MeasurementSystems AnalysisWebinar

• During presentation (11:00 – 11:30) everyone will be muted so that only the presenter will be heard.

• The presentation will be followed by a 30 minute Q&A session.

• Recording will be made available after the webinar on the Industry Forum website.

• If you are experiencing any technical problems please call us on 0121 717 6620.

How to reduce costs by the

effective application of Measurement

System Analysis

11th March 2015

What is measurement?

ISO9001: 2015 “The process to determine a value”

ISO9001: 2015 “Where monitoring and measuring is used as evidence of conformity of products and services to specified requirements the organisation shall determine the resources needed to ensure valid and reliable monitoring and measuring results”

“Measuring instruments shall be verified or calibrated at specified intervals or prior to use against measurement standards traceable to international or national measurement standards”

MSA and the linkage to ISO/TS16949

The Automotive Core Tools

Design FMEA

Process FMEA

Product/ProcessCharacteristics

Control Plan

Standard Operations

Statistical Process Control

MeasurementSystems Analysis

Product approval Process

(e.g. PPAP)

7.6.1 Measurement System Analysis

Statistical studies shall be conducted to analyse the variation present in the results of each type of measuring and test equipment system. This requirement shall apply to measurement systems referenced in the control plan. The analytical methods and acceptance criteria used shall conform to those in customer reference manuals on measurement systems analysis. Other analytical methods of acceptance criteria may be used if approved by the customer”

9

135

140

143

188

203

208

275

292

328

796

0 100 200 300 400 500 600 700 800

7.5.1.4 Preventive & predictive maintenance

7.5.1.1 Control plan

6.2.2 Competence, awareness and training

7.5.1.3 Verification of job set ups

7.6.1 Measurement system analysis

7.5.1 Control of production

7.3.6.3 Prodcut approval process

7.6 Control of measuring & measurement devices

8.2.4 Monitoring & measurement of product

8.5.2 Corrective action

The purpose of measurement

systems analysis (MSA)

Calibration verse MSA

MSA Calibration

Calibration

A set of operations that establish, under specified operating conditions, the relationship between a measuring device and a traceable standard of a known reference and uncertainty.

Done in internal (7.6.3.1) or external laboratory (7.6.3.2)

Calibration

“The organisation shall assess the validity of previous measurements results when the equipment is found not to conform to requirements. The organisation shall take appropriate action on the equipment and any product affected”

Assess risk!

Sources of measurement system variationWork piece(Part)

Instrument(Gauge)

Person(Appraiser)

Method Environment

MEASUREMENTSYSTEMVARIABILITY

Typical reasons for an MSA study

• There is a new manufacturing process.

• There is a new product to manufacture.

• There is new equipment.• There are customer

concerns.• There are internal quality

issues• To meet customer specific

requirements

Measurement System Error

Width (spread)Location

MSA is not just width error (gauge R & R)

Developing an effective calibration and MSA strategy

• Ensure all equipment used to monitor and measure evidence of conformity of products is calibrated

• Determine the different types of measuring systems used (variable and attribute)

• Determine the most appropriate types of MSA studies for each type

• Undertake studies• Evaluate results• Review calibration frequencies and adjust based on

risk

Width

Repeatability

Repeatability

Reproducibility

Reproducibility

Appraiser B Appraiser A Appraiser C

Average and range method (Xbar & R)

Measure

Analyse

Results

Average and range method (Xbar & R)

Average and range method

Not acceptable. Every effort should be made to 

improveOver 30%

May be acceptable based on importance of application, cost of 

repairs etc10% ‐ 30%

Generally considered to be acceptableUnder 10%

NDC

The measurement system can be used for analysis of the process

NDC = 5 or more

The data can be divided into high and low I.e attribute control

NDC = 2

The measurement system cannot differential one part from another ‐ not suitable to measure the process

NDC less than 2

Number of Distinct Categories

Gauge R&R studies

Location

Reference standards

A reference for comparison, normally determined under laboratory conditions or using a more accurate instrument.

