Six Sigma Quality: Concepts & Cases- Volume I

STATISTICAL TOOLS IN SIX SIGMA DMAIC PROCESS WITH

MINITAB APPLICATIONS

Chapter 7

Measurement System Analysis

Gage Repeatability & Reproducibility

(Gage R&R) Study

2010-12 Amar Sahay, Ph.D.

Chapter7:MeasurementSystemAnalysis:Gage(R&R)

ChapterOutline

ChapterOutline
Introduction
TermsRelatedtotheMeasurementSystemsAnalysis
SystematicErrors
RandomErrors
Metrology
Gage
Bias
Resolution
Accuracy,PrecisionRepeatability,andReproducibility
AccuracyandPrecision
GageLinearity
Bias
Stability
Repeatability
Reproducibility
EstimatingMeasurementError:SomeMeasurementModels
ClassificationofMeasurementErrors

GraphicalAnalysisofGageStudy:GageRunChart

Example1
Example2
Example3
Example4
SummaryofExamples1through4

AnalyticalGageStudy:GageR&R

Case1:DeterminingGageCapability
Case2:DeterminingGageCapability
Case3:GageR&RStudy(Crossed):XbarandRMethod:
Case4:GageR&RStudy(Crossed):ANOVAMethodUsingCase3Data:
Case5:ComparingtheResultsofGageRunChart,GageR&R:XbarandR

Method,andGageR&R:ANOVAMethod
Case6:AnotherExampleonComparingtheResultsofGageRunChart,Gage
R&R:XbarandRMethod,andGageR&R:ANOVAMethod
Case7:GageR&RStudy(Nested):ANOVAMethodDeterminingtheBiasandLinearity
Case8:GageLinearityandAccuracy(Bias)Study1
Case9:GageLinearityandAccuracy(Bias)Study2
ComparingTwoMeasuringInstrumentsforPrecisionandAccuracy

Chapter7:MeasurementSystemAnalysis:Gage(R&R)

Case10:
ComparingthePrecisionandAccuracyofTwoMeasuringInstruments:1

Case11:
ComparingthePrecisionandAccuracyofTwoMeasuringInstruments:2

StatisticalControloftheMeasurementProcess
Case12:
UseofIndividualsControlCharttoDetecttheShiftinMeasuringInstruments

HandsonExercises

This sample file contains explanation and a few examples on measurement system analysis
including Gage R & R from Chapter 7 of our Six Sigma Volume 1. For detailed treatment of
Gage R & R- see Chapter 7 of the book. The book contains numerous cases, examples and
step-wise computer instructions.

Chapter7:MeasurementSystemAnalysis:Gage(R&R)

Introduction
Theconclusionsdrawnfromthestatisticalmethodsdependontheaccuracyof
data. If the measuring instrument and the measurement method are not capable of
making accurate and repeatable measurements, the data can have significant
measurementerror.Insuchcases,theconclusionsdrawnfromthedataareinaccurate
andmisleading.Itiscriticaltoassesstheaccuracyofthemeasurementprocessatthe
start of the study. Inaccurate measurements may lead to false signals on control
charts. In the presence of significant error in the measurement process, a capable
process may be confused with an incapable process. Overlooking the measurement
process can be expensive by diverting the effort in fixing the wrong problem. When
themajorsourceofvariationisfromthemeasurementprocess,significanttimeand
moneycanbewastedinfixingandcontrollingtheprocess.Severalfactorsaffectthe
reliabilityofmeasurementsincluding:
differencesinmeasurementprocedures,
differencesamongoperators,
instrumentrepeatabilityandreproducibility,and
instrumentcalibrationandresolution.

:
:

Figure 7.1 shows the measurement errors and their causes. This chapter is
concerned with the analysis of measurement systems including repeatability,
reproducibility,bias,stability,andlinearity.

Measurement Errors

Systematic Errors
(offsets or biases)

Random Errors
(Characterized by the variation)

Value by which an instrument's reading are off

from the true or master value
Systematic errors are estimated and corrected
during equipment calibration

Operator variation

Instrument variation

Environmental changes

Time-to-time variation

Figure7.1:MeasurementErrors

Chapter7:MeasurementSystemAnalysis:Gage(R&R)

The measurement system analysis is commonly known as Gage Repeatability

andReproducibility(GageR&R)study.Thepurposeofmeasurementsystemanalysis
orGageR&Rstudyistodeterminethepartofvariationinthedataresultingfromthe
variationinthemeasurementsystem.

TermsRelatedtoMeasurementSystems

Systematic Errors (or offsets):Theseerrorsaredefinedastheconstantvaluesby

whichameasurementinstrumentsreadingsareofffromthetrueorreferencevalue
(oramastervalue).

Random Errors: These are measurement errors caused by differences among

operators, differences among the measuring equipments, differences over time, or
thedifferencesduetochangeintheenvironmentalconditions.

Metrology:

Gage: Gages are devices of preset dimensions used to compare product

dimensionstocheckwhethertheproductmeetsorexceedsspecifications.
Bias:Itisthedifferencebetweentheaverageofmeasurementsandthetrueor
referencevalueofthepart.Thereferencevalueisalsoknownasthemastervalue.

Resolution: The resolution of measurements refers to the number of digits of

precisionneededofthemeasuredvalue.

CV

:
:

or , C V

x

Accuracy,Precision,Repeatability,andReproducibility

To assess the measurement errors, the concepts of accuracy, precision,

repeatability,andreproducibilityshouldbeclearlyunderstood.

