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    What Are Repeatability and Reproducibility, Part 3 Their Meaning in Gage R&R Methodology, ASTM Data Points, July-August 2009

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    What Are Repeatability and Reproducibility, Part 3 Their Meaning in Gage R&R Methodology, ASTM Data Points, July-August 2009

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    Standardization News Search

    Magazines & Newsletters / ASTM Standardization News

    July/August 2009
    DataPoints

    What Are Repeatability and


    Reproducibility?
    Part 3: Their Meaning in Gage r&R Methodology

    by Stephen Luko

    Q. How are repeatability and reproducibility applied in gage r&R methodology?

    A: Gage r&R methodology was developed in the 1960s to address the estimation of
    measurement system variation as applied to manufacturing. The automotive industry led
    in developing and applying this technique; today, gage r&R is a standard practice in many
    quarters.

    Here, we compare and contrast the use of repeatability (lowercase r) and reproducibility
    (uppercase R) as used in traditional manufacturing with its use in ASTM International
    standards. The most important difference is that the latter use probably contains far more
    applications to raw material testing while the former probably contains more applications
    in metal fabrication, molding and machining, assembly of subsystems and other
    manufacturing­ and fabrication­type gaging. This distinction is important because
    materials­type tests are often subject to more sources of variation than industrial
    processes.

    For ASTM materials testing, the key terms for r&R are repeatability conditions and
    reproducibility conditions. ASTM E177, Practice for Use of the Terms Precision and Bias
    in ASTM Test Methods, defines repeatability conditions as “conditions where independent
    test results are obtained with the same method on identical test items in the same
    laboratory by the same operator using the same equipment within short intervals of time.”
    To adapt this to gage r&R methodology, we interpret test results simply as gage
    measurements and laboratory as facility. The reason is that the term test result is more
    general than measurement, and facility implies that the measurements are made in one
    location — not necessarily a lab. With these distinctions, there is no difference between r
    as used in ASTM or in manufacturing.

    With reproducibility there is a noticeable interpretation difference in using this term in


    ASTM materials testing and its use in manufacturing. E177 defines reproducibility
    conditions as “conditions where test results are obtained with the same method on
    identical test items in different laboratories with different operators using different
    equipment.” Also, “a different laboratory of necessity means a different operator, different
    equipment, a different location and under different supervisory control.” In
    manufacturing, r&R methodology generally does not use different labs, equipment or
    supervisory control. Rather, these aspects of gage r&R methodology are more likely to be
    carefully controlled than allowed to vary.
    The role of reproducibility in gage r&R methodology is to define the variation among
    operator averages. Here, the term operator, or appraiser, refers to the person who uses the
    gage. Operator averages are thought to vary from person to person, and the R effect in
    gage r&R is attempting to estimate the variance due to operator differences in practice.
    The statistical model for r and R in gage r&R methodology (without interaction) is
    Equation 1:

    (1)

    In Equation 1, yijk is the kth repeat measurement of the ith part by the jth operator. The i

    component is the true value of the ith part dimension, the j component is the
    reproducibility effect associated with operator j and the εijk is the random repeatability
    error that occurs with each measurement. Each measurement, y, is composed of these
    three components. The reproducibility term ( ) may be thought of as a kind of personal
    bias associated with an operator, i.e., each operator measures the various parts somewhat
    differently than the true value x, and this is the individual’s effect. When we use several
    operators in a gage r&R study, we effectively pick a random sample (of operators) from a
    potentially infinite universe of all such possible operators. The terms are assumed to
    have a mean of 0 and an unknown variance 2.

    The total variance of all measurements, y, has a variance equal to the sum of the individual
    variance components as in Equation 2.

    (2)

    A gage r&R study is a designed experiment used to estimate the individual variance
    components. Typically, 2 and 2 are the main components of interest. The method,
    based on sample ranges, has enjoyed continued popularity, particularly for small to modest
    sample sizes, for many years. Today, many computer packages will perform gage r&R using
    the analysis of variance (or ANOVA) technique as well as the range technique. The
    following simple illustrations exemplify the method where sample ranges are used.

    Illustrations

    Five repeat measurements of a cylindrical shaft diameter were made by a single appraiser
    using the same measurement system under the same conditions. The resulting data were:
    3.158, 3.157, 3.161, 3.165 and 3.151. The range of the five measurements is R = 0.010. This
    is converted into the repeatability standard deviation by division by a constant d2, in this
    case, 2.326. The resulting estimate of the repeatability standard deviation is =
    0.010/2.326 = 0.0043. For several data sets, use the average range in this calculation.

    More generally, gage r&R experiments will have p appraisers, n parts and m repeats. One
    standard plan is to use p = 3, n = 10 and m = 3, making a total of 90 observations. Suppose
    we have performed such an experiment. The 90 measurements comprise 30 sets of
    repeated measurements. Each set of three will have a range. Denote the average of these
    ranges by and suppose this is equal to 8.4. For m = 3 and np = 30 measurements, the
    d*2 constant is approximately 1.693. Accordingly, the estimate of the repeatability
    standard deviation is:

    (3)

    For reproducibility, we need the appraiser averages range. For three appraisers, the range
    is calculated as the maximum average minus the minimum average. Denote this as RA and

    suppose this is equal to 6.89. Using standard formulas,1 the reproducibility standard
    deviation may be calculated as shown. The conversion constant d*2 = 1.912, appropriate
    for p = 3 appraisers, is used.

    (4)

    The total gage r&R standard deviation is computed as:

    (5)

    Reference
    1. Measurement Systems Analysis Reference Manual, 3rd edition, Automotive Industry
    Action Group, Southfield, Mich., 2005.

    Stephen Luko, Pratt & Whitney Aircraft, is chair of Committee E11 on Quality and
    Statistics, and a fellow of ASTM.

    Dean Neubauer is the DataPoints column coordinator and E11.90.03 publications chair.

    Go to other DataPoints articles.

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