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IOE 466 W08

Gage and Measurement System Analysis

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Topics
Measurement Systems Analysis

Gage R&R for Variable data
Attribute Gage R&R
Case Study
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Measurements Systems Analysis
Purpose:
Determine how much variability is due to the gage
or instrument
Isolate the components of variability of the
measurement system
Assess whether the instrument or gage is capable
(suitable for intended application)
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Components of a Measurement System
Equipment or Gage
Type of Gage:
Attribute: go-no go, vision systems (part present or not present)
Variable: calipers, probe, tape measure, coordinate measurement machines, checking
fixture with inspection device
Discrimination of Measurement General Rules:
At least 1/10 of tolerance (tol = 1 mm, measure to at least 0.1)
Or, at least 1/10 of 6*process standard deviation (6s)
Operator & Operating Instructions
Part locating or orientation scheme
gage must be able to consistently locate the part being measured.
Total variability decomposition





Gage R&R
2
gage
2
product
2
total
s s s
2
ility reproducib
2
ity repeatabil
2
gage
2
error _ t measuremen
s s s s
inherent precision of gage
different operators or conditions
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Gage R&R
In conducting a Gage R&R study, we need to identify # parts, # trials
per part, and # operators.
We also need tolerance width for each feature.
Tolerance Width = USL LSL
USL ~ Upper Spec Limit and LSL ~ Lower Spec Limit.

Common Applications (parts x trials x operators):
5 or 10 parts
2 or 3 trials
2 or 3 operators
Example: 5x3x2 Two operators will measure each of 5 parts three
times.

Gage Capability Criteria

Precision to tolerance ratio or P/T ration



gage error as a percentage of the product variability
1 . 0
LSL USL
6
T
P
gage

% 100

product
gage

s
s
Example 7-7 P354
2
gage
2
product
2
total
s s s
X-bar chart represents variability between different product units
R chart represents the gage measurement variability:
2
gage
d
R
s
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Gage R&R : Example 7-7
Sample
S
a
m
p
l
e

M
e
a
n
19 17 15 13 11 9 7 5 3 1
30
25
20
_
_
X=22.28
UCL=24.06
LC L=20.49
Sample
S
a
m
p
l
e

R
a
n
g
e
19 17 15 13 11 9 7 5 3 1
3
2
1
0
_
R=0.95
UCL=3.104
LC L=0
1
1
1 1
1
1
1 1
1
1
Xbar-R Chart of M1, ..., M2
X-bar: out of control
points, show that
measurement system
can discriminate
between units of
products

R-bar: in-control, show
that operators are
consistent.
Be careful! Dont interpret this like you would a process control
chart.
Example 7-7: continued
Suppose that instead of having only 1 operator measure the parts,
you make 3 operators measure each part twice.
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) x , x , x min( x
) x , x , x max( x
19 . 0
693 . 1
32 . 0
| d
R
32 . 0 28 . 22 60 . 22 x x R
02 . 1
128 . 1
15 . 1
| d
R
15 . 1 ) 2 . 1 25 . 1 1 (
3
1
) R R R (
3
1
R
3 2 1 min
3 2 1 max
3 n 2
x
ility reproducib min max x
2 n 2
ity repeatabil 3 2 1

s
s

(1) average of all ranges

(2) Difference among operators
(3) Each operators average
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Example 7-7: Gage R&R
Gage and Measurement System Capability
Variation Decomposition





2
ility reproducib
2
ity repeatabil
2
gage
2
t measuremen
2
gage
2
product
2
total
s s s s s s s
Use R chart for estimation
r: # of operators
m: # of samples
n: # of repeated measurements
x
kij
:
i: sample index
j: repeated measurement index
k: operator index
rmn
x
x
rmn
x x
r
k
m
i
n
j
kij
r
k
m
i
n
j
kij
total

1 1 1
1 1 1
2
2
1
) (
s
2
ity repeatabil
d
R
s
r
R
R
r
1 k
k

) x ( min ) x ( max R
m
R
R
kij j kij j ki
m
1 i
ki
k

) x , x , x min( x
) x , x , x max( x
; x x R
r , 2 1 min
r , 2 1 max
min max
X

2
X
ility reproducib
d
R
s
mn
x
m
x
x
m
1 i
n
1 j
xij
m
1 i
ki
k

Gage capability: precision-to-tolerance ratio (P/T ratio)
Generally, an adequate gage capability: P/T0.1


gage variability-to-product variability ratio
independent of specification limits


Gage and Measurement System Capability (Conts)
LSL USL
6
T
P
gage

% 100

product
gage

s
s
2
total
s
2
ility reproducib
2
ity repeatabil
s
s
2
gage
s
2
product
s
2
ility reproducib
2
ity repeatabil
2
gage
s s s
2
gage
2
total
2
product
s s s
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Gage R&R for Attribute Variables
Some quality inspection systems rely on human
judgment good/bad or best/good/poor
Examples
Fabric color matching
Contact Lens appraisal
Delamination (printing)
How can we test whether the measurement system is
working accurately?