ACCURACYANDPRECISION

Measurement system errors can be divided into two categories: accuracy and
precision.
Accuracyisthedifferencebetweentheaverageofmeasurementsmadeonapart
andthetruevalueofthatpartor,

Accuracy= x m x

Chapter7:MeasurementSystemAnalysis:Gage(R&R)

Precisionisthedegreetowhichrepeatedmeasurementstendtoagreewitheach
other.Itisgettingconsistentresultsrepeatedly.

Accuracy refers to longterm average of measurements while precision

referstolongtermvariation.

Measurement error is estimated using accuracy and precision. Accuracy and

precisionofameasurementsystemarebrokendownintocomponentsshownbelow
inFigures7.2and7.3.
Accuracy

Linearity

Bias

Stability

Figure7.2:ComponentsofAccuracy

Gagelinearityis

Precision

Repeatability

Reproducibility

Figure7.3:ComponentsofPrecision

REPEATABILITY:

.,repeatabilityofameasuringinstrumentreferstohowwelltheinstrument
isrepeatedlyabletomeasurethesamecharacteristicunderthesamecondition.

Example: The repeatability of a measuring instrument is to be determined. An

operatormeasuredthelengthofastandardGAGEblockof0.500inches10times.The
measuredvaluesareshownbelow.

Length(in.)

0.4980.5000.5020.5000.5000.5000.5010.5020.4990.500
Themeanandstandarddeviationforthesemeasurementsare x m 0 . 5 0 0 2
and s m 0.00119 .Thetruelengthofthegageblockis0.500whichisconstant.The

Chapter7:MeasurementSystemAnalysis:Gage(R&R)

accuracyandprecisionoftheinstrumentare

Accuracy=averageofthemeasurementstruevalueor,

A c c u r a c y x m x 0 .5 0 0 2 0 .5 0 0 0 .0 0 0 2

Theaccuracyof+0.0002meansthatthereadingsobtainedbythemeasuring
instrumentareslightlyhigherthanthetruevalue

Thesixsigma(6s) precision,basedonthenormaldistributionis

6 s 6 (0 .0 0 1 1 9 ) 0 .0 0 7 1

m
Intheaboveexamplethemeasurements.

REPRODUCIBILITY:

..reproducibilityisthevariationduetodifferentoperatorsusingthesame
measuring instrument at different time periods, and different environmental
conditions.

EstimatingMeasurementError:SomeMeasurementModels
Asimplemeasurementmodelcanbewrittenas

Where

x m x (7.1)

x m isthemeasuredvalue,xisthetrueormastervalue,and

isthe

measurement error. The master value is the measurement made with the most
accurateinstrument(AIAGManual).Equation(7.1)canbemodifiedtoincludeerror
termssuchasthemeasurementinstrumenterror,parterror,..

GageR&RStudy
The purpose of measurement system analysis is to assess the variance
componentsanddeterminehowmuchofthevariationisduetothemeasurements.
The measurement system analysis is commonly known as Gage R&R Study. The
variancestobeanalyzedareshowninFigure7.5.

:
Thetotalmeasurementvariationinvolvestwocomponents;variationduetothe
product or part, and the variation due to measurement error or gage. This total
variationcanbewrittenas:

Where,

to2 ta l

2
p a rt

2
gage

(7.2)

Chapter7:MeasurementSystemAnalysis:Gage(R&R)

gage
repeatability
reproducibility
measurementerror
(7.3)

Thevariancecomponentsexplainedinequations(2)and(3)areshowninFigure7.5.The
percentagevariationduetothemeasurementsystemor%R&Risestimatedas

%R& R

m ea su rem en t
X 100%
to ta l

MethodsofGageAnalysis

Figure 7.6 shows the methods of gage analysis. These methods are discussed
withexamplesinsubsequentsections.
Gage Study

Gage Run Chart

X-bar and R
Gage R&R Study
(Crossed)

ANOVA
Gage R&R Study
(Nested)

Gage Linearity and Bias

Study

Attribute Gage Study

(Analytical Method)

Figure 7.6: Methods of Gage R&R Analysis

GraphicalAnalysisofGageStudy:GageRunChart
The gage run chart is a graphical way of assessing the measurement errors. It
provides a plot of the measured values by operator and part number. The plot is a
simple way of looking into the variations in the measured values. The variation in
measurementsduetooperatorsorpartscanbeseenfromthisplot.

GageRunChart:Example1
Table 7.2showsthemeasurementsonasampleofeightpartsselectedfroma
manufacturingprocess.Thepartsrepresentthenormalvariationoftheprocess.Three
operators were selected to measure the parts. Each operator measured the eight
partswiththesameinstrumentthreetimesinarandomorder.Themeasuredvalues
are shown below. We will use the gage run chart to assess the variation in

Chapter7:MeasurementSystemAnalysis:Gage(R&R)

measurementsduetopartsandoperators.

