Measurement Systems

Analysis

Objectives

MSA

At the end of the session, the students are expected to:

Recognize how Minitab is used in measurement
systems analysis

Design a gage capability analysis for variables and
attributes data

MSA

 The importance of measurement systems

 How measurement systems affect data

Variation in part

Variation in measurement

Total variation

Toolbox
 Type I Gage Study  Repeatability and Bias

MSA

 Gage R&R  Repeatability and Reproducibility

 Gage Linearity and Bias Study  Linearity & Bias

Type I Gage Study

MSA

Example
Bear decides to buy a new digital vernier gauge. He wants to
confirm how well his new vernier measures objects so he takes two
metal blocks and measures their lengths on his CPU controlled
laser profiling equipment. The first object has a length of 50 mm
and Bear gives himself a tolerance width of 0.5 mm for measuring
this block in the future. Bear measures the length of this object 50
times and records the results in Worksheet: Type 1GD. The
results are in the Block 1 column.
Use the results and carry out a Type 1 Gage Study to establish if the
measurement system is repeatable and if a bias is present.
Stat<<Quality Tools<<Gage Study<<Type 1 Gage Study

MSA

Type I Gage Study

MSA

Type I Gage Study

Type I Gage Study

MSA

Exercise
The second object has a length of 64.5mm and Bear gives himself a
tolerance width of 0.8 mm for measuring this block in the future.
Bear measures the length of this object 75 times and records the
results in Worksheet: Type IGS. The results are in the Block 2
column.
Use the results and carry out a Type 1 Gage study to establish if the
measurement system is repeatable and if a bias is present. Is the
measurement system suitable?

Gage Repeatability and Reproducibility Study

Create a Randomized Study Worksheet for a GR&R Study

MSA

Stat<<Quality Tools<<Gage study<<Create Gage R&R Study

Worksheet

Gage Repeatability and Reproducibility Study

MSA

Create a Randomized Study Worksheet for a GR&R Study

Automotive Industry Action Group
(AIAG) recommend using:
using:
10 parts
2 or 3 operators
2 or 3 replicates

MSA

Gage Repeatability and Reproducibility Study

Classic Method:
Method: Metrics
%Contribution
%Study Variation
%Tolerance
%Process
Number of Distinct Categories (NoDC)
Assistant:
Assistant: Metrics
%Tolerance
%Process
 %Tolerance:
Tolerance: to improve parts to a specification
 %Study Variation or %Process:
Process: to reduce part-to-part variation

Automotive Industry Action Group

MSA

%Contribution

%Study Variation
%Process
%Tolerance

Ideal

<1%

<10%

Marginal/Acceptable

9%

30%

Unacceptable

>9%

>30%

Gage R&R Study

MSA

Example
My three kids, Iqra, Humzah and Raeesa are not very good at
baking cakes. I give them 10 packets of flour ask them to weight the
packets as a part of a GR&R Study. Each of my kids measures each
packet three times, so there are 10 parts, three operators, three
repeats of each measurement making 90 runs in total. My kids
have short attention spans so I did not need to randomize the study.
The cake baking process at my house does not have a specification
so I choose not to use a tolerance for this analysis.
Worksheet: Cakes

Gage R&R Study

Example

MSA

Stat<<Quality Tools<< Gage Study<<Gage Run Chart

Gage R&R Study

MSA

Example

Gage R&R Study

Example

MSA

Stat<<Quality Tools<< Gage Study<<Gage R&R Study (Crossed)

Gage R&R Study

MSA

Example

Gage R&R Study

MSA

Example

Part-Person Interaction :
dependent upon the part

the persons ability to measure is

Gage R&R Study

MSA

Example

MSA

Gage R&R Study

Example
Bards has set up a study examining the measurement system used
when measuring the caliper of plasterboard. He uses 3 operators
and 10 parts. The parts represent the variation seen within the
process and not the extremes of the process. The tolerance for the
caliper is 0.6 mm. This MSA is part of a project which is intended
to reduce process waste when the product goes out of the tolerance
required by the customer. Bards has also collected historical data
on these measurements to allow a more precise calculation of partto-part variation. The study was originally randomized but has been
ordered for our convenience.
Stat<<QT<<GS<<Gage Run Chart

