Doc. No.

- TACO/QA/F/04
Gauge Repeatability and Reproducibility Study ( Variable ) Rev. No - 00
Rev Date : 01.06.2020

Instrument Name : Digital vernier caliper 0 - 150 MM Specification : 12 ± 0.1 Report No. : 05
Instrument No. : DVC-01-05 Least count : 0.01mm. Date : 20.09.2022
Part Name & No. : Flexible busbar7 '5040020687' Tolerance : 0.20 Performed By : Shivani Godse

OPERATOR A : Shivraj MEASUREMENT UNIT ANALYSIS % PROCESS VARIATION

TRIAL 1 2 3 4 5 6 7 8 9 10 AVERAGE REPEATABILITY-EQUIPMENT VARIATION(EV) %EV= 100(EV/TV)
1 12.02 12.01 12.04 12.03 12.01 12.02 12.03 12.02 12.03 12.04 TRIAL: K1 = 8.31
2 12.03 12.01 12.04 12.03 12.02 12.02 12.03 12.02 12.03 12.04 2 0.8862 %AV= 100(AV/TV)
3 12.02 12.01 12.04 12.03 12.01 12.02 12.03 12.02 12.03 12.04 EV = R*K1 =0.0008 3 0.5908 = 5.30
Avg. 12.02 12.01 12.04 12.03 12.01 12.02 12.03 12.02 12.03 12.04 Xa = 12.0257 Actual 3 0.5908 %R&R = 100(GRR/TV)
Range 0.01 0.00 0.00 0.00 0.01 0.00 0.00 0.00 0.00 0.00 Ra = 0.0020 REPRODUCIBILITY-APPRAISER VARIATION = 9.85
OPERATOR B : Swati OPERATOR: K2 % PV= 100(PV/TV)
TRIAL 1 2 3 4 5 6 7 8 9 10 AVERAGE AV = [(Xdiff*K2)2-(EV2/nr)] 2 0.7071 = 99.51
1 12.01 12.01 12.04 12.03 12.01 12.02 12.03 12.02 12.03 12.04 AV = 0.0005 3 0.5231 ndc= 1.41 ( PV/ GRR )
2 12.02 12.01 12.04 12.03 12.01 12.02 12.03 12.02 12.03 12.04 Actual 3 0.5231 = 14.24
3 12.02 12.01 12.04 12.03 12.01 12.02 12.03 12.02 12.03 12.04 n=no. of parts r=no. of trials ndc = Number of distinct categories
Avg. 12.02 12.01 12.04 12.03 12.01 12.02 12.03 12.02 12.03 12.04 Xb = 12.0247 REPEATABILITY & REPRODUCIBILITY (ndc should be greater than 5 )
Range 0.01 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 Rb = 0.0010 GRR = (EV2 + AV2)
OPERATOR C : Kaustav GRR 0.0009
TRIAL 1 2 3 4 5 6 7 8 9 10 AVERAGE PART VARIATION (PV) PART K3
1 12.02 12.01 12.04 12.02 12.01 12.02 12.03 12.02 12.03 12.04 PV = Rp*K3 0.0094 2 0.7071
2 12.02 12.01 12.04 12.03 12.01 12.02 12.03 12.02 12.03 12.04 3 0.5231 % TOLERANCE VARIATION
3 12.02 12.01 12.04 12.03 12.01 12.02 12.03 12.02 12.03 12.04 4 0.4467 %EV= 100(EV/TV)
Avg. 12.020 12.010 12.040 12.027 12.010 12.020 12.030 12.020 12.030 12.040 Xc = 12.0247 TOTAL VARIATION (TV) 5 0.4030 = 2.36
Range 0.000 0.000 0.000 0.010 0.000 0.000 0.000 0.000 0.000 0.000 Rc = 0.0010 TV = (GRR2 + PV2) 6 0.3742 %AV= 100(AV/TV)
Part
12.020 12.010 12.040 12.029 12.011 12.020 12.030 12.020 12.030 12.040 Rp= 0.0300 TV = 0.0095 7 0.3534 = 1.51
Avg.Xp
Total Varation: 8 0.3375 %R&R = 100(GRR/TV)
R = (Ra + Rb + Rc )/#OF OPR = 0.0013 NO.OF A2 D3 D4 TV = total tolerance/6 9 0.3249 = 2.80
X Diff = _(Max X - Min X) = 0.0010 TRIALS 0.03333 10 0.3146 % PV= 100(PV/TV)
UCL R = _(R*D4) = 0.0034 2 1.880 0 3.267 Actual 3 0.5231 = 28.31
LCL R = (R*D3) = 0.0000 3 1.020 0 2.580
Measurement System Acceptable
X = 12.0250 UCL X= 12.0264 LCL X = 12.0236