Table7.2
Operator A
Trials
1
2
3

Part 1

Part 2

Part 3

Part 4

Part 5

Part 6

Part 7

Part 8

69
68
65

98
97
95

80
78
79

82
85
86

58
56
50

99
98
99

87
89
91

69
72
71

Operator B
Trials
1
2
3

Part 1

Part 2

Part 3

Part 4

Part 5

Part 6

Part 7

Part 8

62
64
65

99
93
96

79
77
78

81
78
79

50
51
52

99
102
101

85
89
80

73
72
70

:
Table7.2mustbeenteredasshowninGAGE3.MTWtodotheplot.Thestepsto
constructtheplotareshowninTable7.3.
Table 7.3
Open the worksheet GAGE3.MTW
From the main menu, select Stat &Quality Tools &Gage Study
&Gage Run Chart
In the Gage Run Chart dialog box, select or type
:
Click the Gage Info tab and provide the details about the Gage
:
:
Type-in a Historical Mean value (or the mean will be calculated
from the data)
Click OK
ThegagerunchartisshowninFigure7.7.

Gage Run Chart (1)

Chapter7:MeasurementSystemAnalysis(GageR&R)

10

Gage Run Chart of Measurements by Part No., Operator

Reported by :
T olerance:
M isc:

G age nam e:
D ate of study :

4
100

Measurements

Mean

O perator
A
B
C

75

50
5

100

Mean

75

50

Operator
Panel variable: Part No.

Figure7.7:AGageRunChartofMeasurementsbyPartNumberandOperatorofGAGE3.MTW

INTERPRETINGTHERESULTS
(a) Figure 7.7 shows the measurement results for the eight parts by each of the three
operators.Eachoperatormeasuredtheparts3times(3trials).EachcolumninFigure7.7
representsapart(1through8).Withineachcolumn,themeasurementsby3operators
are represented by different symbols. The dotted lines represent the mean of the
measuredvalues.Thismeanline(orthereferenceline)helpstosee
:
(b) Figure7.7showsthatparttopartvariationisdominant.Themeasurementsforparts3
and 4 are close to the reference line. For all the other parts, the measurements are
above or below the reference line. In fact, the measured values are far away from the
referencelineforallthepartsexceptparts3and4.Ifthereisasignificantvariationfrom
parttopart,.
(c) The plot also provides an idea about repeatability and reproducibility, which are
variations due to the gage or measurement system and operators. Recall that
repeatabilityofameasuringinstrumentreferstohowwelltheinstrumentisrepeatedly
abletomeasurethesamecharacteristicunderthesamecondition.Themeasurements
bythethreeoperatorsoneachofthepartsshowthatthemeasuredvaluesarecloseto
eachother.
(d)
We can also check the reproducibility from the run chart in Figure 7.7.
Reproducibility is the variation due to differentoperatorsusingthesamemeasuring
instrumentatdifferenttimeperiodsorunderdifferent..

Chapter7:MeasurementSystemAnalysis(GageR&R)

(e)

11

TheconclusionfromFigure7.5isthatparttopartvariationisdominant.

GageRunChart:Example2
Theworksheet GAGE2.MTWshowsthemeasuredvaluesforthreeselectedparts.
The parts are indicative of the range of process variation. Three operators were
selectedtomeasuretheparts
Ga ge Run Cha rt of Me a s ur e me nt by Pa r t , Ope ra t or
R e porte d by :
T olera nce :
M isc:

G a ge na m e:
D a te of study :

O pe ra tor
1
2
3

9.0

Measurement

8.5
8.0
M ean

7.5
7.0
6.5
6.0
5.5

Ope ra t o r
Panel v ariable: Pa rt

Figure7.8:AGageRunChartofMeasurementsbyPartNumberandOperatorof
GAGE2.MTW

Inthiscase,repeatabilityisthedominantfactor.

Case1:DeterminingGageCapability
This example demonstrates how to assess gage capability when one operator
takes multiple measurements on selected parts. Twenty parts are selected and the
operator, who usually performs the measurements, measured each of the twenty
selectedpartstwice.ThemeasurementsareshowninTable7.8.

Table7.8
Part

Operator A
Trial 1
1
2
3
4
5

21
24
20
27
19

20.5
23.5
20.5
27.0
18.5

1
1
1
0
1

Trial 2
20
23
21
27
18

Chapter7:MeasurementSystemAnalysis(GageR&R)

Part

Operator A
Trial 1

6
7
8
9
10
11
:
:
12
13
14
15
16
17
18
19
20

12

Trial 2

23
22
19
24
25
21

21
21
17
23
23
20

22.0
21.5
18.0
23.5
24.0
20.5

18
23
24
29
26
20
19
25
19

19
25
24
30
26
20
21
26
19

18.5
24.0
24.0
29.5
26.0
20.0
20.0
25.5
19.0

2
1
2
1
2
1

Cont.
1
2
0
1
0
0
2
1
0

x 22.3

R 1.0

Notethatthereisonlyoneoperatorinvolvedinthemeasurementprocesssowe
canonlydeterminetherepeatabilityandparttopartvariation.UsingthedatainTable
7.8,thedatafileGAGE1A.MTWwascreatedforanalysis.