MSA

Gage R&R Study

Gage R&R Study

MSA

Get the standard deviation of historical data (for partpart-toto-part

variation)
Gage R&R Study (Crossed)<<Options

MSA

Gage R&R Study

MSA

Gage R&R Study

MSA

Gage R&R Study

Exercise
Omer is running an improvement project where he wants to
improve a metric against specification levels. He sets up a study
examining the measurement system used when measuring the
density of fuel pallets. He uses 3 operators and 10 parts. The
parts represent the variation seen within the process. The
tolerance for the product is 0.6 kg/m3. The historical standard
deviation is given as 0.0753.
Check the results using a Gage Run Chart. Then using the
results given in Worksheet: Fuel Density, carry out a GR&R to
establish if the measurement system is deemed to be acceptable
for tolerance. Marginal is not good enough within the nuclear
industry.

MSA

Gage R&R Study (Nested)

Example
Mahwish has set up a study examining the measurement system
used when measuring the fire resistance of plasterboard. The
measurement given is time taken for the plasterboard to fail
when exposed to a set flame. She uses three operators and six
parts, each part is split into three pieces. The same operator
tests the pieces from the same part. The parts represent typical
parts within the process.
Worksheet: Fire Test

MSA

Gage R&R Study (Nested)

MSA

Gage R&R Study (Nested)

Exercise
Han has set up a study examining the measurement system used
when measuring the impact resistance of steel. He uses 3
operators and 9 parts, and each part is split into three pieces.
The same operator tests the pieces from the same part. The
parts represent the variation seen within the process. The
tolerance for this measurement system is 3kN and the aim of
this study is to improve parts to the tolerance.
Worksheet: Impact Test

MSA

Gage Bias and Linearity Study

Assumptions
At least 5 parts that cover the operating range of the gage must
be used. There must be at least 10 readings for each part
The parts must be reference parts with known readings for each
part
It is best if the runs can be randomized and the parts kept blind

MSA

Gage Bias and Linearity Study

Example
Uzzy wants to carry out a Gage Bias and Linearity Study on the
measurement system used to measure the caliper of plasterboard.
The reference parts representing each of the standard sizes of board
are used. The reference parts are 7.5, 9.5, 12.5, 15.0 and 19.0 mm.
Each one is measured 12 times in a randomized study. It is known
that six times the historical standard deviation is 0.38.
Worksheet: Caliper B&L
Stat<<QT<<GS<<Gage Linearity and Bias Study

MSA

Gage Bias and Linearity Study

MSA

Gage Bias and Linearity Study

Exercise
Parky wants to carry out a Gage bias and linearity study on a weigh
scale. Reference weights are used which cover the range of the
weigh scale. These are 100, 200, 300, 400 and 500 kg. Each one is
measured 10 times in a randomized study. Process variation is 1.5
kg.
Using the results, carry out a Gage bias and linearity study to learn if
the measurement system is suitable.
Worksheet: Weights B&L

Attribute Agreement Analysis

MSA

Example:
Example:
A bank uses manual underwriting to analyze mortgage loan
applications. Each underwriter must use the information supplied
by the applicant and other external information such as credit
history to classify the application into one of foue categories: decline
or or do not fund, fund-1, fund-2, and fund-3. The fund-2 and
fund-3 categories are applicants that are considered low-risk loans
while fund-1 is a higher risk applicant. Suppose that 30 applications
are selected and evaluated by a panel of senior underwriters who
arrive at a consensus evaluation for each application, then three
different underwriters (Sue, Fred and John) are asked to evaluate
each application twice. The applications are blinded (customer
names, addresses and other identifying information removed) and
the two evaluations are performed several days apart.
Refer to Worksheet: Attrib