APPRAISER AVERAGE CHART

OPERATOR A OPERATOR B OPERATOR C

12.0450 12.0450 12.0450

12.0400 12.0400 12.0400
12.0350 12.0350 12.0350
12.0300 12.0300 12.0300
12.0250 12.0250 12.0250
X-BAR OP1 X-BAR OP2 X-BAR OP3
X-BAR CHART 12.0200 12.0200 12.0200
UCL X BAR 12.0150 UCL X BAR
12.0150 12.0150 UCL X BAR
12.0100 LCL X BAR 12.0100 LCL X BAR 12.0100 LCL X BAR
12.0050 X BAR AVG 12.0050 X BAR AVG
12.0050 X BAR AVG
12.0000 12.0000 12.0000
11.9950 11.9950 11.9950
1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10

REPEATABILITY RANGE CHART

0.0120 0.0120
0.0120
0.0100 0.0100
0.0100
R OP1 R OP2
0.0080 0.0080 0.0080
R OP3
UCL R UCL R
R- CHART 0.0060 0.0060
UCL R
LCL R LCL R 0.0060 LCL R
0.0040 R AVG 0.0040 R AVG
0.0040 R AVG

0.0020 0.0020 0.0020

0.0000 0.0000 0.0000
1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10

REAPEATABILITY RANGE CHART: ALL RANGES MUST BE WITHIN CONTROL LIMITS. IF ANY RANGE IS BEYOND THE LIMIT, DISCARD THAT DATA AND RECALCULATE THE LIMITS
ANALYSIS: APPRAISER AVERAGE CHART: AT LEAST 50% DATA SHOULD BE OUT SIDE OF CONTROL LIMITS. IF NOT MEASUREMENT SYSTEM IS NOT CAPABLE FOR MEASURING PART TO PART VARIATION
R&R: IF MS IS USED FOR SPC, CALCULATE R&R AS "% PROCESS VARIATION" OTHERWISE AS "TOLERANCE VARIATION".

Prepared By :Shivani Godse Approved By : Mr. Mohit Sinha

 Doc. No. - F/QA/57
Gauge Repeatability and Reproducibility Study ( Variable ) Rev. No - 01
India Plastic Pvt. Ltd. Rev. Date - 25.06.2018

Instrument Name : Cubing fixture by taper scale (Point 11) Specification : 3±0.25 mm. Report No. : _
Instrument No. : NA Least count : 0.01 mm. Date : 19.03.2019
Part Name & No. : BFS Air Vent & 5E4.819.702.C Tolerance : 0.50 Performed By : Mr. Neha Jogdand