1.ANALYSISUSINGGAGERUNCHART
WewillfirstcreateagagerunchartofdatainTable7.8.Itisaquickwaytosee
differentvariancecomponents.Forexample,fromthischartwecanseewhichvariance
componentisdominant:parttopartvariation,ormeasurementvariation.Toconstruct
agagerunchart,followtheinstructionsinTable7.9.
Table7.9
GAGE RUN CHART

Open the worksheet GAGE1A.MTW

From the main menu select, Stat & Quality Tools & Gage Study
& Gage Run Chart
In the Gage Run Chart dialog box, select or type
:
:
Click OK

Chapter7:MeasurementSystemAnalysis(GageR&R)

13

ThegagerunchartisshowninFigure7.12.
Ga g e R u n Ch a r t o f M e a s u r e me n t b y Pa r t , Op e r a t o r
R e p o rte d b y :
T o le ra n ce :
M isc:

G age nam e:
D a te o f s tu d y :

30

O p e ra to r
A

25
Me a n

Measurement

20
8

10

11

12

13

14

30
25

Me a n
20

30

15

16

17

18

19

20

25
Me a n
20

Ope ra to r
P a n e l v a ria b le : P a rt

Figure7.12:GageRunChartfortheDataofGAGE1A.MTW

INTERPRETINGTHERESULTS
:
The runchartshowsthatparttopartvariationisdominant.Themeasurements
for a few parts are close to the reference line. For the majority of parts, the
measurements are above or below the reference line, indicating partto part
variation.Wecanalsoseesometypeofpattern.Ifthereisasignificantvariation
fromparttopart,sometypeofpatternwillappear(measuredvaluesbeingupor
down).

The plot in Figure 7.12 also provides an idea about repeatability (which is the
variationduetothegageormeasurementsystem).

2.ANALYSISUSINGGAGER&R(CROSSED):ANOVAMETHODOFTHEDATAIN
GAGE1A.MTW

Here, we used the Gage R&R (crossed): ANOVA method in MINITAB to get a
quantitativeanalysis.GageR&R(crossed)methodinMINITABprovidestwooptions:(1)
theXbarandRmethod,and(2)ANOVAmethod.Whenthereisonlyoneoperator(as
inthiscase),theXbarandRmethod..Theresultsaredisplayedonthesession
windowandthegraphsareshownseparatelyonthegraphicswindow.

Chapter7:MeasurementSystemAnalysis(GageR&R)

14

GAGE R&R STUDY

(CROSSED)

Table7.10
Open the worksheet GAGE1A.MTW
From the main menu, select Stat &Quality Tools &Gage
Study &Gage R&R Study (Crossed)
:
;
click OK
Click the Options tab
In the Study Variation box, type 5.15
Under the Process tolerance , type 55 in the box Upper
spec-Lower spec
Click OK
Under Method of Analysis, click the circle next to
ANOVA
Click OK in all dialog boxes

Table 7.11 shows the results from the ANOVA method. The plots are shown in
Figure7.13.
Table7.11
Gage R&R Study - ANOVA Method
* NOTE * No or identical values for Operator - will analyze data without
operator factor.
One-Way ANOVA Table 7.
Source
DF
SS
MS
F
P
Part
19 377.4 19.8632 26.4842 0.000
Repeatability
20
15.0
0.7500
Total
39 392.4
Gage R&R
%Contribution
Source
VarComp
(of VarComp)
Total Gage R&R
Repeatability
Part-To-Part
Total Variation

0.7500
0.7500
9.5566
10.3066

Source

StdDev (SD)

7.28
7.28
92.72
100.00
Study Var
(6 * SD)

Total Gage R&R

0.86603
Repeatability
0.86603
Part-To-Part
3.09137
Total Variation
3.21039
Number of Distinct Categories =

5.1962
5.1962
18.5482
19.2623
5

INTERPRETINGTHERESULTSINTABLE7.11

%Study Var
(%SV)

%Tolerance
(SV/Toler)

26.98
26.98
96.29
100.00

9.45
9.45
33.72
35.02

Chapter7:MeasurementSystemAnalysis(GageR&R)

15

Whenonlyoneoperatormeasuresthepartsortheoperatorisnotenteredinthedata
file,aonefactorANOVAmodelisfitted.TheOnewayANOVAtableinTable7.11shows

thatthevariationduetopartissignificant(pvalueforpartis0.000).

The percent contribution of variance component (%Contribution) column under

GageR&Rshowsthat7.28%ofthevariationisduetoGageR&R.Allthisvariationisdue
to repeatability or measuringequipment.Thereisonlyoneoperatorinvolved,sothe
reproducibilitypartismissing. The%ContributionofParttoPartis92.72%.Itisclearthat
parttopartvariationisdominantinthiscase.Thevariationduetomeasuringequipment
(7.28%)issmallindicatingthatthegageiscapable.Furtheranalysiswilltellmoreabout
thegagecapability.FurtheranalysesofTable7.11areexplainedbelow.

FromGageR&Ranalysis,thevarianceduetorepeatabilityorgageis0.7500.This
isreportedasMSRepeatabilityintheOneWayANOVAtable.

r2e p e a t a b i l i t y 0 . 7 5 0 0

Sincethereisnovariationduetotheoperatorinthisexample,thereproducibility
part is missing from the analysis. The standard deviation of measurement error is

gauge .Thisvalueisreportedin TotalGageR&Rrowand StdDev(SD)columnandcan

bewrittenas

gauge 0.86603

This value is the square root of 0.75000, and is reported under the StdDev (SD)
columnoftheTotalGAGER&Rrow.
Thegagecapabilityisgivenby 6

gauge

assumingthatthemeasurementerror

is normally distributed. The value of gage capability is reported under the Study Var
(6*SD)columnandTotalGageR&Rrow.Thevalueiscalculatedasshownbelow.

