Measurement System Analysis
Measurement System Analysis
Define
Measure
Analyze
Improve
2
Since Measurement systems
y represent
p
a sub-process within a process...
3
Sources of Measurement Variation
•Equipment
q p
•Part
•Operator
•Environment
•Procedure
4
Sources of Measurement Variation
6
Why MSA
U : UNCERTAINITY
RU = U=
0.0001 0.0001 RANDOM UNCERTAINITY –
NATIONAL
STANDARD
FOUND THRU
CALIBRATION
RU = U= LABORATORY
0.001 0.001005 STANDARD
SYSTEM UNCERTAINITY – OF
MASTER
TOTAL UNCERTAINITY –
SQRT( RU*RU + SU*SU)
WORK
RU = 0.01 U=
STANDARD
0.01005
GAUGE FOR
RU = 0.05 U= INSPECTION /
0.05099 TESTING
Process Capability
6σ
Tolerance = T
Uncertainty
6 σ Process
P
Tolerance = T
Knowledge to be obtained
Measurement
Variability
Total Variability
(Observed variability)
12
Effects of Measurement Error
Measurement
System Bias —
Averages Determined through
“Accuracy Study”
Measurement System
Variability Variability —
Determined through
“R&R Study” y
13
Terminology
14
Definition of Terms
• Reference Value
– The theoretically or agreed upon correct
value of the characteristic being
measured, traceable to some standard
• Resolution
– The smallest increment,, or unit of
measure, available from a measurement
process
– Generally at least 1/10th of the specification
range
Definition of Terms
• Precision
– The degree of agreement (or variability)
between individual measurements or test
results from measuring the same
specimen(s)
• Accuracy
y (Bias)
( )
– The difference between the average of the
measurement error distribution and the
reference value of the specimen measured
The Nature of Process Variation
1 2 3 4 5
1 2 3 4
Rule
R l off th thumb:b
. . . . . .Test equipment MUST be a least 10 times
more accurate t & precise
i then
th what’s
h t’ bbeing
i ttested
t d
17
Measurement System Error
Accuracy
Definition of Terms
• Repeatability
p y
– The variation in repeated measurements of the
same items with a single measurement system
– Within appraiser/system variation
• Reproducibility
R d ibilit
– The variation in the average measurements by
diff
different
t appraisers
i or systems
t measuring
i ththe
same items
– Between appraiser/system variation
Terms
• Linearity
– The degree to which bias changes with
changes in the magnitude of the characteristic
measured
• Stability
y
– The dependability, or consistency of the
measurement p
process over time
Measurement
Systems Capability
• The variability resulting from measurement error
must not exceed a significant proportion of the
intended specifications said to be capable
• In addition, it is not desirable for measurement
error to exceed a significant proportion of the
total process variability
• Capability is not the same as
acceptability, acceptability must be determined
on a case by
b case b basis
i
Measurement System Studies
• Potential Studies
– Assess potential of a measurement system to
be capable over the long term
– 10 p
parts measured 2–3 times byy one or more
appraisers
– A “quick and dirty”
y studyy to find out if you
y are in
the ballpark
– Assesses repeatability and reproducibility
– Often called an R&R study
• True value:
– Theoreticallyy correct value – unknown and unknowable
– Reference standards
– NIST standards
• Bias
– Distance between average value of all measurements
and true value
– Amount gage is consistently off target
– Systematic error or offset
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BIAS Definition
Observed
A
Average V
Value
l
ACCURACY IS THE SAME AS BIAS
25
Linearity
Difference in the accuracy values of a gage
through the expected operating range of the gage
55 55
45 45
35 35
Trials
Trials
Y=0.934227+0.994959X Y=0.245295+0.99505X
25 25
R-Squared=0.981 R-Squared=0.982
15 15
5 5
10 20 30 40 50 10 20 30 40 50
Standard Standard
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Stability
Time-2
Stability — Is the total variation in
the measurement obtained with a
measurement system (test / gage ) on
the same master pparts when measuringg
a single characteristic over an
extended time period.
Magnitude
g
Ti
Time-1
1
time
Points to the frequency of Mean center Calibration Stability
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• Total variation in the measurement system
p
• Measure of natural variation of repeated
measurements
• Terms: Random Error, Spread, Test/Retest
error
• Repeatability and Reproducibility
σ 2
MS =σ +σ
2
G
2
O
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Repeatability
p y
σG
• The inherent variability of the measurement system
• Variation in measurements obtained with a gage when
usedd severall titimes b
by one operator
t while
hil measuring
i a
characteristic on one part.
• Estimated by the pooled standard deviation of the
distribution of repeated measurements R
σG =
d 2*
• Repeatability is less than the total variation of the
measurement system
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R
Repeatability
t bilit Definition
D fi iti
REPEATABILITY
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Reproducibility
p y σO
R
σ O = *
d2
32
Reproducibility Definition
Operator-B
Reproducibility — Is the
variation in the average of the
measurements made by different
appraisers using the same measuring
instrument when measuring the
identical characteristic on the same Operator-C
Ope ato C
part.
Operator-A
Reproducibility
d ibili
33
Accuracy of Measurement
36
Types of R&R Studies
37
Basic Terms
38
Gage R&R study
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Preparation
p for a Measurement
Study
• Determine if reproducibility is an issue. If it is, select the
number of operators to participate.
• Operators selected should normally use the measurement
system.
• Select samples that represent the entire operating range.
• Gage must have graduations that allow at least one-tenth
of the expected process variation.
• Insure defined gaging procedures are followed
followed.
• Measurements should be made in random order.
• Study must be observed by someone who recognizes the
importance of conducting a reliable study.
40
Procedure for Performing
g R&R
Study
• Calibrate the gage, or assure that it has been calibrated.
• Have the first operator measure all the samples once in random
order.
• Have the second operator measure all the samples once in
random order.
• Continue until all operators
p have measured the samples
p once
(this is Trial 1).
• Repeat above steps for the required number of trials.
• Use GR&R form to determine the statistics of the study.y
– Repeatability, Reproducibility & %GR&R
– Standard deviations of each of the above
– % Tolerance analysis
• Analyze results and determine action, if any.
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Variable Gage
g R&R
Guidelines
% R&R Results
≤ 10% Gage is OK
10% – 30% Maybe acceptable based upon importance
of application, and cost factor
Over 30% Gage system needs improvement/corrective
action
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Xbar Chart by Operator Operator*Part No. Interaction
A- B- C-
40
40
35
35
30
30
Sample Mean
n
Average
25 25
20 20
15 15
10
10
5
5
0
0 1 2 3 4 5 6 7 8 9 10
Part No.
43
Thanks
44