OPERATOR A : NEHA MEASUREMENT UNIT ANALYSIS % PROCESS VARIATION

TRIAL 1 2 3 4 5 6 7 8 9 10 AVERAGE REPEATABILITY-EQUIPMENT VARIATION(EV) %EV= 100(EV/TV)
1 3.10 2.80 3.10 2.80 3.00 2.90 3.00 3.00 2.80 3.00 TRIAL: K1 = 16.34
2 3.10 2.80 3.10 2.80 3.00 2.90 3.00 3.10 2.80 3.00 2 0.8862 %AV= 100(AV/TV)
3 3.10 2.80 3.10 2.80 3.10 2.90 3.00 3.00 2.80 3.00 EV = R*K1 =0.0158 3 0.5908 = 12.30
Avg. 3.10 2.80 3.10 2.80 3.03 2.90 3.00 3.03 2.80 3.00 Xa = 2.9567 Actual 3 0.5908 %R&R = 100(GRR/TV)
Range 0.00 0.00 0.00 0.00 0.10 0.00 0.00 0.10 0.00 0.00 Ra = 0.0200 REPRODUCIBILITY-APPRAISER VARIATION = 20.45
OPERATOR B : RAJESH OPERATOR: K2 % PV= 100(PV/TV)
TRIAL 1 2 3 4 5 6 7 8 9 10 AVERAGE AV = [(Xdiff*K2)2-(EV2/nr)] 2 0.7071 = 97.89
1 3.10 2.80 3.10 2.80 3.10 2.90 3.10 3.10 2.90 3.00 AV = 0.01186 3 0.5231 ndc= 1.41 ( PV/ GRR )
2 3.10 2.80 3.10 2.80 3.00 2.90 3.00 3.00 2.90 3.00 Actual 3 0.5231 = 6.75
3 3.10 2.80 3.10 2.80 3.00 2.90 3.10 3.00 2.90 3.00 n=no. of parts r=no. of trials ndc = Number of distinct categories
Avg. 3.10 2.80 3.10 2.80 3.03 2.90 3.07 3.03 2.90 3.00 Xb = 2.9733 REPEATABILITY & REPRODUCIBILITY (ndc should be greater than 5 )
Range 0.00 0.00 0.00 0.00 0.10 0.00 0.10 0.10 0.00 0.00 Rb = 0.0300 GRR = (EV2 + AV2) Measurement System Conditionally
OPERATOR C : DHANAJI GRR 0.0197 Acceptable
TRIAL 1 2 3 4 5 6 7 8 9 10 AVERAGE PART VARIATION (PV) PART K3
1 3.10 2.80 3.10 2.80 3.10 2.90 3.10 3.00 2.90 3.00 PV = Rp*K3 0.0944 2 0.7071
2 3.10 2.80 3.10 2.80 3.10 2.90 3.10 3.10 2.90 3.00 3 0.5231 % TOLERANCE VARIATION
3 3.10 2.80 3.10 2.80 3.00 2.90 3.00 3.10 2.90 3.00 4 0.4467 %EV= 100(EV/TV)
Avg. 3.100 2.800 3.100 2.800 3.067 2.900 3.067 3.067 2.900 3.000 Xc = 2.9800 TOTAL VARIATION (TV) 5 0.4030 = 18.91
Range 0.000 0.000 0.000 0.000 0.100 0.000 0.100 0.100 0.000 0.000 Rc = 0.0300 TV = (GRR2 + PV2) 6 0.3742 %AV= 100(AV/TV)
Part
3.100 2.800 3.100 2.800 3.044 2.900 3.044 3.044 2.867 3.000 Rp= 0.3000 TV = 0.0964 7 0.3534 = 14.23
Avg.Xp
Total Varation: 8 0.3375 %R&R = 100(GRR/TV)
R = (Ra + Rb + Rc )/#OF OPR = 0.0267 NO.OF A2 D3 D4 TV = total tolerance/6 9 0.3249 = 23.67
X Diff = _(Max X - Min X) = 0.0233 TRIALS 0.08333 10 0.3146 % PV= 100(PV/TV)
UCL R = _(R*D4) = 0.0688 2 1.880 0 3.267 Actual 3 0.5231 = 113.26
LCL R = (R*D3) = 0.0000 3 1.020 0 2.580 Measurement System Conditionally
X = 2.9700 UCL X= 2.9972 LCL X = 2.9428 Acceptable

APPRAISER AVERAGE CHART

OPERATOR A OPERATOR B OPERATOR C

3.2000 3.2000 3.2000

3.1000 3.1000 3.1000
3.0000 3.0000 3.0000
X-BAR OP1 X-BAR OP2 X-BAR OP3
X-BAR CHART 2.9000 2.9000 2.9000
UCL X BAR UCL X BAR UCL X BAR
2.8000 LCL X BAR 2.8000 2.8000 LCL X BAR
LCL X BAR

