GAUGE R& R STUDY AVERAGE AND RANGE METHOD BASED ON TOLERANCE - DATA SHEET

PART NAME : 10036086 DESCRIPTION : INSIDE DIAMETER GAUGE NO :

PART NO. : SPECIFICATION : 30 Name : Bore Gauge.
DATE : 16.01.2016 Tolerance : 0.05 mm Page 01 of 02

SL. APPRAISER TRIAL # PART SERIAL NUMBER

No. MVJ 1 2 3 4 5 6 7 8 9 10 AVERAGE
1 1 30.025 30.028 30.022 30.022 30.025 30.027 30.025 30.026 30.023 30.027 30.025
2 APPRAISER 1 2 30.023 30.025 30.023 30.023 30.024 30.028 30.022 30.023 30.025 30.028 30.0244
3 3 30.022 30.026 30.026 30.026 30.022 30.029 30.023 30.022 30.026 30.024 30.0246
4 Average 30.023 30.026 30.024 30.024 30.024 30.028 30.023 30.024 30.025 30.026 30.025 Xa
5 UCL x 30.028 30.028 30.028 30.028 30.028 30.028 30.028 30.028 30.028 30.028
6 LCL x 30.021 30.021 30.021 30.021 30.021 30.021 30.021 30.021 30.021 30.021
7 Range 0.003 0.003 0.004 0.004 0.003 0.002 0.003 0.004 0.003 0.004 0.0033 Ra
8 RYK 1 2 3 4 5 6 7 8 9 10 AVERAGE
9 1 30.026 30.023 30.024 30.027 30.024 30.024 30.027 30.027 30.027 30.022 30.0251
10 APPRAISER 2 2 30.027 30.025 30.027 30.023 30.025 30.027 30.029 30.028 30.025 30.023 30.0259
11 3 30.029 30.026 30.023 30.022 30.026 30.023 30.026 30.024 30.023 30.025 30.0247
12 Average 30.027 30.025 30.025 30.024 30.025 30.025 30.027 30.026 30.025 30.023 30.025 Xb
13 UCL x 30.028 30.028 30.028 30.028 30.028 30.028 30.028 30.028 30.028 30.028
14 LCL x 30.021 30.021 30.021 30.021 30.021 30.021 30.021 30.021 30.021 30.021
15 Range 0.003 0.003 0.004 0.005 0.002 0.004 0.003 0.004 0.004 0.003 0.0035 Rb
16 SSB 1 2 3 4 5 6 7 8 9 10 AVERAGE
17 1 30.024 30.023 30.026 30.023 30.024 30.026 30.025 30.027 30.022 30.022 30.0242
18 APPRAISER 3 2 30.026 30.025 30.024 30.025 30.027 30.024 30.027 30.029 30.025 30.024 30.0256
19 3 30.022 30.021 30.022 30.027 30.026 30.023 30.023 30.025 30.024 30.026 30.0239
20 Average 30.024 30.023 30.024 30.025 30.026 0.000 30.025 30.027 30.024 30.024 30.025 Xc
21 UCL x 30.028 30.028 30.028 30.028 30.028 30.028 30.028 30.028 30.028 30.028
22 LCL x 30.021 30.021 30.021 30.021 30.021 30.021 30.021 30.021 30.021 30.021
23 Range 0.004 0.004 0.004 0.004 0.003 0.003 0.004 0.004 0.003 0.004 0.0037 Rc
24 Part 30.0248 Xabc
25 Average Xp 30.025 30.025 30.024 30.024 30.025 30.026 30.025 30.026 30.024 30.025 0.0016 Rp
26 0.0035 Rabc
27 0.0007 Xdiff.
28 Upper Control Limit for range UCLR = Rabc x D4= ( note= D4 is 3.27 for 2 trials and 2.58 for 3 trials ) 0.0090 UCLR
29 Lower Control Limit for range LCLR = Rabc x D3= (note= D3 = 0 for upto 7 trials.) 0.0000 LCLR
30 Upper Control Limit for Averages UCLx = Xabc + A2 x Average R= (note= A2 = 1.023 for 3 trials.) 30.0284 UCLx
31 Lower Control Limit for Averages LCLx = Xabc - A2 x Average R= (note= A2 = 1.023 for 3 trials.) 30.0212 LCLx
NOTE :
.- Plot Range Chart & Average Chart to ensure the adequacy of Measurement System. ADEQUACY : Each range should be within UCL. And in case of X Bar chart - minimume 50% of
X Bar chart should be outside the control limits.
.- The number of distinct Data categories should be equal or more than 5, then only the Measurement System can be declared as acceptable for the analysis of the process.
.- UCLR represents the limit of individual R's. Circle those that are beyond this limit. Identify the cause and correct, Repeat these readings using the same appraiser and unit
as originally used or discard values and reaverage and recompute R and the limiting value from the remaining observations.
* If the instrument /gageis required to be used for the process capability study then select the components within process variation for GR&R study. Simillarly select the components within
tolerance if the instrument / gage is required to be used in final inspection or process control.
 GAUGE R&R STUDY AVERAGE AND RANGE METHOD BASED ON TOLERANCE
CALCULATION AND REPORT
Page 02 of 02
PART NAME : 10036086 DESCRIPTION : INSIDE DIA.
PART NO : SPECIFICATION : 30 PERFORMED BY:
DATE : 16.01.2016 GAUGE NO : MVJ
DIAL NO : RYK
SSB
From data sheet Rabc= 0.00350 X diff = 0.00067 Tolerance = 0.0500
MEASUREMENT UNIT ANALYSIS % TOTAL TOLERANCE
Repeatability i.e. Equipment Variation (EV) % EV= 100 [EV/TV]

