MEASUREMENT SYSTEM

ANALYSIS - MSA

Brijesh.VP
5 Core Tools
4th EDITION

APQP

PPAP

MSA

SPC

FMEA
 IATF 16949 : 2016 Requirement
Clause – 7.1.5.1.1 Measurement System Analysis

Statistical study shall be conducted to analyse

the variation present in the result of each type
of inspection, measurement, and test
equipment system identified in the control
plan.
Why MSA?
Sources Of Variations - Types

Common Cause

Special Case

Sources of Variations
Manufacturing
Process Process design Product Design

Mach Tooli Paramet

er Method Mate Enviro Measu
variation
ine ng variation rial nment rement
 Fundamental Properties of a Good
Measurement system

• Adequate Sensitivity – 10 TO 1 RULE –

Instrument accuracy (Least Count) should
divide the tolerance (process variation) into
10 parts or more
• Measurement system ought to be in
statistical control – presence of only
common causes of variation and not the
special causes
 Agenda

• Accuracy & precision

• Measurements system variation

• Bias, Linearity & Stability

• Repeatability & Reproducibility

Accuracy & Precision
Measurements system variation

Measurement System Variation

Accuracy

Bias

Linearity

Stability

Precision

Repeatability

Reproducibility
 Bias

Bias is the difference between the average of measurements made on

the same object and its true value
 Linearity

Observed Range

Operating Range

Linearity an indicator of the consistency of measurements over the

entire range of measurements.
 Stability

Stability refers to the capacity of a measurement system to produce the

same values over time when measuring the same sample.
 Repeatability

Repeatability is the variation between successive measurements of the

same part, same characteristic, by the same person using the same
gauge.
 Reproducibility

Good Reproducibility Bad Reproducibility

Reproducibility is the difference in the average of the measurements

made by different people using the same instrument measuring the
identical characteristic on the same pieces.
 Measurements system variation

Accuracy

CALIBRATION
Bias

Linearity
CALIBRATION

Stability

GAGE R&R
Precision

Repeatability

Reproducibility
 GAGE R&R
• Gage R&R is a means of assessing the repeatability and
reproducibility of our measurement systems

• Gage repeatability and reproducibility (GR&R) is defined

as the process used to evaluate a gauging instrument’s
accuracy by ensuring its measurements are repeatable and
reproducible.

• Gage R&R studies are carried out in order to discover how

much of a process variation is due to the measurement
device and measurement methods.
GAGE R&R

Gage R&R
Variable Gage R&R Study

Attribute Gage R&R Study

 Variable Gage R&R Study
Requirements:
• A minimum of two operators (3 or 4 recommended)

• At least 10 parts should be chosen to represent the full range of

manufacturing variation
• Each part to be measured 2 or 3 times in a random order

• Operators should not be aware of the previous result when measuring

the same part
 Variable Gage R&R Study : Types

• X- bar and average method

• Analysis of variance (ANOVA) method
• EMP (Evaluating the Measurement Process)
 Variable Gage R&R Study

GAGE REPEATABILITY AND REPRODUCIBILITY DATA SHEET GAGE REPEATABILITY AND REPRODUCIBILITY DATA SHEET
VARIABLE DATA RESULTS VARIABLE DATA RESULTS
Part Number Gage Name Appraiser A Part Number Gage Name Appraiser A
468 AIR GAUGE Bala 468 AIR GAUGE Bala
Part Name Gage Number Appraiser B Part Name Gage Number Appraiser B
IMPELLOR I/14 Muthamizhan IMPELLOR I/14 Muthamizhan
Characteristic Specification Gage Type Appraiser C Characteristic Gage Type Appraiser C
ID 11.820 11.850 DIGITAL Saran Raj ID DIGITAL Saran Raj
Characteristic Classification Trials Parts Appraisers Date Performed Characteristic Classification Trials Parts Appraisers Date Performed
3 10 3 21.02.2021 3 10 3 21.02.2021

APPRAISER/ PART AVERAGE Measurement Unit Analysis % Total Variation (TV)