2.7000 X BAR AVG 2.7000 X BAR AVG 2.7000 X BAR AVG

2.6000 2.6000 2.6000

1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10

REPEATABILITY RANGE CHART

0.1200 0.1200
0.1200
0.1000 0.1000
0.1000
R OP1 R OP2
0.0800 0.0800 0.0800
R OP3
UCL R UCL R
R- CHART 0.0600 0.0600
UCL R
LCL R LCL R 0.0600 LCL R
0.0400 R AVG 0.0400 R AVG
0.0400 R AVG

0.0200 0.0200 0.0200

0.0000 0.0000 0.0000
1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10

REAPEATABILITY RANGE CHART: ALL RANGES MUST BE WITHIN CONTROL LIMITS. IF ANY RANGE IS BEYOND THE LIMIT, DISCARD THAT DATA AND RECALCULATE THE LIMITS
ANALYSIS: APPRAISER AVERAGE CHART: AT LEAST 50% DATA SHOULD BE OUT SIDE OF CONTROL LIMITS. IF NOT MEASUREMENT SYSTEM IS NOT CAPABLE FOR MEASURING PART TO PART VARIATION
R&R: IF MS IS USED FOR SPC, CALCULATE R&R AS "% PROCESS VARIATION" OTHERWISE AS "TOLERANCE VARIATION".

Prepared By : Mr. G. Alam Approved By : Mr. Virendra Patil

 Doc. No. - F/QA/57
Gauge Repeatability and Reproducibility Study ( Variable ) Rev. No - 01
India Plastic Pvt. Ltd. Rev. Date - 25.06.2018

Instrument Name : Cubing fixture by taper scale (Point 12) Specification : 3±0.25 mm. Report No. : _
Instrument No. : NA Least count : 0.01 mm. Date : 19.03.2019
Part Name & No. : BFS Air Vent & 5E4.819.702.C Tolerance : 0.50 Performed By : Mr. Neha Jogdand