EV = Rabc X K1 = 21.4
= 0.010675 Trials K1
2 4.56
3 3.05
Reproducability I.e.Appraiser Variation (AV) % AV= 100[AV/TV]
Appraisers 2 3 = 0.0000
AV = [ (Xdiff x K2)2 - ( EV2 / nr ) ] K2 3.65 2.7
n= Number of parts
Xdiff x K2= 0.0018 EV 0.010675 r = Number of trials
(Xdiff x K2)2= 0.000003 EV2/nr = 0.000004
(Xdiff x K2)2 -(EV2/nr)= -0.000001
AV= 0
Repeatability & Reproducability (R & R) % R & R= 100[R&R/TV]
21.4
R & R= ( EV2+ AV2) EV2 0.000114 Note: Accept if < 10%
AV2 0.000000 Accept on Deviation
R & R= 0.0107 R & R2 0.000114 if >10% and <30%
No.of distinct data categories
= 1.41*(PV/R&R)
NOTE : PV, TV , & % ge of PV are not applicable since the analysis = 6.6 This should be equal
is based on Tolerance. Since PV = TV or more than 5

Remarks:
Acceptable
Accepted On Deviation.
Not Acceptable

Sign. :
Guidelines for acceptance of gauge repeatability and reproducability (% R & R)
1.Under 10 % error = The measurement system is acceptable.
2.10 % to 30 % error = may be acceptable based upon importance of application,cost of gauge,
3.Cost of repairs etc.Over 30 % error= measurement system needs improvement.
Make every effort to identify the problems and have them corrected.
Points for justification to accept the gauge under deviation : ( Tick mark the reason and provide data if applicable)
1 Gauge application is not much important as automatic correction exists.
2 Cost of replacing the gauge is too high.
3 Cost of repairing the gauge is too high.
4 Process Capability is more than 2.5, hence R & R % (10-30%) can be considered as acceptable
on deviation
If R&R% is equal or more than 30% then following analysis to be carried out and
and to have the action plan to get R&R within acceptable limit.

case I If repeatability is comparatively higher than reproducabililty, identify causes related to instrument / equipment
a) The instrument may need maintenance
b) The Gauge may have to be redesigned to be more rigid
c) Clamping or location for gauging needs to be improved.

case II If reproducability is comparatively higher than repeatability, use graphical method and identify following causes
a) The appraiser needs to be better trained in how to use and read the gauge / instrument.
b) Calibrations on the gauge dial are not clear.
c) Fixture of some sort may be needed to help the appraiser use the gauge more consistently.

