Measurement

Systems Analysis

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TOTAL QUALITY MANAGEMENT

M.S.A.

Power Solutions
ABSL
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Outline and Objectives

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Introduce Measurement Systems

Assess Measurement Systems Performance
Understand Measurement System Variation

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Requirements for M.S.A.

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TS16949 Clause 7.6.1. states:

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 and acceptance criteria may be used if
approved by the customer.
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Process Control
A Typical Process
People
Methods
Material
Equipment
Environment

Input

PROCESS

Process / System

Product
Product

Identifying
Improvement
Opportunities

Output

Accurate Measurement
using Measurement System Analysis
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New Process Acceptance

Observed

Process Variation

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Production

Gauge Variation

Actual Process

Variation

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Assessing
Measurement Systems

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Location variation

Bias
Stability
Width variation

Linearity
Repeatability, Reproducibility
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Determining and
Assessing Bias

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Bias is the difference

between the observed

average of measurement
and the reference value.
The reference value, also
known as the accepted
reference value or master
value, is a value that serves
as an agreed-upon reference
for the measured values. A
reference value can be
determined by averaging
several measurements with
a higher level of measuring
equipment.

Observed
Average Value

Bias

Reference
Value

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Determining and Assessing

Stability
Stability (or drift) is the total

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variation in the
measurements obtained with
a measurement system
on the same master or
part when measuring a
single characteristic
over an extended
time period

Reference Value
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Determining and Assessing

Linearity

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Linearity is the difference in the bias values through

the expected operating range of the gauge.

Reference
Value

Observed
Average Value

Smaller
Bias

Reference
Value

Observed
Average Value

Larger
Bias

50mm

200mm
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Determining Repeatability
Repeatability is the

variation in measurements
obtained
By one appraiser
with one measurement
instrument
when used several
times
while measuring the
identical characteristic
on the same part

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Repeatability

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Determining
Reproducibility
Reproducibility is the

variation in the average of

the measurements made
by different appraisers
using the same measuring
instrument
when measuring the
identical characteristic
on the same part

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Reproducibility

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Preparing For A
Measurement System Study
Variable Gauge Study (Average and Range Method)

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The average and range method of gauge study breaks the

gauge error into repeatability and reproducibility.
Optimum conditions:
3 operators;
3 trials;
10 parts.
Study of the results can provide information concerning the
causes of the measurement error.
If reproducibility is large compared to repeatability then;

The operator is not properly trained in how to use and read

the gauge;
Graduations on the gauge are not clear.
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Determining and Assessing

Repeatability and
Reproducibility

There are three methods:

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Range Method;
Average and Range Method;
Analysis of Variation Method (ANOVA).

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Determining and Assessing

Repeatability and
Reproducibility
Range Method

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Gives a quick approximation of measurement variability. It does

not decompose the variability into repeatability and

reproducability.
Conducted with 2 appraisers and 5 parts;
Each appraiser measures each part once;
Evaluate the range at each part;
Estimate the variation between the measurement results over the
average Range (R/d2);
Gauge R&R = 99%-area under the normal distribution curve
(2*2,576*variation).
(not sufficient for PPAP and QS-9000 clause 4.11.4)
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Determining and Assessing

Repeatability and
Reproducibility
Average and Range Method

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Evaluates Repeatability and Reproducibility separately;

Conducted typically with three appraisers and 10 parts;
Each appraiser measures each part three time in a random order;
Evaluation graphical or numerical;
EV (equipment variation)
AV (appraiser variation)

(99%(99% R&R (R&R) = EV + AV

(99% Part Variation PV
(99% Total VariationTV = (R&R) + PV

norm. distr.)
norm. distr.)
norm. distr.)
norm. distr.)
(99%- norm. distr.)

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Determining and Assessing

Repeatability and
Reproducibility
Analysis of Variation Method

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Evaluates Repeatability and Reproducibility separately;

Evaluates Interaction between appraiser and part;
Conducted typically with three appraisers and 10 parts;
Each appraiser measures each part three time in a random order;
Evaluation graphical or numerical;
EV (equipment variation) (99%- norm. distr.)
AV (appraiser variation) (99%- norm. distr.)
R&R (repeatability, reproducibility and interaction (I)
R&R (R&R) = EV + AV+I
(99%- norm. distr.)
Part Variation PV (99%- norm. distr.)
Total Variation TV = (R&R) + PV

(99%- norm. distr.)

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Determining and Assessing

Repeatability and
Reproducibility

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If repeatability is large compared to reproducibility, the reasons

may be:
The instrument needs maintenance;
The gauge should be redesigned to be more rigid;
The clamping or location for gauging needs to be improved;
There is excessive part variation.

If reproducibility is large compared to repeatability, then possible

causes could be:

The appraiser needs to be better trained in how to use and read
the gauge instrument;
Calibrations on the gauge dial are not clear;
A fixture of some sort may be needed to help the appraiser use
the gauge more consistently.
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