Measurement System Analysis
Measurement System Analysis
Analysis
Module Objective:
What is Measurement System
Understanding MSA
Detailed discussion on Measurement Errors
– Variable
Bias
Linearity
R&R
– Attribute studies
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INTRODUCTION
Product
Quality
Ability of
Process Control
Ability to Measure
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Measurement Process
•Standard
•Work piece (part)
•Instrument Measurement Measurement
•Person result
•Procedure
•Environment
Decision (action)
Analysis
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Properties of a Good Measurement System
• Adequate discrimination(resolution)
• Under statistical control
• Accuracy
• Precision
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DISCRIMINATION
required
resolution
6
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DISCRIMINATION
• Rule of 10’s i.e. 1/10th should be followed as a starting point. i.e. least
count/ resolution of equipment should be 1/10th of process Variation
(10 data categories).
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DATA CATEGORIES:
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Properties of a Good Measurement System
• Adequate discrimination
(resolution)
• Under statistical control
• Accuracy
• Precision
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Statistical Control of Measurement System
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Properties of a Good Measurement System
• Adequate discrimination
(resolution)
• Under statistical control
• Accuracy
• Precision
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Accurate &
Accurate
Precise
What?
Precise
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IF Measurement System has accuracy error
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So, we conclude…
total process MS Accuracy error
total
2
2process 2MS Precision error
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Measurement System Analysis
Location Spread
Bias Repeatability
Linearity Reproducibility
Stability
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Bias
Observed
Average
Value
Bias
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Linearity
– The difference of bias through the expected operating
(measurement) range of the equipment.
– This is change of bias with respect to size.
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MEASURMENT POINTS
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Stability (Drift)
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Reproducibility (Between system variation)
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 part.
APPRAISER A C B
REPRODUCIBILITY
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A C B
APPRAISER
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Section-3
DETAILED EXPLANATION
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R&R- STUDY
Key Consideration
Must cover entire process variation
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R&R- STUDY
Data collection:
•Using data collection sheet
•Under ROUTINE measurement condition
•in random order
•using Blind Measurement process
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1 2 3 4 5 6 7 8 9 10
RAKESH 1 48.06 48.055 48.054 48.065 48.064 48.056 48.063 48.064 48.065 48.066 1
2 48.061 48.056 48.055 48.065 48.063 48.055 48.06 48.066 48.062 48.063 2
3 3
AVERAGE X bar a 4
RANGE R barc 5
Sharifi 1 48.06 48.057 48.053 48.065 48.052 48.055 48.063 48.064 48.065 48.063 6
2 48.06 48.056 48.056 48.065 48.053 48.054 48.06 48.065 48.065 48.063 7
3 8
AVERAGE X bar b 9
RANGE R barc 10
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R&R- GRAPHICAL ANALYSIS (Manual)
1) For appraiser A, calculate Average (X bar) & Range(R) for each part and enter in
rows 4 & 5 respectively.
2) Do the same for appraisers B & C and enter results in rows 9, 10 and14, 15
respectively.
3) For appraiser A, calculate average (X bar a) of all the averages (row 4) and
average (R bara) of all the ranges (row 5) and enter in data sheet.
4) Calculate X bar b, R barb & X bar c, R barc for appraisers B & C also and enter the
results in data sheet.
5) Calculate average of all the observations (rows 4, 9 &14) of each part and enter
result in row 16.
6) Calculate Part range (Rp)= Difference of Max. and Min. of row 16 and enter in
data sheet (right most row 16).
7) Calculate X double bar =(X bar )/k and enter in data sheet (right most row 16).