DATA FOR PART APPRAISER AVERAGE CHART

30.023 1
30.026 1
30.024 1 0 30.023 30.026 30.024 30.024 30.024 30.028 30.023 30.024 30.025 30.026
0 30.024 1 0 30.027 30.025 30.025 30.024 30.025 30.025 30.027 30.026 30.025 30.023
30.024 1 0 30.024 30.023 30.024 30.025 30.026 0.000 30.025 30.027 30.024 30.024
30.028 1 grand avg 30.025 30.025 30.025 30.025 30.025 30.025 30.025 30.025 30.025 30.025
30.023 1 UCL 30.028 30.028 30.028 30.028 30.028 30.028 30.028 30.028 30.028 30.028
30.024 1 LCL 30.021 30.021 30.021 30.021 30.021 30.021 30.021 30.021 30.021 30.021
30.025 1
30.026 1
WITHIN LIMIT 10
BEYOND LIMIT 0

30.027 1
30.025 1
0 30.025 1
30.024 1
30.025 1
30.025 1
30.027 1
30.026 1
30.025 1
30.023 1
WITHIN LIMIT 10
BEYOND LIMIT 0

30.024 1
30.023 1
0 30.024 1
30.025 1
30.026 1
0.000 FALSE
 30.025 1
30.027 1
30.024 1
30.024 1
WITHIN LIMIT 9
BEYOND LIMIT 1

TOTAL WITHIN LIMIT 29

TOTAL BEYOND LIMIT 1
% BEYOND LIMITS 3%

DATA FOR ERROR CHARTS

AVERAGE VALUE 30.0248222

0 0 0
TR-1 TR-2 TR-3 TR-1 TR-2 TR-3 TR-1 TR-2 TR-3
PART 1 0.0002 -0.0018 -0.0028 0.0012 0.0022 0.0042 -0.0008 0.0012 -0.0028
PART 2 0.0032 0.0002 0.0012 -0.0018 0.0002 0.0012 -0.0018 0.0002 -0.0038
PART 3 -0.0028 -0.0018 0.0012 -0.0008 0.0022 -0.0018 0.0012 -0.0008 -0.0028
PART 4 -0.0028 -0.0018 0.0012 0.0022 -0.0018 -0.0028 -0.0018 0.0002 0.0022
PART 5 0.0002 -0.0008 -0.0028 -0.0008 0.0002 0.0012 -0.0008 0.0022 0.0012
PART 6 0.0022 0.0032 0.0042 -0.0008 0.0022 -0.0018 0.0012 -0.0008 -0.0018
PART 7 0.0002 -0.0028 -0.0018 0.0022 0.0042 0.0012 0.0002 0.0022 -0.0018
PART 8 0.0012 -0.0018 -0.0028 0.0022 0.0032 -0.0008 0.0022 0.0042 0.0002
PART 9 -0.0018 0.0002 0.0012 0.0022 0.0002 -0.0018 -0.0028 0.0002 -0.0008
PART 10 0.0022 0.0032 -0.0008 -0.0028 -0.0018 0.0002 -0.0028 -0.0008 0.0012
 DATA FOR NORMALISED INDIVIDUALS CHART
0
Part 1 Part 2 Part 3 Part 4 Part 5 Part 6 Part 7 Part 8 Part 9 Part 10
Trial 1 0.00017778 0.0031778 -0.002822222 -0.0028222 0.00017778 0.0021778 0.0001778 0.001178 -0.0018222 0.0021778
Trial 2 -0.00182222 0.0001778 -0.001822222 -0.0018222 -0.0008222 0.0031778 -0.002822 -0.001822 0.0001778 0.0031778
Trial 3 -0.00282222 0.0011778 0.001177778 0.0011778 -0.0028222 0.0041778 -0.001822 -0.002822 0.0011778 -0.0008222

0
Part 1 Part 2 Part 3 Part 4 Part 5 Part 6 Part 7 Part 8 Part 9 Part 10
Trial 1 0.00117778 -0.0018222 -0.000822222 0.0021778 -0.0008222 -0.0008222 0.0021778 0.002178 0.0021778 -0.0028222
Trial 2 0.00217778 0.0001778 0.002177778 -0.0018222 0.00017778 0.0021778 0.0041778 0.003178 0.0001778 -0.0018222
Trial 3 0.00417778 0.0011778 -0.001822222 -0.0028222 0.00117778 -0.0018222 0.0011778 -0.000822 -0.0018222 0.0001778

