- GRR … · XLS file · Web view · 2016-07-12161.9749145744637 162.44964188265271...

Gage R&R Part NumberAverage & Range Method 1 2 3 4 5 6 7 8 9 10

Operator 1 Trial 1 161.4231 162.3718 157.0019 161.7846 163.3008Enter your data here-> Trial2 161.9132 162.6238 157.9703 161.1323 163.9324

Trial3 161.4757 162.9514 157.7953 161.7813 163.6534Trial4 161.4317 162.5259 157.0175 161.4856 163.9879Trial 5 161.3972 162.2686 157.4160 161.2643 163.8683Total 807.6409397 812.74143 787.201 807.44814 818.7428

Average-Appraiser 1 161.5281879 162.54829 157.4402 161.48963 163.7486Range1 0.515936393 0.6827959 0.968456 0.6523251 0.687074







Range Average 0.6946 ConstantsXDiff 0.0659 5 Trials 4 Trials 3 Trials 2 Trials # Trials 5UCL 1.4656 2.11 2.28 2.58 3.27 D4 2.11 UCL represents the limit of the individual R'sLCL 0.0000 0 0 0 0 D3 0 Circle those beyond the limit. Repeatability(EV) 0.2986 0.577 0.729 1.023 1.88 A2 0.577 Identify and correct causesReproducibility(AV) 0.0000 0.4299 0.4857 0.5908 0.8862 K1 0.4299 LCL = 0 D3=0 for up to 7 trialsGage Capability(R&R) 0.2986 0.7071 0.5231 K2 0.5231Spec Tolerance 0.0100 2 Ops 3 OperatorsAcceptability(%) 29.86

% Using % UsingAIAG - Automotive Industry Action Group Formula TV ToleranceEquipment Variation (Repeatability) 0.2986%EV 12.3% 17916%Appraiser Variation (Reproducibility) 0.00000%AV 0.0% 0%R&R (Gage Capability) 0.2986%R&R 12.3% 17916%PV (Part Variation) 2.4110%PV 99.2% 144663%TV (Total Variation) 2.4295

A1

Measurement systems have two components: repeatability and reproducibility.

A2

Measurement systems have two components: repeatability and reproducibility.

B3

Gage R&R needs a minimum of two trials, parts, and operators.

C3

Put trial data for each part into these cells. R&R is calculated below.

D3


E3


F3


G3


C4


D4


E4


F4


G4


C5


D5


E5


F5


G5


C6


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G6


C7


D7


E7


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G7


C10

Range = Max - Min of trials

C11


D11


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C12


D12


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G23


B38

Average of the three average ranges

B39

XDiff = Max (Xbar) - Min (Xbar)

B40

UCL = D4 * Rave

A42

Repeatability is ability of an appraiser, using the same gage, to get the same measurement.

A43

Reproducibility is ability of two or more different appraisers, using the same gauge, to get the same answer.

B45

Spec Tolerance = USL - LSL

B51

EV = Rave * K1 Repeatability - Equipment Variation

B52

%EV = 100*(EV/TV)

B53

AV = sqrt( (Xdiff*K2)^2 - EV^2/(parts*trials) ) Reproducibility - Appraiser Variation

B54

%AV = 100*(AV/TV)

B55

R&R = sqrt(EV^2 + AV^2) Repeatability and Reproducibility

B56

%R&R = 100*(R&R/TV)

A57

PV evaluates part-to-part variation

B57

Part Variation PV = Rp * K3 Rp = Range of part averages

B58

%PV = 100*(PV/TV)

A59

Total Variation includes R&R and part variation

B59

TV = sqrt(R&R^2 + PV^2) Total Variation

Conclusions / RecommendationsGage system may be acceptable based on importance of application and costGage may need maintenance, redesign, or better clamping

# Parts #Trials #Ops5 5 3

Calculate GageR&R using Anova With Interaction Without InteractionAnova Source df SS MS F P F PAppraiser 2 ### ### -4 Err:502 -34 Err:502

A62

%R&R < .1 - Gage System OK %R&R < .3 - May be acceptable %R&R > .3 - Gage System needs improvement

A63

If %AV>%EV retrain operators if %AV<%EV maintain or redesign gage

B71

Degrees of Freedom

C71

Sum of Squares = (Contrast)^2/ (n)*2^2

D71

Mean Square = SS/df

E71

F = Mean Square/ Error Mean Square

G71

F = Mean Square/ Error Mean Square

Parts 4 311.5531 77.888283 0.00033 1.00000 0.00283 0.99998Appraiser x Part 8 ### 234211.31 2E+06 0.00000Gage w AP Interaction 60 5.7022 0.0950Gage w/o AP Interaction 68 ### ###Total 74 318.1575989