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Calculate
Calculate R&R- CALCULATION Appraiser
Average & Average &
Range Range
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Calculate Part R&R- CALCULATION
Average &
Range
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R&R- CALCULATION
Calculate
Calculate Calculate R
X bar diff
UCL Rbar double bar
Calculate
LCL x bar
35
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RANGE CHARTS
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R&R- GRAPHICAL ANALYSIS: RANGE CHARTS
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R&R- ANALYSIS – NUMERICAL (Manual)
Calculate the following and record in report sheet
– Repeatability (EV) = Rdouble bar x K1
K1 = .8862 (2 trials), 0.5908(3 trials)
– Reproducibility (AV) =
X Bar Diff x K2
K2=0 .7071(2 app.) & 0.5231(3 app.)
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R&R- CALCULATION
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R&R- CALCULATION
– Calculate % variation and ndc as follows
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R&R- CALCULATION
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TV Calculation- Different Approaches
Priority order:
1. PV approach
2. Surrogate process variation approach
3. Specification tolerance approach
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TV Calculation- PV Approach
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TV Calculation - Surrogate Process variation Approach
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R&R- DECISIONS
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NDC Graphically:
1 2 3 4 5 6 7 8 9 10 11
PART VARIATION
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No. of Distinct Categories (NDC)
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R&R- DECISIONS
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MSA FOR NON -REPLICABLE Measurement Systems
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GRR STUDY
Sampling:
• Select 6 very similar parts (assumed to be identical) consecutively
or if possible split 1 sample in 6 parts
• Consider these 6 duplicate samples as sample 1
• Mark them 1-1, 1-2,……….1-6
• In similar manner select 10 samples (i.e 10 x 6= 60 parts as-
1-1, 1-2,…………….1-6
2-1, 2-2,……………..2-6
……………………………
10-1, 10-2, …………10-6
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GRR FOR COMPLEX & NON REPEATABLE MS
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GRR FOR COMPLEX & NON REPEATABLE MS
Data collection
Select the following:
• Routine appraiser (2-3),
• Routine measuring equipment
• Routine measurement venue
• Routine measurement environment
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GRR FOR COMPLEX & NON REPEATABLE MS
DATA COLLECTION EXAMPLE
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MSA FOR COMPLEX & NON REPEATABLE MS
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Recall: Bias
Observed
Average
Value
Bias
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DETERMINING BIAS
1. Obtain sample and determine reference value
2. Collect data
3. Determine Bias
4. Plot bias histogram
5. Compute Average bias
6. Compute Repeatability Standard deviation
7. Determine acceptability of repeatability
8. Determine t statistic for bias
9. Compute bias Confidence Interval and decision
making
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Step 1: Obtain REFERENCE SAMPLE SELECTION
Priority order
1. Sample piece else
2. Production part else
3. Similar other component else
4. Metrology standard
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Step- 2. DATA COLLECTION
Under routine measurement condition
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Step-3
Determine Bias for each reading:
biasi=xi- Reference Value
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Step 4. Graphical Analysis
Plot the bias as a histogram
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Sum bias 0.1000
Avg bias 0.0067
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Compute Repeatability Standard Deviation
Obs Value
Trials True Value (x) x‐ Avg(x) Sq[x‐ Avg(x)]
1 6.00 5.8 ‐0.2067 0.0427
2 6.00 5.7 ‐0.3067 0.0940
To calculate repeatability 3 6.00 5.9 ‐0.1067 0.0114
(EV) you can also use R 4 6.00 5.9 ‐0.1067 0.0114
Bar/d2, but when sample 5 6.00 6.0 ‐0.0067 0.0000
6 6.00 6.1 0.0933 0.0087
size large (number of
7 6.00 6.0 ‐0.0067 0.0000
reading are large), Root
8 6.00 6.1 0.0933 0.0087
Mean Square method is 9 6.00 6.4 0.3933 0.1547
better. 10 6.00 6.3 0.2933 0.0860
11 6.00 6.0 ‐0.0067 0.0000
12 6.00 6.1 0.0933 0.0087
13 6.00 6.2 0.1933 0.0374
14 6.00 5.6 ‐0.4067 0.1654
15 6.00 6.0 ‐0.0067 0.0000
Sum (x) 90.1000 Sum= 0.6293
Avg (x) 6.0067 Sigma‐r 0.2120
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8. Determine Bias standard error
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Decision Making
Bias is acceptable
at 100(1-)% confidence level
if
L<0<U
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43.97
BIAS: Exercise 43.96
43.92
43.99
43.95
43.96
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Linearity
– The difference of bias through the expected operating
(measurement) range of the equipment.