OPERATOR A : NEHA MEASUREMENT UNIT ANALYSIS % PROCESS VARIATION

TRIAL 1 2 3 4 5 6 7 8 9 10 AVERAGE REPEATABILITY-EQUIPMENT VARIATION(EV) %EV= 100(EV/TV)
1 2.90 3.20 2.80 2.90 3.10 2.80 2.90 3.10 2.80 3.10 TRIAL: K1 = 8.77
2 2.90 3.20 2.80 2.90 3.10 2.80 2.90 3.10 2.80 3.10 2 0.8862 %AV= 100(AV/TV)
3 2.90 3.20 2.80 2.90 3.10 2.80 2.90 3.10 2.80 3.10 EV = R*K1 =0.0098 3 0.5908 = 2.66
Avg. 2.90 3.20 2.80 2.90 3.10 2.80 2.90 3.10 2.80 3.10 Xa = 2.9600 Actual 3 0.5908 %R&R = 100(GRR/TV)
Range 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 Ra = 0.0000 REPRODUCIBILITY-APPRAISER VARIATION = 9.16
OPERATOR B : RAJESH OPERATOR: K2 % PV= 100(PV/TV)
TRIAL 1 2 3 4 5 6 7 8 9 10 AVERAGE AV = [(Xdiff*K2)2-(EV2/nr)] 2 0.7071 = 99.58
1 2.90 3.10 2.90 3.00 3.10 2.80 2.90 3.10 2.80 3.10 AV = 0.00299 3 0.5231 ndc= 1.41 ( PV/ GRR )
2 2.90 3.10 2.80 2.90 3.10 2.80 2.90 3.10 2.80 3.10 Actual 3 0.5231 = 15.33
3 2.90 3.10 2.80 2.90 3.10 2.80 2.90 3.10 2.80 3.10 n=no. of parts r=no. of trials ndc = Number of distinct categories
Avg. 2.90 3.10 2.83 2.93 3.10 2.80 2.90 3.10 2.80 3.10 Xb = 2.9567 REPEATABILITY & REPRODUCIBILITY (ndc should be greater than 5 )
Range 0.00 0.00 0.10 0.10 0.00 0.00 0.00 0.00 0.00 0.00 Rb = 0.0200 GRR = (EV2 + AV2)
Measurement System Acceptable
OPERATOR C : DHANAJI GRR 0.0103
TRIAL 1 2 3 4 5 6 7 8 9 10 AVERAGE PART VARIATION (PV) PART K3
1 2.90 3.10 2.90 3.00 3.10 2.80 2.90 3.10 2.80 3.10 PV = Rp*K3 0.1119 2 0.7071
2 2.90 3.20 2.80 2.90 3.10 2.80 2.90 3.10 2.80 3.10 3 0.5231 % TOLERANCE VARIATION
3 2.90 3.20 2.80 2.90 3.10 2.80 2.90 3.10 2.80 3.10 4 0.4467 %EV= 100(EV/TV)
Avg. 2.900 3.167 2.833 2.933 3.100 2.800 2.900 3.100 2.800 3.100 Xc = 2.9633 TOTAL VARIATION (TV) 5 0.4030 = 11.82
Range 0.000 0.100 0.100 0.100 0.000 0.000 0.000 0.000 0.000 0.000 Rc = 0.0300 TV = (GRR2 + PV2) 6 0.3742 %AV= 100(AV/TV)
Part
2.900 3.156 2.822 2.922 3.100 2.800 2.900 3.100 2.800 3.100 Rp= 0.3556 TV = 0.1123 7 0.3534 = 3.59
Avg.Xp
Total Varation: 8 0.3375 %R&R = 100(GRR/TV)
R = (Ra + Rb + Rc )/#OF OPR = 0.0167 NO.OF A2 D3 D4 TV = total tolerance/6 9 0.3249 = 12.35
X Diff = _(Max X - Min X) = 0.0067 TRIALS 0.08333 10 0.3146 % PV= 100(PV/TV)
UCL R = _(R*D4) = 0.0430 2 1.880 0 3.267 Actual 3 0.5231 = 134.23
LCL R = (R*D3) = 0.0000 3 1.020 0 2.580 Measurement System Conditionally
X = 2.9600 UCL X= 2.9770 LCL X = 2.9430 Acceptable

APPRAISER AVERAGE CHART

OPERATOR A OPERATOR B OPERATOR C

3.3000 3.2000 3.2000

3.2000
3.1000 3.1000
3.1000
3.0000 3.0000 3.0000
X-BAR OP1 X-BAR OP2 X-BAR OP3
X-BAR CHART 2.9000 2.9000 2.9000
UCL X BAR UCL X BAR UCL X BAR
2.8000 2.8000
LCL X BAR 2.8000 LCL X BAR
LCL X BAR
2.7000
X BAR AVG 2.7000 X BAR AVG 2.7000 X BAR AVG
2.6000
2.5000 2.6000 2.6000
1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10

REPEATABILITY RANGE CHART

0.0500 0.1200
0.1200
0.0400 0.1000
0.1000
R OP1 R OP2
0.0800 0.0800
R OP3
0.0300 UCL R UCL R
R- CHART 0.0600
UCL R
LCL R LCL R 0.0600 LCL R
0.0200
R AVG 0.0400 R AVG
0.0400 R AVG
0.0100 0.0200 0.0200
0.0000 0.0000 0.0000
1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10

REAPEATABILITY RANGE CHART: ALL RANGES MUST BE WITHIN CONTROL LIMITS. IF ANY RANGE IS BEYOND THE LIMIT, DISCARD THAT DATA AND RECALCULATE THE LIMITS
ANALYSIS: APPRAISER AVERAGE CHART: AT LEAST 50% DATA SHOULD BE OUT SIDE OF CONTROL LIMITS. IF NOT MEASUREMENT SYSTEM IS NOT CAPABLE FOR MEASURING PART TO PART VARIATION
R&R: IF MS IS USED FOR SPC, CALCULATE R&R AS "% PROCESS VARIATION" OTHERWISE AS "TOLERANCE VARIATION".

Prepared By : Mr. G. Alam Approved By : Mr. Virendra Patil