Estimate of Variance Std. Dev 5.15* StdevRepeatability 0.09504 0.30828125 EV 1.587648 0% 0%Appraiser 46842.2448910731 216.430693 AV 1114.618 65% 43%AppraiserxPart 46842.2439281724 216.4306908 INT 1114.618 65% 43%R&R 93684.58386 306.0793751 R&R 1576.309 93% 86%Part 15608.89509 124.9355638 PV 643.4182 38% 14%

TV 1702.568

% Study Variation

% Contribution

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Part by Appraiser Plot (Stacked)

Average-Appraiser 1Average-Appraiser 2

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Part by Appraiser Plot

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Appraiser 1 Appraiser 3

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Range of Parts by Appraiser

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Range of Parts by Appraiser (Stacked)

Range1Range2

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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 twice3. Then enter the results of each measurement in Cells C3:L7, C11:L15, C19:L234. The template will automatically calculate all of the values based on your data5. Evaluate your measurement system based on %R&R and make adjustments as required.

Gage Repeatability and ReproducibilityMeasurement is one common cause of variation. Gage R&R helps improve measurement systems

is larger than reproducibility, reasons include:1. Gage instrument needs maintenance2. Gage needs to be redesigned 3. Clamping or location needs to be improved4. Excessive within-part variation

is larger than repeatability, reasons include:1. Operator needs to be better trained in how to use and read gage2. Calibrations on gage are not clear3. 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

If repeatability (EV - Can the same person using the same gauge measure the same thing consistently)

If reproducibility (AV-can two appraisers measure the same thing and get the same result)

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Sum805.882807.572807.657806.449 Xbar1 Reference806.214 161.350971 12.500 <-Insert Reference Value Here

BiasRbar1 148.8510.70131748

806.463806.301807.004806.464 Xbar2 Reference806.456 161.307486 12.500

BiasRbar2 148.807

0.8131265806.144807.522805.924805.984 Xbar3 Reference806.552 161.285025 12.500

BiasRbar3 148.7850.56929478

UCL represents the limit of the individual R'sCircle those beyond the limit. Identify and correct causesLCL = 0 D3=0 for up to 7 trials

O6

Reference value can be determined by averaging several measurements using higher level equipment.

N7

Xbar = Average (trials)

O7

To calculate bias, insert reference value here.

O8

Bias (i.e., accuracy) is the difference between the observed average and the reference value.

O9

If Bias is large, check for errors in the reference value or instrument: 1. worn 2. made to wrong dimension 3. measuring wrong charateristic 4. not calibrated properly 5. used improperly by appraiser 6. correction algorithm incorrect

N10

Rbar = Average (Ranges)

O14


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O24


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Part by Appraiser Plot (Stacked)

Average-Appraiser 1Average-Appraiser 2

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Range Method

Range Method Insert Your Data HerePart 1 2 3 4 5 Average g

Appraiser 1 12 22 12 10 11 13.4 ###Appraiser 2 11 23 13 12 21 16 d2

Range 1 1 1 2 10 3 1.19###

GR&R 2.521008 ###

5.121849 ###%GR&R 49% ###

Insert Process Standard Deviation

A1

Provides quick approximation of overall measurement variability. Does not reflect repeatability and reproducibility.

A2

According to the QS9000 MSA Guide, Range Method uses two appraisers and five parts.

B3


B7

GR&R=Ave(Range)/d2

B8

Insert Process Variation

Bias

Value Bias n Stdev5.8 6.0 -0.2 15 6.006667 0.21202 0.2251409 0.1146835.7 -0.3 Bias 0.0067 0.0581311 2.20645.9 -0.15.9 -0.1 95% Confidence6.0 0.0 Lower Upper6.1 0.1 -0.118656 0.1319896.0 0.0 Bias Acceptable6.1 0.16.4 0.4 Reference: AIAG MSA Version 3 pgs 85-886.3 0.36.0 0.06.1 0.16.2 0.25.6 -0.46.0 0.0

Reference Value

Average/ Mean

Stdev(r) Stdev(b)

t-Statistic/ critical

A2

Insert measured values of the same part here

B2

Insert reference value here

Bias

d2*/d2 df g 2 3 4 5 63.55333 10.8 d2* 1.41421 1.91155 2.23887 2.48124 2.672533.47193 df 1 2 2.9 3.8 4.7

d2 1.12838 1.69257 2.05875 2.3593 2.53441t crit 95% 4.303 3.182 2.776 2.571 2.447

