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209 Msa
209 Msa
209 Msa
Systems Analysis
2
DFSS Work Flow
RACI Diagram Discussion Guide
Determine Voice of the Customer Market Perceived Value Profile Image KJ
Customer Selection Matrix Weakness KJ
C
CONCEPT
Develop requirements and Translation Worksheet QFD HOQ
measurable top level CFR(s) Requirements KJ CPM Scorecard
Importance Questionnaire
3
Measurement Process
5
Measurement Process Model
“True” value
σMS
7
Effect of Measurement System
Variation – Poor Capability
Actual Product or
Process Variability
Measurement
Variability
Total Variability
(Observed
variability)
LSL USL
8
Information to be obtained
9
Sources of Measurement
Variation
Measurement variation can come from many sources.
A gage R&R study, if conducted correctly, can capture many of
the sources, if the studies are designed to look at both short and
long term sources of variation.
There are sources of measurement variation that can not be
captured through repeated measurements and must be
evaluated separately.
10
Categories of Measurement
Variation
Reference Environment
Standard
Total
Measurement
Variation
Definition of Procedures Software
Measurand Calculations
Physical Personnel
Constants
12
Measurement Accuracy vs.
Precision
Accuracy
– Closeness of the agreement between the result of a measurement
(Observed) and the true value of the measurand (reference value).
Precision
– The net effect of discrimination, sensitivity, repeatability over the
range of interest of the measurement system.
– In some organizations precision is used interchangeably with
repeatability.
13
A B
C D
X X
15
Repeatability
16
Reproducibility
17
Bias
Bias
Measurement Expected
Result Value
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Stability
Bias t3
Bias t2
Time
Bias t1
Non-Linear
Measurement Results
20
Sources of Variation that can be
Evaluated by a Gage R&R
Repeatability
Reproducibility
Linearity
Stability
Bias
21
Sources of Variation that
“Typically” Evaluated by R&R
Repeatability
Reproducibility
Linearity
Stability
Bias
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A Measurement Capability Index
- P/T
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Precision to Tolerance Ratio
LSL USL
Product Tolerance
P/T = 100%
P/T = 200%
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Uses of P/T Ratio (% Tolerance)
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Another Measurement Capability
Index -- %R&R or Gage R&R
σ MS
% R& R = × 100 Usually expressed
σ Total as percent
26
% Repeatability &
Reproducibility
%R&R = 75%
%R&R = 100%
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Uses of %R&R (% Study
Variation)
The %R&R is the best measure for the Design Specialist
– This estimates how well the Measurement System performs with
respect to the overall process variation
– %R&R is the best estimate when performing Design studies
28
LSL USL
Product Tolerance
Observed
Process Variation
32
Gage R&R Study Set-up
33
Designing Your MSA Study
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Potential Sources of Variation in
Your MSA Study
35
Gage R&R Study Sample
Selection
For an accurate Gage R&R calculation, samples should be pulled from
the process that span the normal variation of the process
– Example: If you produce a material with a mean thickness of 0.010” and a
sigma of 0.001”, get samples that have thicknesses from 0.007 - 0.013”
(99% of the range)
– If the part-to-part variation is too small the GR&R value would be artificially
high
Do not compare different part numbers
– If you produce the same base material with different assays with the same
process, sub-group them and perform the R&R study
– Example:
• A process produces a material with thicknesses of 0.025, 0.050, and 0.080 all with
a +/- 0.005 tolerance, all measured with the same system
• Perform 3 studies - one for each thickness
– If you lumped the above samples together, the GR&R value would be
artificially low
In either case, the σMS will still be accurate
36
What if the Test is Destructive?
Sample Selection Guidelines
Sample selection is an issue with destructive and on-line
measurement systems
True repeatability is not possible
Sample selection can be done to minimize between part
variability in the following manner
– Collect the number of ‘Master’ samples necessary for your study
– Sub-divide them into enough smaller samples to cover the Operator
x Sample x Trial value
Assumption
– The variability between the smaller samples is negligible and can be
ignored
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Destructive Testing
Sample Selection Example
6 7 8 9 10
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Destructive Testing Methods
Procedure
– For each Operator / Trial / Sample combination, randomly pick a
smaller sample from the respective group
– Each operator performs the measurement independently
39
General Procedure for
Performing an R&R Study
Calibrate the gage, or assure that it has been calibrated
Have the operator 1 measure all samples once in random order
Have the operator 2 measure all samples once in random order
Continue until all operators have measured samples once (this is
Trial 1)
Repeat steps 2-4 for the required number of trials
Use the form provided to determine the statistics of the R&R
study
– Repeatability
– Reproducibility
– Standard deviations of each of the above
– %R&R
– P/T Ratio
Analyze results and determine follow-up action, if any 40
Gage R&R Example
41
Gage R&R Example: Laminate
Thickness Measurement
This is a gage study for an over-arm micrometer to measure the
thickness of a material
The values represented are multiplied by 1000 for ease of data
entry (i.e. 8.9 = 0.0089”)
The specification value is needed to determine %P/T. For this
example the specification is +/-0.7, or a tolerance of 1.4
Let’s start analyzing the data
– Stat>Quality Tools>Gage Study>Gage R&R Study (Crossed)
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MINITAB GR&R Study
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Options / Info Screens
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MINITAB Output
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Gage R&R Report
LCL
LSL UCL
USL
100% Noise
LCL
LSL
UCL
USL
Attribute Data
LCL
LSL
UCL
USL
48
Gage R&R X / R Chart
50
R-Chart Indicators
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Operator-Part Interaction Plot
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By Operator
• The graph shows the average (crossed circle) and spread of the
values for each part
• We want to see minimal variability for each part and large
variability between parts (large part-to-part variation)
55
P/T and GR&R Metrics -
Guidelines
Number of
Distinct
P/T R&R Categories
%Study %Contribution (Discrimination
Ratio Variation (Ratio of Variances) Index)
Red
8% 14% 2% 10
Green
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Exercise
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Exercise
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Gage Run Chart
Gage Run Chart of Thickness by Part, Operator
R eported by :
G age nam e: T olerance:
D ate of study : M isc:
1 2 3 4 5 O perator
D oug
7.7 Rich
Rick
Mean 7.6
Thickness
s
7.5
6 7 8 9 10
7.7
7.6 Mean
7.5
Ope rator
Panel variable: Part
The chart shows the average values for each Sample by Trial by Operator
Look for anomalies - we want flat lines at the same value for all operators!
59
Measurement System Analysis
Questions
Written inspection/ measurement procedure?
Detailed process map developed?
Specific measuring system and set-up defined?
Trained or Certified Operators?
Instrument calibration performed in a timely manner?
Tracking Accuracy?
Tracking R&R?
Tracking Bias?
Tracking Linearity?
Tracking Discrimination?
Correlation with supplier or customer where appropriate?
60
Measurement System Analysis
Questions
Have you picked the right measurement system? Is this
measurement system associated with either critical inputs or
outputs?
What do the precision, accuracy, tolerance, P/T ratio, %R&R and
trend chart look like?
What are the sources of variation and what is the measurement
error?
What needs to be done to improve this system?
Have we informed the right people of our results?
Who owns this measurement system?
Who owns trouble shooting?
Does this system have a control plan in place?
What’s the calibration frequency? Is that frequent enough?
Do identical systems match?
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Variables MSA
62
GR&R Exercise
The Department of Health has decided to let you check your own
waste water cleanliness provided you can measure the water
volume with acceptable repeatability and reproducibility
Due to the nature of the materials being measured, if you touch
the container while measuring you will be exposed to potentially
high levels of biological and chemical toxins.
If you touch the container while measuring, you will not be
permitted to perform your own measurements, costing the
company thousands of $$ in labor and testing by outside
laboratories
63
GR&R Exercise
Equipment needed
– 10 plastic containers
– 1 measurement device
Specifications
– See instructor
Procedure
– Have each of three operators independently measure the height of
the water three times (use proper MSA techniques), WITHOUT
touching the container and following the order of the worksheet
• REMEMBER - Maintain one operator per trial!
– Record the measurements in the “MSA Exercise” worksheet in the
MSA.MPJ MINITAB file.
– The measurement order of the containers is randomized (i.e.,
1,3,7,5,2,...) for each operator
Analyze the results and present to class
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Summary
65
Appendix
66
Categories of Measurement
Variation
Reference Environment
Standard
Total
Measurement
Variation
Definition of Procedures Software
Measurand Calculations
Physical Personnel
Constants
67
Example Sources of
Measurement Variation
Measurement Set-Up
– Fixturing/part location
– Contact angle/Cosign error
– Flexure
– Probe type/size
Reference Standards
– Gage blocks/rings/pins
– Ball bar/hole plate
– Torque transducer
68
Example Sources of
Measurement Variation
Measurement Equipment
– Range
– Sensitivity
– Resolution
– Linearity
– Stability
– Frequency response
– Digital interface
69
Example Sources of
Measurement Variation
Environment
– Temperature
– Humidity
– Vibration
– Electrical power quality
– Note: Environmental sources of variation can many time be very
dependent on time of day or shift.
Measurement Subject
– Cleanliness
– Surface finish
70
Example Sources of
Measurement Variation
Definition of Measurand
– Referenced the correct datum
– GD&T call out
Physical Constants
– Temperate coefficient of material
Measurement Procedures
– Number of points measured
– Location of measurement points
– Settling time
– Checking calibration prior to measurement
71
Example Sources of
Measurement Variation
Personnel
– Properly trained
– Fail safes
Software/Calculations
– Algorithms verified
• Example calculating a cone
– Filtering
• Frequency filtering
• Sampling frequency
72
MINITAB Gage R&R Data Matrix
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Data Matrix Development
74
Making Patterned Data
75
Pull Down Menus
Trials
(1:a)bc
1:a
bc
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Operators
a(1:b)c
1:b
77
Samples
ab(1:c)
1:c
ab
78
MINITAB Gage R&R File
79
Coding Variables
80
Coding Variables
81
Last Checks...
Before running your study, make sure that you have the right
number of cells for each operator and sample
To do this we use Cross Tabulation
82
Cross Tabulation
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Table Statistics
The table should contain equal counts for all operators and
all parts before continuing
84
Mathematical Terms
85
Mathematical Relationships
Gage R&R
– Total variation of measurement system, GRR = EV 2 + AV 2
equipment and appraiser
Total Variation
– Total variation of study
TV = GRR 2 + PV 2
86
Mathematical Relationships
% of Equipment Variation
– Ratio of gage and fixturing variation [
% EV = 100 * EV
TV
]
compared to total variation
% of Appraiser Variation
– Ratio of appraiser variation compared to
total variation
% AV = 100 * AV[ TV
]
% Gage Variation
– Ratio of measurement process variation
compared to total study variation
[
%GRR = 100 * GRR
TV
]
% Part Variation
– Ratio of variation of the parts compared
to total study variation
[
% PV = 100 * PV
TV
]
87