0
Part 1 Part 2 Part 3 Part 4 Part 5 Part 6 Part 7 Part 8 Part 9 Part 10
Trial 1 -0.00082222 -0.0018222 0.001177778 -0.0018222 -0.0008222 0.0011778 0.0001778 0.002178 -0.0028222 -0.0028222
Trial 2 0.00117778 0.0001778 -0.000822222 0.0001778 0.00217778 -0.0008222 0.0021778 0.004178 0.0001778 -0.0008222
Trial 3 -0.00282222 -0.0038222 -0.002822222 0.0021778 0.00117778 -0.0018222 -0.001822 0.000178 -0.0008222 0.0011778

Part 1 Part 2 Part 3 Part 4 Part 5 Part 6 Part 7 Part 8 Part 9 Part 10 Part 1 Part 2 Part 3 Part 4
Trial 1 0.00017778 0.0031778 -0.002822222 -0.0028222 0.00017778 0.0021778 0.0001778 0.001178 -0.0018222 0.0021778 0.00117778 -0.0018222 -0.000822 0.002178
Trial 2 -0.00182222 0.0001778 -0.001822222 -0.0018222 -0.0008222 0.0031778 -0.002822 -0.001822 0.0001778 0.0031778 0.00217778 0.00017778 0.002178 -0.001822
Trial 3 -0.00282222 0.0011778 0.001177778 0.0011778 -0.0028222 0.0041778 -0.001822 -0.002822 0.0011778 -0.0008222 0.00417778 0.00117778 -0.001822 -0.002822
 GAUGE R& R STUDY AVERAGE AND RANGE METHOD BASED ON TOLERANCE - DATA SHEET
PART NAME : 10036086 DESCRIPTION : INSIDE DIAMETER GAUGE NO :
PART NO. : SPECIFICATION : 30 Name : Bore Gauge.
DATE : 16.01.2016 Tolerance : 0.05 mm Page 01 of 02

SL. APPRAISER TRIAL # PART SERIAL NUMBER

No. MVJ 1 2 3 4 5 6 7 8 9 10 AVERAGE
1 1 30.025 30.028 30.022 30.022 30.025 30.027 30.025 30.026 30.023 30.027 30.025
2 APPRAISER 1 2 30.023 30.025 30.023 30.023 30.024 30.028 30.022 30.023 30.025 30.028 30.0244
3 3 30.022 30.026 30.026 30.026 30.022 30.029 30.023 30.022 30.026 30.024 30.0246
4 Average 30.023 30.026 30.024 30.024 30.024 30.028 30.023 30.024 30.025 30.026 30.025 Xa
5 UCL x 30.028 30.028 30.028 30.028 30.028 30.028 30.028 30.028 30.028 30.028
6 LCL x 30.021 30.021 30.021 30.021 30.021 30.021 30.021 30.021 30.021 30.021
7 Range 0.003 0.003 0.004 0.004 0.003 0.002 0.003 0.004 0.003 0.004 0.0033 Ra
8 RYK 1 2 3 4 5 6 7 8 9 10 AVERAGE
9 1 30.026 30.023 30.024 30.027 30.024 30.024 30.027 30.027 30.027 30.022 30.0251
10 APPRAISER 2 2 30.027 30.025 30.027 30.023 30.025 30.027 30.029 30.028 30.025 30.023 30.0259
11 3 30.029 30.026 30.023 30.022 30.026 30.023 30.026 30.024 30.023 30.025 30.0247
12 Average 30.027 30.025 30.025 30.024 30.025 30.025 30.027 30.026 30.025 30.023 30.025 Xb
13 UCL x 30.028 30.028 30.028 30.028 30.028 30.028 30.028 30.028 30.028 30.028
14 LCL x 30.021 30.021 30.021 30.021 30.021 30.021 30.021 30.021 30.021 30.021
15 Range 0.003 0.003 0.004 0.005 0.002 0.004 0.003 0.004 0.004 0.003 0.0035 Rb
16 SSB 1 2 3 4 5 6 7 8 9 10 AVERAGE
17 1 30.024 30.023 30.026 30.023 30.024 30.026 30.025 30.027 30.022 30.022 30.0242
18 APPRAISER 3 2 30.026 30.025 30.024 30.025 30.027 30.024 30.027 30.029 30.025 30.024 30.0256
19 3 30.022 30.021 30.022 30.027 30.026 30.023 30.023 30.025 30.024 30.026 30.0239
20 Average 30.024 30.023 30.024 30.025 30.026 0.000 30.025 30.027 30.024 30.024 30.025 Xc
21 UCL x 30.028 30.028 30.028 30.028 30.028 30.028 30.028 30.028 30.028 30.028
22 LCL x 30.021 30.021 30.021 30.021 30.021 30.021 30.021 30.021 30.021 30.021
23 Range 0.004 0.004 0.004 0.004 0.003 0.003 0.004 0.004 0.003 0.004 0.0037 Rc
24 Part 30.0248 Xabc
25 Average Xp 30.025 30.025 30.024 30.024 30.025 30.026 30.025 30.026 30.024 30.025 0.0016 Rp
26 0.0035 Rabc
27 0.0007 Xdiff.
28 Upper Control Limit for range UCLR = Rabc x D4= ( note= D4 is 3.27 for 2 trials and 2.58 for 3 trials ) 0.0090 UCLR
29 Lower Control Limit for range LCLR = Rabc x D3= (note= D3 = 0 for upto 7 trials.) 0.0000 LCLR
30 Upper Control Limit for Averages UCLx = Xabc + A2 x Average R= (note= A2 = 1.023 for 3 trials.) 30.0284 UCLx
31 Lower Control Limit for Averages LCLx = Xabc - A2 x Average R= (note= A2 = 1.023 for 3 trials.) 30.0212 LCLx

