Gauge Capability

Studies

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Bonus Points # 3

• In teams of 4 people, go to the Project Office and perform a gage R &

R study on the 7 parts.
• Half of the teams measured with the micrometer
• Half of the teams measured with the dial calipers
• Entire team works together to analyze the data – for the 4 Operators,
estimate:
• σ2 total
• σ2 repeatability
• σ2 reproducability
• σ2 product
• P/T for gage, assuming USL – LSL = 0.005”

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Bonus Points # 4

• In teams of 4 people, go to the CIM Lab (CM 203) and set up a control chart strategy
for the “pipe-bomb” machine.
• Dr. Jensen will demonstrate the system, each team operates afterward.
• The team will collect data using the scale, and track the data using the spreadsheet
template, each control chart should have 30 samples.
• Entire team works together to collect and analyze the data for the system, and to
create and interpret x – and R – charts.
• For the lab exercise, briefly report:
• What your control chart strategy is (what did you measure and why)
• Turn in print out of your trial control charts, and describe how the limits were developed
• For each control chart, use your Trial Control Limits* on all 30 sample points, and interpret
each chart for control using the 4 Western Electric Rules:
• Convert your Trial Control Limit data to Standards
• Circle Western Electric Rule violations, and describe what they show

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Gage Capability Studies

• Ensuring adequate gage and inspection system capability

• In any problem involving measurement the observed variability in

product is due to two sources:
• Product variability - σ2product

• Gage variability - σ2gage

i.e., measurement error

• Total observed variance in product:

σ2total = σ2product + σ2gage (system)

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e.g. Assessing Gage Capability

• Following data were taken by one operator during gage

capability study.
Measurement
Part #

1
1
21
2
20
x-bar R
20.5 1 x  22.3
2
3
24
20
23
21
23.5
20.5
1
1
R  1.0
4 27 27 27 0
5 19 18 18.5 1
6 23 21 22 2
… … … … …
17 20 20 20 0
18 19 21 20 2
19 25 26 25.5 1
20 19 19 19 0
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e.g. Assessing Gage Capability Cont'd

• Estimate standard deviation of measurement error:

 gage  R d 2  1.0 1.128  0.8865

• Dist. of measurement error is usually well approximated by the Normal, therefore
• Estimate gage capability:

6ˆ  6  0.8865   5.32

• That is, individual measurements expected to vary as much as
gage
owing to gage error.

3 gage  3  0.8865   2.67

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Precision-to-Tolerance
(P/T) Ratio

• Common practice to compare gage capability with the width of the

specifications
• In gage capability, the spec width is called the tolerance band
• (not to be confused with natural tolerance limits, NTLs)

6ˆ gage
P T 
USL  LSL
• Specs for above example: 32.5 ± 27.5
6ˆ gage 6  0.8865 
PT   0.0967
USL  LSL 55
• Rule of Thumb:
• P/T  0.1  Adequate gage capability

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Estimating Variance Components of Total
Observed Variability

• Estimate total variance:

ˆ total
2
 S2
1 n
  xi  x 
2
S  2

n  1 i 1
1 n
  xi  22.3  10.05
2

39 i1
• Compute an estimate of product variance
• Since :
 2
total 2
product 
2
gage

 10.05   0.8865   9.26

2
ˆ product
2
 ˆ total
2
 ˆ gage
2

ˆ product  9.26  3.04

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Gage Std Dev Can Be Expressed as % of
Product Std Dev

• Gage standard deviation as percentage of product standard

deviation :

ˆ gage 0.8865
 100%   100%  29.2%
ˆ product 3.04
• This is often a more meaningful expression, because it does not
depend on the width of the specification limits

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Using x and R-Charts for a Gage Capability
Study

• On x chart for measurements:

• Expect to see many out-of-control points
• x chart has different meaning than for process control
• shows the ability of the gage to discriminate between units (discriminating power of
instrument)
• Why? Because estimate of σx used for control limits based only on
measurement error, i.e.:  x   gage  R d 2
X-bar Chart for Measurements
30
UCL = 24.18
28 CTR = 22.30
26 LCL = 20.42
X-bar

24
22
20
18
0 4 8 12 16 20
Subgroup
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Using x and R-Charts for a Gage Capability
Study

• On R-chart for measurements:

• R-chart directly shows magnitude of measurement error
• Values represent differences between measurements made by same operator on same
unit using same instrument

Range Chart for Measurements

4
UCL = 3.27
CTR = 1.00
3
LCL = 0.00
Range

0
0 4 8 12 16 20
Subgroup

• Interpretation of chart:
• In-control: operator has no difficulty making consistent measurements
• Out-of-control: operator has difficulty making consistent measurements

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Repeatability & Reproducibility:
Gage R & R Study

• If more than one operator used in study then measurement (gage) error
has two components of variance:

σ2total = σ2product + σ2gage

σ2reproducibility + σ2repeatability
• Repeatability:
• σ2repeatability - Variance due to measuring instrument

• Reproducibility:
• σ2reproducibility - Variance due to different operators
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Ex. Gage R & R Study

• 20 parts, 3 operators, each operator measures each part twice

Operator i xi Ri
1 22.30 1.00
2 22.28 1.25
3 22.10 1.20

• Estimate repeatability (measurement error):

R 1
3 R1  R2  R3 
 1
3  1.00  1.25  1.20   1.15
R 1.15
ˆ repeatabiltiy    1.0195
d 2 1.128
• Use d2 for n = 2 since each range uses 2 repeat measures
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Ex. Gage R & R Study Cont'd

• Estimate reproducibility:
• Differences in xi  operator bias since all three operators measured the same
parts

xmax  max  x1 , x2 , x3   22.30

xmin  min  x1 , x2 , x3   22.10

Rx  xmax  xmin  0.20

Rx 0.20
ˆ reproducibility    0.1181
d 2 1.693

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• Use d for n = 3 since R is from sample of size 3
Ex. Gage R & R Study Cont'd

• Total Gage variability:

ˆ gage
2
 ˆ repeatability
2
 ˆ reproducibility
2

  1.0195    0.1181  1.0533

2 2
ˆ gage
2

• Gage standard deviation (measurement error):

ˆ gage  1.0533  1.0263
• P/T Ratio:
• Specs: USL = 60, LSL = 5

P 6ˆ gage 6  1.0263

   0.1120
T USL  LSL 60  5
• Note:
P T  0.1120  0.1
• Would like P/T < 0.1
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Comparison of Gage Capability Examples

σ2 repeatability σ2 reproducibility σ2 product P/T

Single
0.8865 0.0967
operator
Three
1.0195 0.1181 1.0263 0.1120
operators

• Gage capability is not as good when we account for both

reproducibility and repeatability
• Train operators to reduce σ2reproducability = 0.1181
• Since σ2repeatability = 1.0195 (largest component), direct effort toward finding
another inspection device.

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