6 g a u g e 6 (0 .8 6 6 0 3) 5 .1 9 6 2

The Gage capability means that the individual measurements are expected to
varyasmuchas

3 g a u g e 3 ( 0 .8 6 6 0 3 ) 2 .5 9 8

due to gage error. Percent Tolerance (% Tolerance): The percent tolerance or

precisiontotoleranceiscalculatedas

Chapter7:MeasurementSystemAnalysis(GageR&R)

% T o le r a n c e

gauge

16

SV
5 .1 9 6 2

0 .0 9 4 5 o r 9 .4 5 %
T o le r a n c e
60 5

U SL LSL

This value is reported under the %Tolerance column and Total Gage R&R
.

Themeasurementmayalsobeexpressedinthefollowingway:

gauge
0 .8 6 6 0 3
X 100
X 1 0 0 2 8 .0 1 %
p a rt
3 .0 9 1 3 7

ThevaluesarefromTable7.11undertheStdDev(SD)column.Thisratiodoesnot
requirethetolerancevalue.

Reminder:Theformulastoestimatethevarianceandstandarddeviation(parttopart
and repeatability) can be obtained from the help screen of GAGE R&R (crossed):
ANOVAmethodinMINITAB.

ANALYSISOFGRAPHS
Several graphs are produced as a part of the analysis. The graphs from this
analysisareshowninFigure7.13.Theinterpretationforeachgraphisprovidedbelow.
Ga ge R& R (A NOV A ) for Me a s ure me nt
R e porte d by :
T ole ra nce :
M isc:

G a ge na m e :
D a te of study :

C omponents of V ar iation

R C har t
% Co ntr i b utio n
% Stu d y Va r
% To le r a nce

50

UC L= 3.267

3
Sample Range

Percent

100

2
_
R= 1

1
0

Gage R &R

LC L= 0
1

Part -to-Part

M e asur ement by P ar t

11
Pa rt

13

15

17

19

X B ar C har t

30
Sample Mean

30

25

20

10 11 12 13 14 15 16 17 18 19 20

Pa rt

25

UC
_
_ L= 24.18
X = 22.3
LC L= 20.42

20
1

11
Pa rt

13

15

17

19

Figure7.13:PlotsforGageR&RAnalysis:ANOVAMethod

Thecomponentofvariationgraphshowsthatparttopartvariationisdominant.

Chapter7:MeasurementSystemAnalysis(GageR&R)

17

The Gage R&R variation is much smaller than the parttopart variation. Gage R&R
variation is the variation due to repeatability and reproducibility. In this case, the
reproducibilityorvariationduetooperatorsismissing,
:
:
MeasurementbyPartGraph

ThisplotinFigure7.13showsaclearparttopartvariationinmeasurements.The
averageofthemeasurementsforeachpartisconnectedusingastraightline.

XBarChart
chartshowsmanyoutofcontrolpoints.Whenparttopartvariationisdominant,
anXbarchartwillhaveoutofcontrolpoints.Thechartshowstheabilityofthegage(or
measuringequipment)to..

RChart
The R chart shows the gage capability or the magnitude of measurement error.
The points on the R chart show the difference between measurements on the same
partusingthesamemeasuringequipment.TheRchartinourexampleiswithincontrol,
which means that the operator is not having any problem in making consistent
measurements. When the R chart shows out of control points, it is an indication that
theoperatorishavingdifficultyusingtheequipment.

Case2:DeterminingGageCapability
In this example, twenty parts are measured by 3 operators. Each operator
measures the twenty parts twice or, three operators take multiple measurements of
the selected parts. The variation in this case would be parttopart variation, the
variation due to measurement instrument or repeatability, and variation due to
operators or reproducibility. This case has three components: repeatability,
reproducibility,andparttopartvariation.
The measurements are shown in Table 7.12. Using the data in Table 7.12 the
worksheet GAGE1B.MTW was created. We analyzed the data using the following
methodsinMINITAB:
1.GageRunChart
2.GageR&R(Crossed):XbarandRMethod
3.GageR&R(Crossed):ANOVAMethod
TheANOVAmethodismoreaccuratebecauseittakesintoaccounttheoperator
andoperatorbypartinteraction.
:
:

1.ANALYSISUSINGGAGERUNCHART
Using the worksheet GAGE1B.MTW, we created the gage run chart shown in
Figure 7.14. To do this chart, open the worksheet GAGE1B.MTW and follow the

18

Chapter7:MeasurementSystemAnalysis(GageR&R)

instructionsinTable7.9.

Table 7.12
Part

Operator A

Operator B

Trail 1

Trail 1

Operator C
Trial 2

Trail 1

Trial2

Trail 2
1
2
3
4
5
6
7

51
54
49
57
49
53
52

56
57
55
63
42
58
58

50
54
49
58
49
54
52

50
54
51
56
48
51
54

49
53
50
57
48
53
52

51
54
52
58
51
52
50

:
:

Gage Run Chart of Measurement by Part, Operator

Reported by :
T olerance:
M isc:

G age nam e:
D ate of study :

60
Mean

Measurement

50

40

10

11

12

13

O perator
A
B
C

14
60

Mean

50

15

16

17

18

19

40

20

60
Mean

50

40

Operator
Panel variable: Part

Figure7.14:GageRunChartfortheMeasurementDatainGAGE1B.MTW
:
:

2.ANALYSISUSINGGAGER&RSTUDY(CROSSED):XBARANDRMETHOD
WeanalyzedthedatainfileGAGE1B.MTWusingtheXbarandRmethod.Agage

Chapter7:MeasurementSystemAnalysis(GageR&R)

19

runchartofthisdataisshowninFigure7.14.Whilethegagerunchartisagraphical
wayoflookingintothevariationsinthemeasureddata,theXbarandRchartprovides
aquantitativeanalysis.WewillcomparetheconclusionsfromFigure7.14withtheX
bar and R method in this section. Follow the steps in Table 7.13 for the Xbar and R
method.