GAUGE R&R STUDY AVERAGE AND RANGE METHOD BASED ON TOLERANCE

CALCULATION AND REPORT
Page 02 of 02
PART NAME : 10036086 DESCRIPTION : INSIDE DIA.
PART NO : SPECIFICATION : 30 PERFORMED BY:
DATE : 16.01.2016 GAUGE NO : MVJ
DIAL NO : RYK
 SSB
From data sheet Rabc= 0.00350 X diff = 0.00067 Tolerance = 0.0500
MEASUREMENT UNIT ANALYSIS % TOTAL TOLERANCE
Repeatability i.e. Equipment Variation (EV) % EV= 100 [EV/TV]

EV = Rabc X K1 = 21.4
= 0.010675 Trials K1
2 4.56
3 3.05
Reproducability I.e.Appraiser Variation (AV) % AV= 100[AV/TV]
Appraisers 2 3 = 0.0000
AV = [ (Xdiff x K2)2 - ( EV2 / nr ) ] K2 3.65 2.7
n= Number of parts
Xdiff x K2= 0.0018 EV 0.010675 r = Number of trials
(Xdiff x K2)2= 0.000003 EV2/nr = 0.000004
(Xdiff x K2)2 -(EV2/nr)= -0.000001
AV= 0
Repeatability & Reproducability (R & R) % R & R= 100[R&R/TV]
21.4
R & R= ( EV2+ AV2) EV2 0.000114 Note: Accept if < 10%
AV2 0.000000 Accept on Deviation
R & R= 0.0107 R & R2 0.000114 if >10% and <30%
No.of distinct data categories
= 1.41*(PV/R&R)
NOTE : PV, TV , & % ge of PV are not applicable since the analysis = 6.6 This should be equal
is based on Tolerance. Since PV = TV or more than 5

Remarks:
Acceptable
Accepted On Deviation.
Not Acceptable

Sign. :
 DATA FOR NORMALISED INDIVIDUALS CHART
0
Part 1 Part 2 Part 3 Part 4 Part 5 Part 6 Part 7 Part 8 Part 9 Part 10
Trial 1 #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF!
Trial 2 #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF!
Trial 3 #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF!

0
Part 1 Part 2 Part 3 Part 4 Part 5 Part 6 Part 7 Part 8 Part 9 Part 10
Trial 1 #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF!
Trial 2 #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF!
Trial 3 #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF!

0
Part 1 Part 2 Part 3 Part 4 Part 5 Part 6 Part 7 Part 8 Part 9 Part 10
Trial 1 #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF!
Trial 2 #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF!
Trial 3 #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF!

Part 1 Part 2 Part 3 Part 4 Part 5 Part 6 Part 7 Part 8 Part 9 Part 10 Part 1 Part 2 Part 3 Part 4
Trial 1 #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF!
Trial 2 #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF!
Trial 3 #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF!
Part 5 Part 6 Part 7 Part 8 Part 9 Part 10 Part 1 Part 2 Part 3 Part 4 Part 5 Part 6 Part 7 Part 8 Part 9 Part 10
#REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF!
#REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF!
#REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF!