MSA

MEASUREMENT SYSTEM ANALYSIS

 TERMINOLOGY
GAUGE
Any device used to obtain measurements, frequently used to refer

specifically to the devices used on the shop floor;Includes go/ nogo

devices
MEASUREMENT SYSTEM
The collection of operations, procedures,gauges and other

equipment, soft ware, amd personel used to assign a number to

the characteristics being measured; the complete process used

To Obtain measurements.
 All the measurement system must have following certain properties

1. The Measurement system must be in statistical control.

2. Variability of measurement must be small compared with the

manufacturing process varaibility.

3. Variability must be samll compared with the specification limits.

4. The increments of measure must be small relative to the
samaller of either the process variability or the specification
limits
5. The stastical properties of the measurement system may change
as the items being measured vary.
Measure system error can be classified on to five catagories;

BIAS

Measurement
Linearity System Stability
Error

Repeatability Reproducibility
 OBJECTIVE

To quantify the variation present in the measurement system

Ensure the stability of the measurement system

Initiate appropriate actions to minismise the contamination of

Measurement system variation in total process variation
Application of such a study provide the following

A criterion to accept new measuring equipment

A comparision of one measuring device against another.

A bassis of evaluating a gage suspected of being deficient

A comparision for measuring equipment before and after repair.

A required component for calculating process variation, and the

accepatability level for a production process

Information necessary to develop a gauge performace curve(GPC),

which indicate the probability of accepting a part of some value.
Like every process, the distribution that can be used to
describe the measurement system`s variation can be
characterized by
1)Location :
Staility

bias

Linearity

2) Width or spread

Repeataility

Reproduciility
 BIAS

Bias is the difference between the observed avearage of

measurements and the reference value(mean).

The reference is also known as the accepted reference value or

Master value.(ASTM D 3980-88 ).

Bias

Reference
value
Observed average value
 BIAS

If the bias is relatively large, look for these posible causes:

1) Error in the master

2) Worn components

3) Instrument made to the wrong charcteristics.

4) Instrument measuring the wrong characteristics.

5) Instrument no calibrated properly.

6) Instrument used improperly by appraiser.

Obtain accepted reference value for the part
Use tool room or layout equipment
Measure same part minimum 10 times using gauge under
evolution
Calculate average of readings
Calculate the Bias ; Bias = Observed average – Refrence value
Draw histogram , interpet for normality
Calculate the sigma R= (Min-Max)/ d2 (d2 = Standard)
Calculate the Sigma Bias= R/ Sqrt n
Calculate t statistic for bias = Bias/ sigma bias

Calculate the lower limit of t distribution of Bias

Calculate higer limit of t distribution of Bias
 Example:1

Reference value = 0.80

Variation of the part = 0.70(Tolerance)

Observed values are 0.75,0.75,0.80,0.80,0.65,0.80,0.75,0.75,0.75,7.0

Observed average = 7.5/10=0.75.
Bias = Observed average- reference value
= 0.75-0.80 = - 0.05
The percent of process variation
% of Bias = 100(bias/Process variation
= 100(0.05/0.70) = 7.1%

Therefore R&Rstudy of gauge has a bias of –0.05 mm.This means

that the Observed measurement average will be 0.05 mm smaller
than the reference value which is 7.1% of the process variation.
 Repeatability

Repeatability Is the variation in measurements Obtained with

One measurement instrument when used several times by one

appraiser while measuring the identical charactristics on the

same part.
 Reproducibility

Reproducibility is the variation in the average of the measurements

made by different appraisers using the same Measuring instruments

when measuring the identical Characteristic on the same part.

Appraiser C

Appraiser B

Appraiser A
Reproducibility
 STABILITY

Stability is the total variation in the mesurements obtained with a

Measurement system on the same master or parts when meaureing

A single characterstics over an extend time period. It is also called

as Drift.
 LINEARITY

Linearity is the differnece in the bias values through the

expected operating range of the gauge .

Linearity can be determined by chossing parts throughout the

operating range of the meaurement instrument. The linearity graph is
Plotted between biases and reference values throughout the operating
range.
Possible causes for measurement system having non - linearity

1) Instrument not calibrated properly at both lower and

upper end of the operating range.

2) Error in the minimun or maximum master

3) Wornout instrument

4) Internal instrument design characteristics.

Linearity Example
One Appraiser / 12 Trails / 5 Parts-selected throughout the
Operating range of the measurement system

Part Reference 1 2 3 4 5
Value 2.00 4.00 6.00 8.00 10.00
1 2.70 5.10 5.80 7.60 9.10
2 2.50 3.90 5.70 7.70 9.30
3 2.40 4.20 5.90 7.80 9.50
T 4 2.50 5.00 5.90 7.70 9.30
R 5 2.70 3.80 6.00 7.80 9.40
I 6 2.30 3.90 6.10 7.80 9.50
A 7 2.50 3.90 6.00 7.80 9.50
L 8 2.50 3.90 6.10 7.70 9.50
S 9 2.40 3.90 6.40 7.80 9.60
10 2.40 4.00 6.30 7.50 9.20
11 2.60 4.10 6.00 7.60 9.30
12 2.40 3.80 6.10 7.70 9.40
Part Average 2.49 4.13 6.03 7.71 9.38
Reference value 2.00 4.00 6.00 8.00 10.00
Bias 0.49 0.12 0.02 -0.29 -0.62
Range 0.40 1.30 0.70 0.30 0.50
 Percentage Points t α,ν of the t-Distribution
0.0250
α 0.4000 0.2500 0.1000 0.0500 0.0100 0.0050 0.0025 0.0010 0.0005
( 0.975)
ν
1 0.325 1.000 3.078 6.314 12.706 31.821 63.657 127.320 318.310 636.620
2 0.289 0.816 1.886 2.920 4.303 6.965 9.925 14.089 23.326 31.598
3 0.277 0.765 1.638 2.353 3.182 4.541 5.841 7.453 10.213 12.924
4 0.271 0.741 1.533 2.132 2.776 3.747 4.604 5.598 7.173 8.610
5 0.267 0.727 1.476 2.015 2.571 3.365 4.032 4.773 5.893 6.869
6 0.265 0.718 1.440 1.943 2.447 3.143 3.707 4.317 5.208 5.959
7 0.263 0.711 1.415 1.895 2.365 2.998 3.499 4.029 4.785 5.408
8 0.262 0.706 1.397 1.860 2.306 2.896 3.355 3.833 4.501 5.041
9 0.261 0.703 1.383 1.833 2.262 2.821 3.250 3.690 4.297 4.781
10 0.260 0.700 1.372 1.812 2.228 2.764 3.169 3.581 4.144 4.587
11 0.260 0.697 1.363 1.796 2.201 2.718 3.106 3.497 4.025 4.437
12 0.259 0.695 1.356 1.782 2.179 2.681 3.055 3.428 3.930 4.318
13 0.259 0.694 1.350 1.771 2.160 2.650 3.012 3.372 3.852 4.221
14 0.258 0.692 1.345 1.761 2.145 2.624 2.977 3.326 3.787 4.140
15 0.258 0.691 1.341 1.753 2.131 2.602 2.947 3.286 3.733 4.073
16 0.258 0.690 1.337 1.746 2.120 2.583 2.921 3.252 3.686 4.015
17 0.257 0.689 1.333 1.740 2.110 2.567 2.898 3.222 3.646 3.965
18 0.257 0.688 1.330 1.734 2.101 2.552 2.878 3.197 3.610 3.922
19 0.257 0.688 1.328 1.729 2.093 2.539 2.861 3.174 3.579 3.883
20 0.257 0.687 1.325 1.725 2.086 2.528 2.845 3.153 3.552 3.850
21 0.257 0.686 1.323 1.721 2.080 2.518 2.831 3.135 3.527 3.819
22 0.256 0.686 1.321 1.717 2.074 2.508 2.819 3.119 3.505 3.792
23 0.256 0.685 1.319 1.714 2.069 2.500 2.807 3.104 3.485 3.767
24 0.256 0.685 1.318 1.711 2.064 2.492 2.797 3.091 3.467 3.745
25 0.256 0.684 1.316 1.708 2.060 2.485 2.787 3.078 3.450 3.725
26 0.256 0.684 1.315 1.706 2.056 2.479 2.779 3.067 3.435 3.707
27 0.256 0.684 1.314 1.703 2.052 2.473 2.771 3.057 3.421 3.690
28 0.256 0.683 1.313 1.701 2.048 2.467 2.763 3.047 3.408 3.674
29 0.256 0.683 1.311 1.699 2.045 2.462 2.756 3.038 3.396 3.659
30 0.256 0.683 1.310 1.697 2.042 2.457 2.750 3.030 3.385 3.646
40 0.255 0.681 1.303 1.684 2.021 2.423 2.704 2.971 3.307 3.551
60 0.254 0.679 1.296 1.671 2.000 2.390 2.660 2.915 3.232 3.460
120 0.254 0.677 1.289 1.658 1.980 2.358 2.617 2.860 3.160 3.373
0.253 0.674 1.282 1.645 1.960 2.326 2.576 2.807 3.090 3.291
ν - degrees of freedom
 REPEATABILITY