GAGE R&R
(CROSSED)

Table7.13
Open the worksheet GAGE1B.MTW
From the main menu select, Stat &Quality Tools &Gage

Study
&Gage
R&R Study (Crossed)
:
:
Under Method of Analysis, click the circle next to Xbar and R
Click OK
The results shown in Table 7.14 are displayed on the session window. The plots are
shown in Figure 7.15.
Table 7.14
Gage R&R Study - XBar/R Method
Source

VarComp

%Contribution
(of VarComp)

Total Gage R&R

Repeatability
Reproducibility
Part-To-Part
Total Variation

6.0397
5.5192
0.5206
9.2073
15.2471

39.61
36.20
3.41
60.39
100.00

Source

StdDev (SD)

Study Var
(6 * SD)

Total Gage R&R

2.45759
Repeatability
2.34929
Reproducibility
0.72151
Part-To-Part
3.03436
Total Variation
3.90475
Number of Distinct Categories = 1

14.7455
14.0957
4.3291
18.2062
23.4285

%Study Var
(%SV)

%Tolerance
(SV/Toler)

62.94
60.16
18.48
77.71
100.00

19.66
18.79
5.77
24.27
31.24

Chapter7:MeasurementSystemAnalysis(GageR&R)

20

Ga g e R & R ( X b a r / R ) fo r M e a s u r e me n t
R e p o rte d b y :
T o le ra n ce :
M isc:

G a ge na m e :
D a te o f stu d y :
Co m p o n e n ts o f Va ria tio n

M e a su re m e n t b y P a rt

80

% C o n t r ib u t io n

Percent

% S tu d y Va r

60

% T o le r a n ce

40

50
40
G a g e R& R

Re p e a t

Re p r o d

P a r t- to - P a r t

R Ch a rt b y O p e ra to r
Sample Range

M e a su re m e n t b y O p e ra to r

U CL= 8 .6 5 8

60

_
R= 2 .6 5

50

LCL= 0

40

B
Ope rat or

Xb a r Ch a rt b y O p e ra to r
B

O p e ra to r * Pa rt I n te ra ctio n

60
U CL= 5 7 .6 6
_
_
X = 5 2 .6 8

54
48

Average

Sample Mean

10 11 12 13 14 15 16 17 18 19 20
P art

60

O p e ra to r

54

B
C

48

LCL= 4 7 .6 9
1

10

11

12

13

14

15

16

17

18 19 20

P a rt

Figure7.15:PlotsusingGageR&R(Crossed):XBarandRMethodofDatain
GAGE1B.MTW
Table7.14providesthevariancecomponents,andthepercentageofthevariance
componentsrelativetothetotalvariance

INTERPRETATIONOFPLOTSINFIGURE7.15
ThecomponentofvariationplotshowsthepercentageofvariationduetoGage
R&R which is sums of the variations due to repeatability, reproducibility, and the
percent variation of parttopart. Each component of variation gage R&R,
repeatability,reproducibility,andparttoparthasthreebars.Thefirstbarshows..

3.ANALYSISUSINGGAGER&RSTUDY(CROSSED):ANOVAMETHOD
Table7.15

Chapter7:MeasurementSystemAnalysis(GageR&R)

21

Gage R&R Study - ANOVA Method

Two-Way ANOVA Table 7. With Interaction
Source
DF
SS
Part
Operator
Part * Operator
Repeatability
Total

19
2
38
60
119

1249.83
57.65
291.35
387.50
1986.33

MS

65.7803
28.8250
7.6671
6.4583

8.57954
3.75957
1.18716

0.000
0.032
0.272

Two-Way ANOVA Table 7. Without Interaction

Source
Part
Operator
Repeatability
Total

DF
19
2
98
119

SS
1249.83
57.65
678.85
1986.33

MS
65.7803
28.8250
6.9270

F
9.49616
4.16123

P
0.000
0.018

Gage R&R
%Contribution
(of VarComp)

Source

VarComp

Total Gage R&R

Repeatability
Reproducibility
Operator
Part-To-Part
Total Variation

7.4745
6.9270
0.5474
0.5474
9.8089
17.2834

Source

StdDev (SD)

Total Gage R&R

2.73395
Repeatability
2.63193
Reproducibility
0.73990
Operator
0.73990
Part-To-Part
3.13191
Total Variation
4.15733
Number of Distinct Categories = 1

43.25
40.08
3.17
3.17
56.75
100.00
Study Var
(6 * SD)

%Study Var
(%SV)

%Tolerance
(SV/Toler)

16.4037
15.7916
4.4394
4.4394
18.7915
24.9440

65.76
63.31
17.80
17.80
75.33
100.00

29.82
28.71
8.07
8.07
34.17
45.35

INTERPRETATIONOFGRAPHICALOUTPUTSOFGAGER&R:XBARANDRSTUDY
The Gage R&R: Xbar and R analysis provides graphs for the analysis of
measurement data. Figure 7.16 shows the graphs for this example.

22

Chapter7:MeasurementSystemAnalysis(GageR&R)

Ga ge R& R (X ba r/ R) for Me a s ur e me nt s
R e porte d by :
T ole ra nce :
M isc:

G a ge na m e :
D a te of study :
Co m po ne nts o f Va ria tion

M e a sure m e nts by Pa rt No .