TRIAL # 1 2 3 4 5 6 7 8 9 10 Repeatability - Equipment Variation (EV)
1. A 1 11.835 11.835 11.842 11.839 11.838 11.842 11.835 11.836 11.842 11.843 11.8387 EV = R x K1 Trials K1 % EV = 100 (EV/TV)
2. 2 11.835 11.836 11.841 11.839 11.839 11.842 11.835 11.835 11.841 11.843 11.8386 = 0.001 x 0.5907 2 0.8865 = 100(0.000/0.002)
3. 3 11.836 11.835 11.842 11.839 11.839 11.842 11.835 11.835 11.842 11.843 11.8388 = 0.000 3 0.5907 = 13.56
4. AVE 11.835 11.835 11.842 11.839 11.839 11.842 11.835 11.835 11.842 11.843 xa= 11.8387 Reproducibility - Appraiser Variation (AV)
5. R 0.001 0.001 0.001 0.000 0.001 0.000 0.000 0.001 0.001 0.000 ra= 0.0006 AV = {(xDIFF x K2) - (EV /nr)}
2 2 1/2
% AV = 100 (AV/TV)
6.B 1 11.835 11.835 11.842 11.839 11.838 11.842 11.835 11.835 11.842 11.843 11.8386 = {(0.00 x 0.5236)^2 - (0.00 ^2/(10 x 3))}^1/2 = 100(0.000/0.002)
7. 2 11.836 11.836 11.842 11.839 11.839 11.842 11.836 11.835 11.841 11.842 11.8388 = 0.000 = 0.00
8. 3 11.835 11.835 11.842 11.839 11.839 11.842 11.835 11.835 11.842 11.843 11.8387 Appraisers 2 3
9. AVE 11.835 11.835 11.842 11.839 11.839 11.842 11.835 11.835 11.842 11.843 xb= 11.8387 n = parts r = trials K2 0.7087 0.5236
10. R 0.001 0.001 0.000 0.000 0.001 0.000 0.001 0.000 0.001 0.001 rb= 0.0006 Repeatability & Reproducibility (GRR) % GRR = 100 (GRR/TV)
{(EV + AV )}
2 2 1/2
11. C 1 11.835 11.835 11.842 11.839 11.839 11.842 11.835 11.836 11.842 11.843 11.8388 GRR = Parts K3 = 100(0.000/0.002)
12. 2 11.836 11.836 11.841 11.839 11.839 11.842 11.835 11.835 11.841 11.843 11.8387 = {(0.000^2 + 0.000^2)}^1/2 2 0.7087 = 13.56
13. 3 11.835 11.835 11.842 11.839 11.839 11.842 11.835 11.835 11.842 11.843 11.8387 = 0.000 3 0.5236 Gage system may be acceptable
14. AVE 11.835 11.835 11.842 11.839 11.839 11.842 11.835 11.835 11.842 11.843 xc= 11.8387 Part Variation (PV) 4 0.4464
15. R 0.001 0.001 0.001 0.000 0.000 0.000 0.000 0.001 0.001 0.000 rc= 0.0005 PV = RP x K3 5 0.4032 % PV = 100 (PV/TV)
16. PART X= 11.8387 = 0.008 x 0.3145 6 0.3745 = 100(0.002/0.002)
AVERAGE 11.835 11.835 11.842 11.839 11.839 11.842 11.835 11.835 11.842 11.843 Rp= 0.0078 = 0.002 7 0.3534 = 99.08
17. (ra + rb + rc) / (# OF APPRAISERS) = R= 0.0006 Total Variation (TV) 8 0.3378
xDIFF = (Max x - Min x) = xDIFF= {(GRR + PV )}
2 2 1/2
18. 0.0000 TV = 9 0.3247 ndc = 1.41(PV/GRR)
19. * UCLR = R x D4 = UCLR= 0.0015 = {(0.000^2 + 0.002^2)}^1/2 10 0.3145 = 1.41(0.002/0.000)
= 0.002 = 10
* D4 =3.27 for 2 trials and 2.58 for 3 trials. UCLR represents the limit of individual R's. Circle those that are Gage discrimination acceptable
beyond this limit. Identify the cause and correct. Repeat these readings using the same appraiser and unit as originally used or
discard values and re-average and recompute R and the limiting value from the remaining observations. For information on the theory and constants used in the form see MSA Reference Manual , Third edition.
CONCLUSION : THE MEASURMENT SYSTEM IS ACCEPTABLE Page 1/2 Page 2/2
 AIAG Gage R&R Acceptance Criteria

% R&R Decision Comments

Generally considered to be an Recommended, especially useful when
Under 10 acceptable measurements trying to sort or classify parts or when
system. tightened process control is required.
Decision should be based upon for
example, importance of the application
May be acceptable for some
10 to 30 measurement, cost of measurement
applications.
device, cost of rework or repair. Should be
approved the customer.
Every effort should be made to improve
Over 30 Considered to be unacceptable
the measurement system.
 Improving the measurement system
Gauge Incapable
• Repeatability (Gage)
– Take multiple measurements and use average (short term fix)
– Mistake Proofing (eg. Provision of tooling to hold part during measurement)
– May need maintenance
• Reproducibility (Operators)
– Use one operator(short term fix)
– Have several operators measure the part and take the average (short term fix)
– Ensure consistency (training, SOPs, Work Instructions etc.,)
– Mistake Proofing (eg. Provision of tooling to hold part during measurement)
– Calibrations on the gage may not be clear
 Attribute Gage R&R

• A Gage R&R study can also be carried out on

attribute data
• Using attribute data we would have a problem with
the measurement system if:
– Operators disagree with each others evaluation of a piece

