Gage R&R Values Gage R&R Percentages

Gage R&R Part Number

Average & Range Method 1 2 3 4 5 6 7 8 9 10 Sum
Appraiser 1 Trial 1
Enter your data here-> Trial2
Trial3
Trial4 Xbar1
Trial 5
Total
Average-Ap Rbar1
Range1
Appraiser 2 Trial 1
Enter your data here-> Trial2
Trial3
Trial4 Xbar2
Trial 5
Total
Average-Ap Rbar2
Range2
Appraiser Trial 1
Enter your data here-> Trial2
Trial3
Trial4 Xbar3
Trial 5
Total
Average-Ap Rbar3
Range3
Range Average #DIV/0! Constants
XDiff 0.0000 5 Trials 4 Trials 3 Trials 2 Trials # Trials 0
UCL Err:522 2.11 2.28 2.58 3.27 D4 Err:522 UCL represents the limit of the individual R's
LCL 0.0000 0 0 0 0 D3 Err:522 Circle those beyond the limit.
Repeatability(EV) Err:522 0.577 0.729 1.023 1.88 A2 Err:522 Identify and correct causes
Reproducibility(AV) 0.0000 0.4299 0.4857 0.5908 0.8862 K1 Err:522 LCL = 0 D3=0 for up to 7 trials
Gage Capability(R&R) Err:522 0.7071 0.5231 K2 0.7071
Spec Tolerance 0.012 2 Ops 3 Operators
Acceptability(%) Err:522 Err:522
% Using % Using Err:522
AIAG - Automotive Industry TV Tolerance
EV (Equipment Variation) Err:522 Equipment Variation (EV)
%EV Err:522 Err:522 # Parts #Trials #Ops % of Total Variation (TV)
AV: (Appraiser Variation) 0.00000 0 0 2 Appraiser Variation(AV)
%AV 0.0% 0% % of Total Variation (TV)
R&R (Gage Capability) Err:522 Repeatability and Reproducibility (R&R)
%R&R Err:522 Err:522 % of Total Variation (TV)
PV (Part Variation) #VALUE! Part Variation (PV)
%PV #VALUE! #VALUE! % of Total Variation (TV)
TV (Total Variation) Err:522 Total Variation (TV)
Calculate GageR&R using Anova With Interaction Without Interaction
Anova Source df SS MS F P F P
Appraiser 1 #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0!
Parts -1 #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0!
Appraiser x Part -1 #DIV/0! #DIV/0! #DIV/0! #DIV/0!
Gage w AP Interactio 0 #VALUE! #VALUE!
Gage w/o AP Interacti -1 #DIV/0! #DIV/0!
Total -1 #VALUE!

%
Estimate of % Study Contributio
Variance Std. Dev 5.15* Stdev Variation n
Repeatability #VALUE! #VALUE! EV #VALUE! #VALUE! #VALUE!
Appraiser #DIV/0! #DIV/0! AV #DIV/0! #DIV/0! #DIV/0!
AppraiserxPart #DIV/0! #DIV/0! INT #DIV/0! #DIV/0! #DIV/0!
R&R #VALUE! #VALUE! R&R #VALUE! #VALUE! #VALUE!
Part #DIV/0! #DIV/0! PV #DIV/0! #DIV/0! #DIV/0!
TV #VALUE!
 Part by Appraiser Plot (Stacked)

12

10
Averagge

8
Average-Appraiser 1
Average-Appraiser 2
6
Average-Appraiser 3

0
1 2 3 4 5 6 7 8 9 10
Part

Part by Appraiser Plot

12

10
Averagge

6 Row 9

0
 2

0
1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10
Appraiser 2
Appraiser 1 Appraiser 3

Range of Parts by Appraiser (Stacked)

12

10
Range

Range1
6 Range2
Range3

0
1 2 3 4 5 6 7 8 9 10
Parts

Range of Parts by Appraiser

12

10
Range

6
Row 10

4
 Range of Parts by Appraiser

12

10
Range

6
Row 10

0
1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10
Appraiser 2
Appraiser 1 Appraiser 3
Instructions 1. Select 10 DIFFERENT parts and at least two "appraisers" and one gage
(If you don't use enough parts, part variation will be small and magnify the appraiser/equipment variation)
2. RANDOMLY, have appraisers measure each part at least twice
3. Then enter the results of each measurement in Cells C3:L7, C11:L15, C19:L23
4. The template will automatically calculate all of the values based on your data
5. Evaluate your measurement system based on %R&R and make adjustments as required.

Gage Repeatability and Reproducibility

Measurement is one common cause of variation. Gage R&R helps improve measurement systems
If repeatability (EV - Can the same person using the same gauge measure the same thing consistently)
is larger than reproducibility, reasons include:
1. Gage instrument needs maintenance
2. Gage needs to be redesigned
3. Clamping or location needs to be improved
4. Excessive within-part variation

If reproducibility (AV-can two appraisers measure the same thing and get the same result)
is larger than repeatability, reasons include:
1. Operator needs to be better trained in how to use and read gage
2. Calibrations on gage are not clear
3. Fixture required to help operator use gage more consistently

Gage System Acceptability

%R&R<10% Gage System Okay (Most variation caused by parts, not people or equipment)
%R&R<30% May be acceptable based on importance of application and cost of gage or repair
%R&R>30% Gage system needs improvement (people and equipment cause over 1/3 of variation)

Verified using AIAG Measurement Systems Analysis 3rd Edition

 Gage R&R Percentages

Reference
12.500 <-Insert Reference Value Here
Bias
#VALUE!

Reference
12.500
Bias
#VALUE!