100

% Co n t r ib u t io n

100

Percent

% S t u d y Va r

75

50

50
G a g e R& R

Re p e a t

Re p r o d

P a r t- to - P a r t

R Cha rt by Ope ra to r
Sample Range

10

_
R=3 .5 4

LCL=0

50
A

B
Operator

O pe ra tor * Pa rt No . I nte ra ctio n

C
100
_
_ CL=8 3 .2 5
U
X=7 9 .6 3
LCL=7 6 .0 0

50

Average

Sample Mean

75

100

75

100

Xba r Cha rt by Ope ra to r

B

M e a sure m e nts by Ope ra to r

C
U CL=9 .1 2

4
5
P art No.

O p e ra t o r
A
B
C

75
50
1

4
5
P art No.

Figure7.16:GraphsforGageR&R:XbarandRMethodGAGE3.MTWData

INTERPRETATIONOFPLOTSINFIGURE7.16
The Gage R&R study produces six graphs shown in Figure 7.16. These graphs
provideadditionalinsightforimprovementopportunities.EachgraphinFigure7.16is
describedbelow.
ComponentsofVariation
This graph provides bars for each of the variance components including Gage
R&R,repeatability,reproducibility,andparttopartvariation.Notethatthegraphdoes
notprovidethebarforoperatororoperatorbypartvariance.
:
:

OtherExamplesintheChapter

Case3:GageR&RStudy(Crossed):XbarandRMethod
Case4:GageR&RStudy(Crossed):ANOVAMethodusingCase3Data

Case 5:

Comparing the Results of The Gage Run Chart, The Gage R&R: Xbar and R

Method, and The Gage R&R: ANOVA Method

Chapter7:MeasurementSystemAnalysis(GageR&R)

23

The data file GAGE2.MTW shows the measurements of three selected parts. The parts are
indicative of the range of process variation (full scale). Three operators were selected to
measure the parts. Each operator measured the parts four times in a random order. The
measured values are shown in Table 7.4. The worksheet GAGE2.MTW was created using the
datainTable7.4.UsingtheworksheetGAGE2.MTW:

CreateaGageRunChart

PerformaGageR&RStudy(Crossed)usingtheXbarandRMethod

PerformaGageR&RStudy(Crossed)usingtheANOVAMethod

Comparetheresultsfromtheabovemethods.
Ga g e R u n C h a r t o f M e a s u r e m e n t b y P a r t , O p e r a t o r
R e p o rt e d b y :
T o le ra n c e :
M is c :

G age nam e:
D a te o f s tu d y :

O p e ra to r
1
2
3

9 .0

Measurement

8 .5
8 .0
M ean

7 .5
7 .0
6 .5
6 .0
5 .5

Ope ra tor
P a n e l v a r ia b le : P a r t

Figure7.19:GageRunChartofDatainGAGE2.MTW
Case 6: Another Example on Comparing the Results of a Gage Run Chart,

Gage R&R:

Xbar and R Method, and A Gage R&R: ANOVA Method

The data file GAGE4.MTW shows the measured values on a sample of 10 parts from a
manufacturingprocess.AgagerunchartforthisdatawasshowninFigure7.10.Aninvestigation
of Figure 7.10 shows repeatability, reproducibility, and parttopart to variations in the data.
HerewewillanalyzethedatausingtheGageR&R:XbarandR,andGageR&R:ANOVAmethods.

GageR&R:XbarandRMethod:

OpentheworksheetGAGE4.MTW
ToperformaGageR&RStudy(Crossed)usingXbarandRMethod,followthestepsin
Table7.10.Makesureyouselecttheappropriatevariablenamesinthedialogboxes.The
resultsoftheXbarandRmethodareshowninFigure7.22.

Chapter7:MeasurementSystemAnalysis(GageR&R)

24

Gage R&R Study - XBar/R Method

VarComp

%Contribution
(of VarComp)

Total Gage R&R

Repeatability
Reproducibility
Part-To-Part
Total Variation

0.0000180
0.0000159
0.0000021
0.0000061
0.0000240

74.80
66.15
8.64
25.20
100.00

Source
Total Gage R&R
Repeatability
Reproducibility
Part-To-Part
Total Variation

StdDev (SD)
0.0042398
0.0039873
0.0014414
0.0024611
0.0049023

Source

Study Var
(6 * SD)
0.0254388
0.0239236
0.0086482
0.0147665
0.0294140

%Study Var
(%SV)
86.49
81.33
29.40
50.20
100.00

Ga ge R& R (X ba r / R) for Me a s ur e me nt
R e po rte d by :
T o le ra nce :
M isc:

G a ge na m e :
D a te o f study :
Co m po ne nts o f Va ria tio n

M e a sure m e nt by Pa rts
% C o n t r ib u t io n
% S tu d y Va r

Percent

80

40

5 .0 1
5 .0 0
4 .9 9

G a g e R& R

Re p e a t

Re p r o d

P a r t- to - P a r t

R Cha rt b y O pe ra to rs
Sample Range

0 .0 1 6

0 .0 0 0

10

M e a sure m e nt by O p e ra to rs

_
R= 0 .0 0 6 7 5

5 .0 0

LCL= 0

4 .9 9

Operators

O pe ra to rs * Pa rts Inte ra ctio n

D
U CL= 5 .0 0 9 4 3
_
X= 5 .0 0 2 5 2

4 .9 9 8
LCL= 4 .9 9 5 6 2

O p e ra to rs

Average

Sample Mean

U CL= 0 .0 1 7 3 8

Xba r Cha rt by O pe ra to rs

5 .0 0 4

6
P arts

5 .0 1

0 .0 0 8

5 .0 1 0

5 .0 0 5

B
C
D

5 .0 0 0
4 .9 9 5

5
6
P arts

10

Number of Distinct Categories = 1

Figure 7.22: Gage R&R: X bar/R Method for GAGE4.MTW Data in Example 8

Case 7: Gage R&R Study (Nested): ANOVA Method

The GageR&RStudy(Nested)usestheANOVAmethodofanalysis.Thismethodisusedwhen
only one operator measures each part. The basic assumption is that all parts within a single
batchareidenticalsothatwecanclaimthatthepartsarethesame.ThisisunliketheGageR&R
Study(Crossed)wherethesamepartcouldbemeasuredbymultipleoperators.

In the Gage R&R Study (Nested), the part is nested within the operator because each
operatormeasuresuniqueparts,thereforethedataareanalyzedusinganesteddesign.

Determining the Bias and Linearity

Chapter7:MeasurementSystemAnalysis(GageR&R)

25

Besidesrepeatabilityandreproducibility,theotherpartofameasurementsystemanalysisisto
determinetheaccuracyorbiasandlinearity.Accuracyisdefinedasthedifferencebetweenthe
measured value and the parts actual value or the master value. The accuracy is divided into
followingthreecomponents

(a)Linearity
(b)Bias,and
(c)Stability.

Gage linearity is the measure of accuracy or bias of the measurements through the
expected range of the measurements. The linearity determines if the gage has the same
accuracy for different sizes of parts being measured. It also tells us how the size of the part
affectstheaccuracyofthemeasurementsystem.

The bias (or gage accuracy) determines the difference between the observed average
measurementandthemasterortruevalue.

Thestabilityorthedriftisthetotalvariationinmeasurementswhenthemeasurements
areobtainedwiththesamemeasurementequipmentonthesamepartwhilemeasuringasingle
characteristicoveranextendedperiodoftime.
Case8:GageLinearityandAccuracy(Bias)Study
Example 1: To determine the linearity and bias of a gage, five parts were selected from a
manufacturingprocess.Thesepartsrepresenttheentireoperatingrange(orfullscale)ofthe
measurements. Each of the selected five parts was measured by the tool room to determine
the master value. Once the master values for the parts were determined, an operator
measured each of the parts 15 times randomly. The data are shown inTable7.22.Usingthis
data,thedatafileGAGELIN1B.MTWwascreated.Usethisdatafileto

(a)determinetheprocessvariationusingGageR&RStudy:ANOVAMethod,and

(b)usetheprocessvariationtodeterminethegagelinearityandbias.

Note: A Gage Linearity and Bias Study can also be conducted without knowing the process
variation.

Comparing Two Measuring Instruments for Precision and Accuracy

Comparing two measuring instruments might be necessary in cases when the vendors and
customers measurements are not consistent, or do not agree. If both parties are using the
same measuring instruments and the same measuring procedure, simple tests can be

Chapter7:MeasurementSystemAnalysis(GageR&R)

26

performedtocomparetheaccuracyandprecisionoftheinstruments.Inthissectionwewillbe
discussingtwotestsinvolvingvariablesmeasurement.

(1)comparingvariances(precision)forpaireddata
(2)comparingtheaverageofmeasurementsobtainedbytwomeasuring
instrumentsusingapairedttest

Thefirsttestdeterminesifthetwoinstrumentshavethesameprecisionasmeasuredby
the standard deviation of the measurements. The second test determines if there is a
significantdifferenceintheaveragemeasurementsofthetwoinstruments.Inotherwords,the
firsttestdeterminestheprecisionwhilethesecondtestdealswiththeaccuracy.
Case12: Use of Individuals Control Chart to Detect the Shift in Measuring
Instruments
I C hart of M easurem ent
5 .4
U C L= 5 .3 2 5 5

5 .3

Individual Value

5 .2
6

5 .1

2
2

_
X=5

5 .0
4 .9
6

4 .8
2

4 .7

LC L= 4 .6 7 4 5

4 .6
1

11

16

21
26
31
O b s e r v a t io n

36

41

46

51

Figure 7.30: Individuals Chart of Measurement

Figure7.30showsnooutofcontrolpointsbutthetestresultsforspecialcausesinTable7.36
showsthefollowing

TEST2.9pointsinarowonsamesideofcenterline.

TestFailedatpoints:22,23,24,44

Theruleof9pointsonthesamesideofthecenterlineisviolatedondays22,23,24
andagainonday44.ThechartinFigure7.30showsapatternwherethemeasuredpointsare
plotting above the centerline until about day26,andthenstarttoplotbelowthecenterline.
Thistypeofupanddownpatternisindicativeofashiftordriftfromthenominalvalueof5.0in.
The pattern in the individuals chart shows a shift in the upward direction and eventually a
downwardshift.
Chapter

of

Six

Sigma

Volume

contains

detailed

analysis

and

Chapter7:MeasurementSystemAnalysis(GageR&R)

27

interpretation of process capability analysis with data files and step-wise

computer instructions for both normal and non-normal data.
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