– The same operator gains different results from a repeat

evaluation of the same piece
 Conducting Attribute Gage R&R

1. Select a minimum of 30 parts from the process. These

parts should represent the full spectrum of process
variation (good parts, defective parts, borderline parts).
2. An expert inspector performs an evaluation of each part,
classifying it as good or not good
3. Independently and in a random order, each of 2 or 3
operators should assess the parts as good or not good
4. Calculate effectiveness scores
 Definitions
Acceptance Criteria
Effectiveness: It is the ratio of no of
Area Target%
correct decisions & total
Effectiveness >=90%
opportunities for a decision
Miss Rate <5%
Miss Rate: Decision is OK for
False Alarm <=10%
rejected parts
Kappa >75%
False Alarm : Decision is rejected for
OK Parts
Kappa : (Po-Pe)/(1-Pe)
Po – Probability observed
Pe – Probability Expected
 Attribute Gage R&R Study
DOC NO: SHI/QA/CAL/06
SRI HARI INDUSTRIES MSA - ATTRIBUTE GAUGES REV/DATE:00/01.06.2013

GAUGE ID NO : G/119 DATE OF STUDY : 26.05.2022

PART NAME : SHROUD BRACKET
PART NUMBER : H05-4614
Cross Tabulation : Accp.limit
0-0/
Bala Gopi Birendra
0-1 1-0
SL NO
TRIAL 1 TRIAL 2 TRIAL 3 TRIAL 1 TRIAL 2 TRIAL 3 TRIAL 1 TRIAL 2 TRIAL 3
Reference Actual
Bala 1-1 % Effeciveness= 100 % Min 90%
1 1 1 1 1 1 1 1 1 1 1
2 0 0 0 0 0 0 0 0 0 0 150 0 0
3
4
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
% Miss Rate= 0.00 % Max 2%
5
6
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0 % False Rate= 0.00 % Max 5%
7 1 1 1 1 1 1 1 1 1 1
8 0 0 0 0 0 0 0 0 0 0
9 1 1 1 1 1 1 1 1 1 1
10 0 0 0 0 0 0 0 0 0 0
11 1 1 1 1 1 1 1 1 1 1
12 1 1 1 1 1 1 1 1 1 1 0-0/
13 0 0 0 0 0 0 0 0 0 0 0-1 1-0
14 1 1 1 1 1 1 1 1 1 1 Gopi 1-1 % Effeciveness= 100 % Min 90%
15 1 1 1 1 1 1 1 1 1 1
16 1 1 1 1 1 1 1 1 1 1
17 1 1 1 1 1 1 1 1 1 1 150 0 0 % Miss Rate= 0.00 % Max 2%
18 1 1 1 1 1 1 1 1 1 1
19 0 0 0 0 0 0 0 0 0 0
20 1 1 1 1 1 1 1 1 1 1 % False Rate= 0.00 % Max 5%
21 1 1 1 1 1 1 1 1 1 1
22 1 1 1 1 1 1 1 1 1 1
23 1 1 1 1 1 1 1 1 1 1
24 1 1 1 1 1 1 1 1 1 1
25 1 1 1 1 1 1 1 1 1 1
26 1 1 1 1 1 1 1 1 1 1
27 1 1 1 1 1 1 1 1 1 1 0-0/
28 1 1 1 1 1 1 1 1 1 1 0-1 1-0
29 1 1 1 1 1 1 1 1 1 1 Birendra 1-1 % Effeciveness= 100 % Min 90%
30 1 1 1 1 1 1 1 1 1 1
31 1 1 1 1 1 1 1 1 1 1
32 1 1 1 1 1 1 1 1 1 1 150 0 0
33
34
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
% Miss Rate= 0.00 % Max 2%
35
36
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1 % False Rate= 0.00 % Max 5%
37 0 0 0 0 0 0 0 0 0 0
38 1 1 1 1 1 1 1 1 1 1
39 1 1 1 1 1 1 1 1 1 1
40 1 1 1 1 1 1 1 1 1 1
41 1 1 1 1 1 1 1 1 1 1
42 1 1 1 1 1 1 1 1 1 1
43 0 0 0 0 0 0 0 0 0 0
44 1 1 1 1 1 1 1 1 1 1
45 1 1 1 1 1 1 1 1 1 1
46 0 0 0 0 0 0 0 0 0 0
47 0 0 0 0 0 0 0 0 0 0
48 1 1 1 1 1 1 1 1 1 1
49 1 1 1 1 1 1 1 1 1 1
50 1 1 1 1 1 1 1 1 1 1

38
Cross Tabulation : Accp.limit
0-0/
0-1 1-0
Bala 1-1 % Effeciveness= 100 % Min 90%
150 0 0
% Miss Rate= 0.00 % Max 2%
% False Rate= 0.00 % Max 5%

0-0/
0-1 1-0
Gopi 1-1 % Effeciveness= 100 % Min 90%
150 0 0 % Miss Rate= 0.00 % Max 2%
% False Rate= 0.00 % Max 5%

0-0/
0-1 1-0
Birendra 1-1 % Effeciveness= 100 % Min 90%
150 0 0
% Miss Rate= 0.00 % Max 2%
% False Rate= 0.00 % Max 5%

RESULT : Since the % rates are within acceptable limit , the gauge can be accepted.