Reference
12.500
Bias

UCL represents the limit of the individual R's

 Average-Appraiser 1
Average-Appraiser 2
Average-Appraiser 3

8 9 10

Row 9
 10 1 2 3 4 5 6 7 8 9 10

Appraiser 3

Range1
Range2
Range3

7 8 9 10

Row 10
 Row 10

10 1 2 3 4 5 6 7 8 9 10

Appraiser 3
 Range Method

Range Method Insert Your Data Here

Part 1 2 3 4 5 Average
Appraiser 1 1 1
Appraiser 2 1.1 1.1 d2
Range 0.1 0 0 0 0 0.02 1.41

GR&R 0.014184

Insert Process
Standard
Deviation 0.070711
%GR&R 20%

Page 11
 Bias

t-
Reference Average/ Stdev(r) Statistic/
Value Value Bias n Mean Stdev Stdev(b) critical
6.0 0 #DIV/0! #DIV/0! #N/A #N/A
Bias #DIV/0! #N/A #N/A

95% Confidence
Lower Upper
#N/A #N/A
#N/A

Reference: AIAG MSA Version 3 pgs 85-88

Page 12
 Bias

d2*/d2 df g 2 3 4 5 6 7
#N/A #N/A d2* 1.41421 1.91155 2.23887 2.48124 2.67253 2.82981
#N/A df 1 2 2.9 3.8 4.7 5.5
d2 1.12838 1.69257 2.05875 2.3593 2.53441 2.70436
t crit 95% 4.303 3.182 2.776 2.571 2.447 2.365

Version 3 pgs 85-88

Page 13
 Bias

8 9 10 11 12 13 14 15 16
2.96288 3.07794 3.17905 3.26909 3.35016 3.42378 3.49116 3.55333 3.61071
6.3 7 7.7 8.3 9 9.6 10.2 10.8 11.3
2.8472 2.97003 3.07751 3.17287 3.25846 3.33598 3.40676 3.47193 3.53198
2.306 2.262 2.228 2.201 2.179 2.16 2.145 2.131 2.12

Page 14
 Bias

17 18 19 20
3.66422 3.71424 3.76118 3.80537
11.9 12.4 12.9 13.4
3.58788 3.64006 3.68896 3.735
2.11 2.101 2.093 2.086

Page 15
 Linearity

Part
Trials 1 2 3 4 5
1 2.7 <- Insert Your Data Here
2
3 Linearity evaluates a gauge's abi
4 to measure accurately across a w
5 Imagine measuring a baseball ba
6 1. at the grip
7 2. in the middle
8 3. and at the widest part
9
10
11
12
Average 2.70
Reference
Values 2.00 <- Insert Known Reference Values Here
Bias 0.70
Range 0.00 0.00 0.00 0.00 0.00
bias=
slope*ref+b
Slope= Err:502
b= Err:502
Goodness of
fit Err:502
Insert
Process
Variation
Linearity Err:502
%Linearity Err:502

Linearity Plot

0.80

0.70

0.60
Bias

0.50

0.40

0.30

0.20

0.10

0.00
1.50 2.00 2.50 3.00 3.50 4.00
Reference Value

Page 16
 Linearity

evaluates a gauge's ability

e accurately across a wide range
measuring a baseball bat:

he widest part

rence Values Here

Page 17
 Appraiser A Appraiser B Appraiser C Reference Results
Part # Trial 1 Trial 2 Trial 3 Trial 1 Trial 2 Trial 3 Trial 1 Trial 2 Trial 3 Reference Ref Value Code LSL USL %R&R
1 1 X
2 1 X 1. Enter Spec Limits Above
3 1 X 2. Have 3 appraisers accept/reject 10+ par
4 1 X 3. Enter pass/fail in columns B-J
5 1 X 4. Enter Reference value in column L
6 1 X 5. Evaluate effectiveness columns AJ-AV
7 1 X
8 1 X
9 1 X
10 1 X
11 1 X
12 1 X
13 1 X
14 1 X
15 1 X
16 1 X
17 1 X
18 1 X
19 1 X
20 1 X
21 1 X
22 1 X
23 1 X
24 1 X
25 1 X
26 1 X
27 1 X
28 1 X
29 1 X
30 1 X
31 1 X
32 1 X
33 1 X
34 1 X
35 1 X
36 1 X
37 1 X
38 1 X
39 1 X
40 1 X
41 1 X
42 1 X
43 1 X
44 1 X
45 1 X
46 1 X
47 1 X
48 1 X
49 1 X
50 1 X
0 = Fail + = within spec limits
1 = Pass - = outside spec limits
x = gray area around spec limits
 A-B B-C C-A A-REF B-REF C-REF
Gray zone 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3
0.00000

sers accept/reject 10+ parts Crosstabulation Crosstabulation

in columns B-J B Total REF Total Effectiveness
ce value in column L A 0 1 A 0 1 A
tiveness columns AJ-AV 0 0 0 0 0 0 0 0 B
1 0 0 0 1 0 0 0 C
Total 0 0 0 Total 0 0 0 System

C Total REF Total Effectiveness

B 0 1 B 0 1 Acceptable
0 0 0 0 0 0 0 0 Marginal
1 0 0 0 1 0 0 0 Unacceptable
Total 0 0 0 Total 0 0 0

A Total REF Total

C 0 1 C 0 1
0 0 0 0 0 0 0 0
1 0 0 0 1 0 0 0
Total 0 0 0 Total 0 0 0
 Miss
Effectiveness Rate
#DIV/0! #DIV/0!
#DIV/0! #DIV/0!
#DIV/0! #DIV/0!
#DIV/0! #DIV/0!
#DIV/0!
Effectiveness
Acceptable >= 90%
Marginal >=80%
Unacceptable <80%