– This is change of bias with respect to size.
1 2 3
MEASURMENT POINTS
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Linearity
-1
REFERENCE VALUE
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LINEARITY STEPS
Determine Process Range
Calculate Bias
Take Decision
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DETERMINING LINEARITY
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DETERMINING LINEARITY
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Excel Results
– Statistics:
For the best fit line,
yi = axi + b Where,
xi = reference value
yi = bias average
xy – 1 x y
gm
a = = slope
x2 – 1 ( x)2
gm
b = y – ax = intercept
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Determine Confidence band for the Line: Complex
Calculation.
Use Excel
Work sheet
1/2
1 (x0 – x)2
Lower: b + ax0 – tgm-2,/2 +
gm s
(xi – x)2
1/2
1 (x – x)2
Upper: b + ax0 + tgm-2,/2 + 0 s
gm (xi – x)2
s= y i – b yi – a xiyi
2
gm-2
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Linearity Acceptability
83
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line
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Stability (Drift)
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DETERMINING STABILITY
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DETERMINING STABILITY
Analysis
Calculate control limits for X-R chart.
Plot data on chart
Analyse for any out of control situation.
Decision
Measurement system is stable & acceptable if
no out of control condition is observed other
wise not stable and needs improvement .
Remember these are same you draw for process control (SPC)
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LSL USL
LSL USL
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ATTRIBUTE MEASUREMENT SYSTEMS STUDY
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ATTRIBUTE MEASUREMENT SYSTEMS
STUDY(Effectiveness Hypothesis based)
This method will enable you compare agreement within the appraiser, between the
appraiser and references as follows:
% Appraiser1 %Score vs Attribute2
Operator Operator Operator
Source #1 #2 #3 Operator #1 Operator #2 Operator #3
Total Inspected 20 20 20 20
# Matched 10 16 10 16
False Negative (operator biased toward
rejection) 0 0 0
False Positive (operator biased toward acceptance) 0 0 0
Mixed 10 4 0
95% UCL
Calculated Score 50.0% 80.0% 50.0% 80.0%
95% LCL
Screen % Effective Score3 Screen % Effective Score vs Attribute4
Total Inspected 20 20
# in Agreement 10 10
95% UCL
Calculated Score 50.0% 50.0%
95% LCL
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ATTRIBUTE MEASUREMENT SYSTEMS STUDY
Decision Making
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Kappa Method
Compare agreement between the appraisers
using cross tabulation :
No. 30 in the first column first Row of above table has been calculated as under:
“when Operator A declared “1”i.e. Bad , Operator B also declared it as “1”i.e. Bad
Similarly, 4 in Second column first Row of above table has been calculated as under:
when Operator A declared “1”i.e. Bad , Operator B declared it as “2” i.e. Good
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Attribute Measurement Systems Study
Kappa Method
Compare agreement between the appraisers
using cross tabulation :
No. 30 in the first column first Row of above table has been calculated as under:
“when Operator A declared “1”i.e. Bad , Operator B also declared it as “1”i.e. Bad
Similarly, 5 in Second column first Row of above table has been calculated as under:
when Operator A declared “1”i.e. Bad , Operator B declared it as “2” i.e. Good
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Attribute Measurement Systems Study
po-pe
•Calculate kappa : Kappa =
1-pe
(52/60)- (30.5/60)
Kappa = = 0.727
1- 30.5/60
Where,
po = sum of observed proportion in diagonal cells
pe = sum of expected proportion in diagonal cells
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Attribute Measurement Systems Study
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QUESTION – ANSWER
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