Capability Analysis and MSA Introduction

To measure or to guess
An Introduction into
Capability Analysis
&
Measurement System Analysis

Albert Eisele
MSA-Introduction-ASQ
What we see / Total Variation

Process A
2
Observed
(Total)
Process B
Total Variability
(Observed variability)
Which process is better?

Albert Eisele
Pg 2
Influence of the Measurement System

Process A
2
Measurement
System
2
Observed
(Total)
Process B
Measurement
Variability
Total Variability
(What we see)

Albert Eisele
Pg 3
The whole picture!

Process A
Measuring
2
Measurement
2
Part
/
Real Process
System
2
Observed
(Total)
Process B
Guessing
Part Variability
(What we produce)
Measurement
Variability
Total Variability
(What we see)

Albert Eisele
Pg 4
We always have an error.

What is the error due to our measurement
system? and
Is our measurement error within the agreed
boundaries?
There are 2 specific sources leading to an error:

Accuracy
Resolution
Bias
Linearity
Stability
Precision
Repeatability
Reproducibility
Albert Eisele
Accurate
Precision:
Accuracy:
Accuracy
The spread or Variance

of measured values
when measuring the
values
Difference between the

observed average value
of the measurements
and the master value
Albert Eisele
Precise
Accuracy:
RESOLUTION
Alias: smallest readable unit,
measurement resolution,
detection limit.
Resolution or discrimination is
Capability to detect the smallest
significant/tolerable changes in
order to detect present variation!
10 to 1 rule of thumb:
Increments in the measurement
system should be one9
one9tenth of
the product specification or
process variation!
Albert Eisele
Accuracy:
BIAS
Bias is the difference between
the true value (the reference
value) and the observed
average of measurements of
the same characteristic on the
same part.
Bias is the measure of the
systematic error of the
measurement system.
system
Bias can be minimized by the
use of calibration procedures!
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Accuracy:
LINEARITY
The difference of bias
throughout the expected
operating (measurement) range
of the equipment is called
linearity.
Linearity can be thought of as a
change of bias with respect to
size!
Does my gauge have the same
accuracy for all sizes of objects
being measured?
Albert Eisele
Accuracy:
STABILITY
Stability (or drift) is the total
variation in the measurements
obtained with a measurement
system on the same master or
parts when measuring a single
characteristic over an extended
time period.
That is, stability is the change in
bias over time!
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10
Precision:
Reference Value
REPEATABILITY
Repeatability is traditionally
referred to as the within
appraiser variability.
Repeatability is the variation in
measurements obtained with
one measurement instrument
by one appraiser while
measuring the identical
characteristics on the same
part!
Repeatability is the within9
within9
system9
system9variation!
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Precision: REPRODUCIBILITY
Reproducibility is traditionally
referred to as the between
appraiser variability.
Reference Value
Reproducibility is typically defined

as the variation in the average of
the measurements made by
different appraisers using the
same measuring instrument
when measuring the identical
characteristics on the same part!
Repeatability is the between9
between9
systems9
systems9variation!
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Summary:
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Components of variation
13
Statistical Output: Requirements

Gage R&R
Decision
Comments
Under 10
percent
Generally considered to
be an acceptable
measurement system.
Recommended, especially useful when trying to

sort or classify parts or when tightened process
control is required.
10 percent to
30 percent
May be acceptable for

some applications.
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.
Over 30
Percent
Considered to be
unacceptable.
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.
Measurement Systems Analysis (MSA)

AIAG Reference Manual, Fourth Edition, 2010 page 78
Chrysler Corporation, Ford Motor Company, General Motors Corporation.
Albert Eisele
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Statistical Output: Requirements

Measurement System Standard Deviation
(R&R) as a percentage of Total Observed
Process Standard Deviation.
Includes both repeatability and reproducibility.
9 Less than 10% is ideal
9 10930% depends on the situation
This number represents the number of non9

overlapping confidence intervals that will span
the range of product variation. For example, if
the number of distinct categories was three,
the Measurement System could only put
things into small9medium9large buckets.
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Statistical Output: Example
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16
Practical Exercise:
Capability Analysis
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17
Practical Exercise: Capability Analysis

Tolerance:
Measurement:
10,0 +/9
+/9 1 mm
Sample of 50 values
OK or NOK?
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18

Tolerance:
Measurement:
10,0 +/9
+/9 1 mm
Sample of 50 values
Min
Max
OK?
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19
Practical Exercise: Capabilty Analysis
OK or NOK?
Analysis using Minitab
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20

Tolerance:
10 +/9
+/9 1m
Min: 9,1144
Max: 10,469
Seems to be ok?
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21

Tolerance:
10 +/9
+/9 1m
StDev:
StDev: 0,3245
Min:
9,1144
Max:
10,469
Whats about the Standard Deviation?

Albert Eisele
22

Recall the properties of the Standard Normal Distribution:
99.7%
95.5%
68.3%
-6
-5
-4
-3
-2
-1
+1
+2
+3
+4
+5
+6
68.27 % of the data will fall within +/- 1 Standard Deviation

95.45 % of the data will fall within +/- 2 Standard Deviations
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23
23
Process Performance over time:

Cpk = 0,61 Ppm = 33.555 = 3,36% nok
Result:
Result: 66 nok Units/day
Units/day (based on 1850)
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Capability Analysis & Sample Size
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Capability Analysis & Sample Size

Rule of Thumb based on our example
Sample
Size
Tolerance
Mean
5
10
30
50
+/- 1 mm
+/- 1 mm
+/- 1 mm
+/- 1 mm
9,71 +/- 0,5 mm

9,71 +/- 0,3 mm
9,70 +/- 0,15 mm
9,77 +/- 0,1 mm
Albert Eisele
Confidence
Interval
for Mean
Blocked Available
Tolerance Tolerance
[%]
[%]
50%
30%
15%
10%
50%
70%
85%
90%
26
Q&A
Albert Eisele
27

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To measure or to guess

Measurement System Analysis

What we see / Total Variation

Which process is better?

Influence of the Measurement System

Which process is better?

The whole picture!

Which process is better?

We always have an error.

There are 2 specific sources leading to an error:

The spread or Variance

Difference between the

Reproducibility is typically defined

Statistical Output: Requirements

Recommended, especially useful when trying to

May be acceptable for

Decision should be based upon, for example,

Every effort should be made to improve the

Measurement Systems Analysis (MSA)

Statistical Output: Requirements

This number represents the number of non9

Statistical Output: Example

Practical Exercise: Capability Analysis

Practical Exercise: Capability Analysis

Practical Exercise: Capabilty Analysis

Practical Exercise: Capability Analysis

Practical Exercise: Capability Analysis

Whats about the Standard Deviation?

Practical Exercise: Capability Analysis

68.27 % of the data will fall within +/- 1 Standard Deviation

Practical Exercise: Capability Analysis

Process Performance over time:

Capability Analysis & Sample Size

Capability Analysis & Sample Size

9,71 +/- 0,5 mm

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