Bias

Measurement SystemObserved Average

Reference Value

BIAS

Linearity

AverageReferenceValue 1

BIAS

AverageReference Value N

BIAS

Typical linearity plot in Minitab

Stability

Time 1

Time 2

STABILITY

StabilityPart Number Issue Machine Type Characteristic Operation Sample Size Chart Number

C 5 1Part Name Machine Number Section Specification Code / Location Sample Frequency Date Control Limits Calculated

25 PART Mar-31

1 71.0 69.5 73.5 71.0 69.2 68.7 68.8 73.5 72.8 71.6 69.1 68.6 69.0 69.0 70.3 74.0 69.6 69.0 68.3 67.2 70.5 69.2 68.7 68.8 71.6

2 72.0 68.5 70.0 71.0 68.8 70.7 69.3 69.5 66.7 71.5 70.1 70.0 69.5 69.7 68.8 72.8 68.7 70.7 71.2 69.9 72.0 68.8 70.7 69.3 71.5

3 71.5 71.0 72.5 70.5 69.1 71.1 71.7 70.0 71.1 73.3 69.2 70.9 69.1 70.2 70.1 70.8 70.2 71.6 70.2 70.5 71.4 69.1 71.1 71.7 73.3

4 72.0 72.0 71.5 71.0 70.1 72.6 69.4 70.4 71.8 73.6 69.1 71.9 73.1 71.4 71.8 72.5 71.9 71.4 71.1 72.6 70.5 70.1 72.6 69.4 73.6

5 73.0 71.0 67.5 73.0 70.4 71.2 68.6 70.3 72.4 68.4 70.8 69.8 72.7 70.2 71.6 70.1 71.3 68.6 71.3 73.0 72.0 70.4 71.2 68.6 68.4

359.5 352.0 355.0 356.5 347.6 354.3 347.8 353.7 354.8 358.4 348.3 351.2 353.4 350.5 352.6 360.2 351.7 351.3 352.1 353.2 356.4 347.6 354.3 347.8 358.4

71.90 70.40 71.00 71.30 69.52 70.86 69.56 70.74 70.96 71.68 69.66 70.24 70.68 70.10 70.52 72.04 70.34 70.26 70.42 70.64 71.28 69.52 70.86 69.56 71.68

2.00 3.50 6.00 2.50 1.60 3.90 3.10 4.00 6.10 5.20 1.70 3.30 4.10 2.40 3.00 3.90 3.20 3.00 3.00 5.80 1.50 1.60 3.90 3.10 5.20Constants for n = 5

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 D2 = 2.326

8:30 09:00 09:30 10:00 10:30 11:00 11:30 12:00 12:30 13:00 13:30 14:00 14:30 15:00 15:30 16:00 16:30 17:00 17:30 18:00 18:30 19:00 19:30 20:00 20:30 D3 = 0

20.7 20.7 20.7 20.7 20.7 20.7 20.7 20.7 20.7 20.7 20.7 20.7 20.7 20.7 20.7 20.7 20.7 20.7 20.7 20.7 20.7 20.7 20.7 20.7 20.7 D4 = 2.11

A2 = 0.58

STATUS

LogTime

Date

Sig

1sd = R/d2 Cpk = Range

RESULTS

COMPONENTS

Cpk = minimum of :-

Cpu = USL - X Cpl = X - LSL

= =

X Sum

X Bar

68.62 0

RANGE R

LCLX LCLR

= X - A2R = D3R

72.64 7.31

UCLX UCLR

= X + A2R = D4R

3.46AVERAGE X BAR

CHART ANALYSIS

X R

70.63

PIPE A 70mm +/- 5mm

X5678 MULTITRON OVERALL LENGTH BEND

66.00

67.00

68.00

69.00

70.00

71.00

72.00

73.00

74.00

75.00

0.00

1.00

2.00

3.00

4.00

5.00

6.00

7.00

8.00

9.00

10.00

3sd 3sd

R

X

UCL

LCL

UCL

LCL

33

Measuring System

Attribute/ variable

R&R Bias  Linearity Stability Attribute

0‐25mm Micrometer

V X X X X

25‐50mm Micrometer

V X X X X

0‐150mm Vernier 

V X

CMM V X X X

Vickers hardness

V X X X

Shadowgraph  V X

Go/No go A X

Visual A X

How can MSA reduce calibration costs?

• Effective use of Measurement System Analysis data can be a justification to extend calibration frequency without any increase in risk

• Early identification of equipment damage or drift can reduce the risk of shipment of nonconforming parts

How can MSA reduce calibration costs?Example:

Micrometer used to measure a special characteristic calibrated annuallyLinearity and Stability studies implementedTwo reference standards createdOperator measure reference standards at beginning of each shiftResults analysed

Based on confidence calibration interval extended to every two years

Calibration cost halved

Training and Support• 5 day Core Tool Certification Course

– Includes case studies, and knowledge and application exam

– Certification from SMMT

• 1 day modules on each of the core tools

Training held at SMMT Industry Forum, Birmingham or in-house

For more information visit www.industryforum.co.ukor call 0121 7176614

Thank you for attending