acceptable
4% 20%

May be acceptable
Between 4% and Between 20% and
for some
9% 30% applications

Over 9% Over 30% Poor

 AIAG Standards for Gage Acceptance

• When gage evaluation result is between 10 and 30%: The gage may be
acceptable for some applications. The Decision should be based upon,
for example, importance of application measurement, cost of
measurement device, cost of rework or repair. Should be approved by
the customer.

• When gage evaluation result is over 30%: Every effort should be made
to improve the measurement system. This condition may be addressed
by the use of an appropriate measurement strategy; for example, using
the average result of several readings of the same part characteristic in
order to reduce final measurement variation.
 Gage Evaluation

Which metrics to use ? %StudyVar, %Tolerance or %Process ?

Use %Tolerance or %StudyVar to evaluate the measuring system, depending on the
use of the measuring system:

• Product Control Situation: If the measurement system evaluates parts relative

to specifications (i.e. conformance or nonconformance to the feature
specification), %Tolerance is a more appropriate metric.

• Process Control Situation: If the measurement system is used for process

improvement (reducing part-to-part variation) or process monitoring,
%StudyVar and %Process are better estimates of measurement precision.
 Number of Distinct Categories

The number of distinct categories tells you how many

Number of Distinct
separate groups of parts the system is able to distinguish.
Categories

p
Unacceptable for estimating  2
process parameters and
indices
M
Only indicates whether the
process is producing
conforming or Always round
1 Data Category down to the
nonconforming parts
nearest whole
number.
Generally unacceptable for
estimating process If the calculated
parameters and indices value is less
Only provides coarse than one, then
2 - 4 Categories
estimates
the number of
distinct
Recommended categories is
equal 1.
5 or more Categories
 Gage Acceptance

If the Variation due to Gage R & R is high, consider:

• Procedures revision
• Gage update
• Operator issue
• Tolerance validation
Exercise
Gage R&R
 Exercise

Consider the gage R&R study stored in the Minitab file

INJECTION.MTW :

1. Analyze the measurement system variation with

MINITAB (process tolerance = 8)

2. Interpret the results. Is the measurement system

acceptable?
Exercise
Gage R&R
 Exercise

Consider the gage R&R study stored in the Minitab file

Gage_RR_2.MTW :

1. Analyze the measurement system variation with

MINITAB

2. Interpret the results. Is the measurement system

acceptable?