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Gage R&R for Attribute Variables
Gage R&R Study set up steps
Select 20-30 product samples (include mix of
good and bad parts)
Identify # of parts, # of inspectors and # of trials
Have a master appraiser (expert) rate each part
Inspectors rate each part an x number of trials, at
random, without knowing the master results

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Gage R&R for Attribute Variables
Then:


inspected parts of number
standard with agree operators all times of #
ess Effectiven System Overall
inspected parts of number
standard with matches of #
ess Effectiven Individual
n
ity Repeatabil Operator
ity Repeatabil System Overall
inspected parts of number
ials within tr matches t measuremen of #
ity Repeatabil Operator
n
1 i
n
n

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Gage R&R for Attribute Variables
General Guideline: 90% effectiveness is acceptable

Next steps:
Identify best measurement system procedure
Document standardized work
Train all operators in new system
Periodically check gage R&R of system

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Gage R&R for Attribute Variables: Example
A hospital is trying to evaluate the consistency of their doctors in rating
mammograms. Each mammogram is rated according to the following
scale:

1 No cancer (best)
2 Benign cancer
3 Possible malignancy
4 Malignancy (worst)

A sample of 15 mammograms is collected, and three randomly selected
doctors within that specialty are selected. Each doctor rates each
mammogram three times at random. In the study, these ratings will also
be compared to a standard (ratings provided by a panel of senior
doctors).
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Gage R&R for Attribute Variables: Example
Mammogram Standard
1 4 4 4 4 4 4 4 4 4 3
2 4 4 4 4 4 4 4 4 4 4
3 2 2 2 2 2 2 2 2 2 2
4 3 3 3 3 3 3 3 2 3 2
5 2 2 2 2 2 2 2 1 2 2
6 1 1 1 1 2 2 1 2 1 2
7 3 3 3 3 3 3 3 2 2 3
8 4 4 4 4 4 4 3 4 4 4
9 4 4 4 4 4 4 4 3 3 4
10 2 2 1 1 2 2 2 2 2 2
11 2 2 2 2 2 2 2 2 2 1
12 4 4 4 4 4 4 4 4 4 4
13 1 2 2 2 1 1 1 1 2 1
14 1 1 1 1 1 1 1 1 1 2
15 3 3 3 3 3 3 2 4 4 4
Doctor 3 Doctor 2 Doctor 1
1
2
3
4
No cancer
Benign cancer
Possible malignancy
Malignancy
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Gage R&R for Attribute Variables: Example
Results






System Repeatability = 71.1%
Overall Effectiveness = 87.7%

Repeatability
Individual
Effectiveness
Doctor 1 93.3% 93.3%
Doctor 2 80.0% 93.3%
Doctor 3 40.0% 80.0%
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Case Study:
Improving Data Reliability for Valve Bodies
Need to adequately measure bore diameter data.
Excessive variation is causing rejects from process.
Suspected that data for water valve bodies not reliable
Critical measurement is the bore diameter, with a
specification of 1.334 +/- .002


Bore diameter

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Problem Definition
Need to adequately measure bore diameter data.
Excessive variation is causing rejects from process
need to ensure diameter is measured properly
because of small tolerance for error.
Currently utilizing a dial caliper method


To find the current state of the process:
10 x 3 x 3 Gage R&R experiment
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Current State: Gage R&R results

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Current State: Gage R&R results
Appraiser variation takes up 58% of tolerance width
Equipment variation takes up 69% of total variation
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Current State: Cause and Effect Diagram

data
diameter
bore
Variability in
Environment
Measurements
Methods
Material
Machines
Personnel
Dial caliper not precise
Dial caliper not accurate
operators
V ariability between
Lack of training
caliper
Improper use of
work
Lack of standardised
Cause-and-Effect Diagram
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Improvement alternatives
Use different type of gage
Plug-gages
Internal calipers
Self centering electronic bore gauge

Gage R&R done for top two alternatives, internal
calipers and electronic bore gauge.


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Self centering bore gauge: Gage R&R results

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Self centering bore gauge: Gage R&R results
Appraiser variation takes up 2.7% of tolerance width
Equipment variation takes up 5.2% of total variation
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Results
Switch from Dial Caliper to Self Centering Bore Gage

Reduced % of R&R compared to total variance
from 90.2% to 6.2%.

Expected reduction in errors reported is 75%