R&R Analysis for Non-Destructive Measurements

An example of a GR&R application appropriate for non-destructive measurements is checking part dimensions with a micrometer.
For example, 2 appraisers could each measure 5 parts, 2 times.

First, look at the Repeatability.

Repeatability looks at the variation between measurements of the same part when measured by the same appraiser with the same measurement device. For determining the Repeatability of the measurement system, we'll look at the differences between the measurement trials of the same parts. The Repeatability statistic is sE (or EV.) The sub-E in sE stands for (Measuring) Equipment; EV stands for Equipment Variation. sE =

R dE Re peatabilit y = 5.15( s E ) We use 5.15 because 5.15 standard deviations is an estimation of 99% of the variation. AIAG (Automotive Industry Action Group) allows the option to set Repeatability for 6s to cover 99.7% of the measurement equipment variation.

Next, look at the Reproducibility.

Reproducibility is the difference in measurements between appraisers. The Reproducibility statistic is sA (or AV). o o The sub-A in sA stands for Appraisers. AV stands for Appraiser Variation.

X DIFF sA = d A
where:

s2 E nr

DIFF = (highest of appraiser grand averages) - (lowest of appraiser grand averages); actually a range value dA = d2 value for Reproducibility n = number of parts r = number of trials, or runs

The R&R will tell us the total variation in the measurement system that comes from Repeatability and Reproducibility together.
To calculate R&R, add the squares of both the standard deviation values for Repeatability and the Reproducibility and then take the square root of the result.

To determine if the R&R variation is acceptable or unacceptable...

Compare the Measurement System Variation to the total variation and to the tolerance.

R & R = s 2 + s 2 or EV 2 + AV 2 E A To compare the R&R to the total variation:

%GR & R TV =

s2 + s2 E A s2 + s2 + s2 Parts E A

100%

To compare the R&R to the total tolerance:

%GR & R Tolerance =

5.15 R & R 100% UpperSpecLimit LowerSpecLimit

Is the %GR&R acceptable or not?

If %GR&R represents >30% of the total process variation or takes up >30% of the total tolerance, the measurement system must be improved or replaced. If %GR&R <30% but >10%, the measurement system is marginal. If %GR&R <10%, the measurement system is acceptable.