Reference: AIAG MSA Version 3 pgs 85-88

Bias

7 8 9 10 11 12 13 142.82981 2.96288 3.07794 3.17905 3.26909 3.35016 3.42378 3.49116

5.5 6.3 7 7.7 8.3 9 9.6 10.22.70436 2.8472 2.97003 3.07751 3.17287 3.25846 3.33598 3.40676

2.365 2.306 2.262 2.228 2.201 2.179 2.16 2.145

Bias

15 16 17 18 19 203.55333 3.61071 3.66422 3.71424 3.76118 3.80537

10.8 11.3 11.9 12.4 12.9 13.43.47193 3.53198 3.58788 3.64006 3.68896 3.735

2.131 2.12 2.11 2.101 2.093 2.086

Linearity

PartTrials 1 2 3 4 5

1 2.7 <- Insert Your Data Here23 Linearity evaluates a gauge's ability4 to measure accurately across a wide range5 Imagine measuring a baseball bat:6 1. at the grip7 2. in the middle8 3. and at the widest part9

101112

Average 2.70

2.00 <- Insert Known Reference Values HereBias 0.70Range 0.00 0.00 0.00 0.00 0.00

Slope= Err:502b= Err:502Goodness of fit Err:502

Linearity Err:502%Linearity Err:502

ReferenceValues

bias=slope*ref+b


1.50 2.00 2.50 3.00 3.50 4.000.00

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Linearity Plot

Reference Value

Bia

s

B2

Select five parts whose measurements, due to process variation, cover the operating range of the gage.

B23


Linearity

<- Insert Your Data Here

Linearity evaluates a gauge's abilityto measure accurately across a wide rangeImagine measuring a baseball bat:1. at the grip2. in the middle3. and at the widest part

<- Insert Known Reference Values Here

Appraiser A Appraiser B Appraiser C Reference ResultsPart # Trial 1 Trial 2 Trial 3 Trial 1 Trial 2 Trial 3 Trial 1 Trial 2 Trial 3 Reference Ref Value Code LSL USL

1 1 1 1 1 1 1 1 1 1 1 0.476901 + 0.45 0.552 0 0 0 0 0 0 0 0 0 0 0.576459 - 1. Enter Spec Limits Above3 1 1 0 1 1 0 1 0 0 1 0.544951 X 2. Have 3 appraisers accept/reject 10+ parts4 0 - 3. Enter pass/fail in columns B-J5 0 - 4. Enter Reference value in column L6 0 - 5. Evaluate effectiveness columns AJ-AV7 0 -8 0 -9 0 -

10 0 -11 0 -12 0 -13 0 -14 0 -15 0 -16 0 -17 0 -18 0 -19 0 -20 0 -21 0 -22 0 -23 0 -24 0 -25 0 -26 0 -27 0 -28 0 -29 0 -30 0 -31 0 -32 0 -33 0 -34 0 -35 0 -36 0 -37 0 -38 0 -39 0 -40 0 -

41 0 -42 0 -43 0 -44 0 -45 0 -46 0 -47 0 -48 0 -49 0 -50 0 -

0 = Fail + = within spec limits1 = Pass - = outside spec limits

x = gray area around spec limits

A-B B-C C-A A-REF B-REF C-REF%R&R Gray zone 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 1 2 325% 0.02500 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

1. Enter Spec Limits Above 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 02. Have 3 appraisers accept/reject 10+ parts 1 1 0 1 -1 0 1 -2 0 1 1 -2 1 1 -2 1 -2 -2 Crosstabulation Crosstabulation3. Enter pass/fail in columns B-J B Total REF Total4. Enter Reference value in column L A 0 1 A 0 15. Evaluate effectiveness columns AJ-AV 0 4 0 4 0 3 0 3

1 0 5 5 1 1 5 5Total 4 5 9 Total 4 5 9

C Total REF TotalB 0 1 B 0 1

0 4 1 5 0 3 0 31 0 4 4 1 1 5 6

Total 4 5 9 Total 4 5 9

A Total REF TotalC 0 1 C 0 1

0 4 0 4 0 3 0 31 1 4 5 1 2 4 6

Total 5 4 9 Total 5 4 9

x = gray area around spec limits

MissEffectiveness Rate

A 89% 11%B 89% 11%C 78% 22%

System 85% 15%85%

EffectivenessAcceptable >= 90%

Marginal >=80%Unacceptable <80%

- GRR … · XLS file · Web view · 2016-07-12161.9749145744637 162.44964188265271...

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