Two common sources of repeatability error are

a) Measurement variation due to instrument itself

b) Positional variation of the part in the instrument.

The range chart will show the consistency of the measurement

If the range chart is out of control, there is a problem generaly with

the consistency of the measurement process.

Those points identifies as out of control should be investigate for their

Special cause of inconsistency and corrected.
 REPEATABILITY

The standard deviation for repeatability of instrument variation

 Is estimated by R/d2.

The instrument variation or repeatability would be 5.51 or 4.56 

Which represents 99% of the measurements for a normal distribution.
Repeatability eample
 Limits for Range chart: R = 0.16/10 =
0.016
D3 = 0.0000 D4 = 2.575
UCL R = R x D4 = 0.016 x 2.575 LCL R = R x D3 = 0.0 x 2.575
= 0.0412 = 0

 = R/D2 = 0.016 /1.72 = 0.009

The repetability study is calculated by 5.15 (99%) =5.15x0.009
= 0.046
The repetability study is calculated by 6 (99.9%) =6x0.009
= 0.046=0.055
 Reproducibility

Reproducibility of the measurement process implies varaibility

Among appraisers is consistant.If this bias or appraiser variability
Does exit, the individual appraiser overall averages will deffer.
This can be seen on the average control chart by comparing the
appraiser averages for each part.

The appraier variation or reproducibility is estimated by determaining

the overall average for each appraiser and then finding the range (R 0)
by subtracting the smallest appraiser average from the largest.

i..e ) R0/ d2.

The reproducibility would be 5.15Ro/d2 or 3.65 R0.

 Reproducibility Example

Ro = 12.958-12.955 = 0.003

Estimated Appraiser standard deviation = Ro/ d2

= 0.003/ 1.41

= 0.002

The reproducibility = 5.15Ro/d2 = 0.0215

Since the estimate is contaminated by the variation due to the gauge,
it must be adjusted by subtracting a fraction of the repeatability.
The adjusted reproducibility.

= [5.15Ro/d2]² - [(5.15e)²/(nr)]
Where n = number of parts and r = number of trails

= 0.00215 –0.00014

= 0.04472

Adjusted appraiser standard deviation  o= 0.00868

 PART –TO-PART VARIATION

Part to part variation can be seen on the average control chart.Since

the control limits for the part average are based on the repeatability
error, rather than the part-to-part variation, many of the subgroup
averages are outside these limits.
The measurement system standard deviation is estimated by
m = ( e² + o²)

Where e is the gauge standard deviation and o is the appraiser deviation

 Gauge R&R Calculation

Steps involved in Gauge R& R method

1) Select 2 or 3 appraiser – regulerly using persons
2) Take the 10 componets (within spec and througout the range)
3) Number the parts and not visible to appraisers.
4) Ensure the gauge is calibrated
5) Measure the componets randomly
6) Meaure the components 3 times by each appriaser.
7) Follow the steps 5 & 6 with other appraisers.
8) Put the datas in GRR data sheet
9) Calculate Appriser variation, Equipment variation,
Repetability,&Reproducibility, GRR, Part variation &
total variation.
10) And calculate the Non distinct categories (NDC).
 Acceptance Guide lines for R&R Study

If R&R % is less than 10% , System is accepted

If 10% < % R & R < 30%, system may be acceptable based
on importance of application, cost of gage, cost of repair, etc.,