Measurement System Analysis

BY : E.H.
ANSARI
Measurement System Analysis

Why Measurement System Analysis ?
To find out the correctness of the measurement
results.
What Are the sources of variation in
Measurement Systems??
Variation due to Gage.
Variation due to Appraiser.
Variation due to Environment.
Variation due to Parts.

What is the effect on decisions.
1. A good part can be called bad.
(Type I error , Producers risk or false
alarm).
2. A bad part can be called good.
(Type II error , Consumers risk or miss
rate).

Important Terms
Standard
Accepted basis for comparison.
Criteria for acceptance.
Known value, within stated limits of
uncertainty, accepted as true value.
Reference value.

Discrimination, readability , resolution
Smallest readable unit, measurement
resolution, scalelimit or detection limit.
10 to 1 is thumb rule.

Effective resolution
The sensitivity of a measurement system to
process variation for a particular
application.

ndc
This is number of distinct catagories.
This should be greater than or equal to 5.

Reference value
A measured value that is recognised and
serves as an agreed upon reference or
master value for comparison.

True value
Actual value of an artifact.
It is unknown & unknowable.

ACCURACY
Closeness to the true value or to an accepted

reference value.

PRECISION
Closeness of repeated readings to each other.

UNCERTAINTY
An estimated range of values about the
measured value in which the true value is believed
to be continued.

BIAS
Its the difference between the observed average
value of measurements & the reference value.
Bias
Measurement Systems
Average
Reference Value

LINEARITY
Its the change in bias over the normal operating
range .
Bias
Size 1
Bias
Size N

STABILITY
Its the change in bias over a period of time .
Bias
Bias
Bias
Time
Size 1

REPEATABILITY
Its the variation in the measurements
obtained with One measuring instrument ,
one appraiser , one part , same characteristic
used several times.
Repeatability

REPRODUCIBILITY
Its the variation in the measurements
obtained by different appraisers using
One measuring instrument , one part , same
characteristic several times.
A
Reproducibality

GAGE REPEATABILITY & REPRODUCIBILITY
(GRR)
The combined estimate of measurement system

repeatability & reproducibility.
It is a measurement system capability.

Measurement Process
Process
to be
managed
Measurement
Value
Data
Analysis
Decision

for
Variable Data

Bias Evaluation Study
1. Take a sample & establish its reference value by
lay out method.
2. Have a single operator measure the sample
n > 10 times in normal manner.
3. Plot the data as histogram relative to the
reference value.

Bias ,Uncertainity & Linearity Study
Instrument Name
Vernier Caliper
Date
17-Jul-02
Instrument No.
VC/38
Tol or Proce es
Variation
0.5
Range
0 TO 300 mm
Permissible
Error
Referance
Value
0.04
Least Count
10
70
0.02 mm
150
220
300
Observations
Parts
1
10.020
70.000
150.000
220.000
300.000
10.020
70.000
150.020
219.980
300.000
10.000
70.020
150.000
220.020
300.000
10.000
70.000
150.020
220.000
300.000
10.000
70.020
149.980
220.020
300.000
10.000
70.020
150.000
220.000
300.020
9.980
69.980
150.000
220.020
300.000
10.000
70.000
150.000
220.000
300.000
10.000
70.020
150.000
220.000
300.000
10
10.020
70.000
150.000
220.020
300.000

Average
10.004
70.006
150.002
220.006
300.002
Range
0.0400
0.0400
0.0400
0.0400
0.0200
Bias
0.004
0.006
0.002
0.006
0.002
Sigma R
0.012582
0.012582
0.012582
0.012582
0.006291
Sigma b
0.003979
0.003979
0.003979
0.003979
0.001989
t Calculated
1.005304
1.507956
0.502652
1.507956
1.005304
Uncertainity
0.008582
0.008582
0.008582
0.008582
0.004291
Bias-uncer
-0.004582
-0.002582
-0.006582
-0.002582
-0.002291
Bias+uncer
0.012582
0.014582
0.010582
0.014582
0.006291
Bias %
0.800
1.200
0.400
1.200
0.400
d2
3.07751
d2*
3.17905
t value(table)
2.2281
Result
Ok
Acceptance criteria:
1 Bias & Linearity error should not exceeds the permissible error.
2 Zero should lie between (Bias + Uncertainity) & (Bias - Uncertainity)

1.
2.
3.
Linearity Evaluation Study

Select 5 parts whose measurement covers the
operating range of the Gage.
Determine reference value of each part by lay
out inspection method.
Have a single operator measure all 5 samples
n > 10 times in normal manner.
Select the parts random to minimize appraiser
recall bias in the measurement.

4.
5.
6.
7.
8.
Linearity Evaluation Study

Calculate the part bias for each measurement and
the bias average for each part.
Plot the individual bias & bias average with
respect to the reference values on a linear graph.
Calculate & plot the best fit line.
Plot the bias=0 line and confidence bands.
Review the graph, bias=0 line must lie within
confidence band of the fitted lines.

LINEARITY STUDY
P art name
Part no.
Part Characteristics
Specification
No. of reference standards (g)
Avg
Bias
ref.
value
4
GRAPHICAL ANALYSIS
12
ref.
value
ref.
value
8
10
Obs.
value
Obs.
value
Obs.
value
Obs.
value
Obs.
value
2.700
2.500
2.400
2.500
2.700
2.300
2.500
2.500
2.400
2.400
2.600
2.400
5.100
3.900
4.200
5.000
3.800
3.900
3.900
3.900
3.900
4.000
4.100
3.800
5.800
5.700
5.900
5.900
6.000
6.100
6.000
6.100
6.400
6.300
6.000
6.100
7.600
7.700
7.800
7.700
7.800
7.800
7.800
7.700
7.800
7.500
7.600
7.700
9.100
9.300
9.500
9.300
9.400
9.500
9.500
9.500
9.600
9.200
9.300
9.400
LINEARITY CHART
1
0.8
0
0.6 0
0
0.4 0
0
0.2
B IA S
T rials(m )
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
ref.
value
Gage name
gage No.
gage type
Least count
No. of t rials (m )
ref.
value
t TABLE
v
t(v,.025)
Date
-0.2
10
-0.4
-0.6
-0.8
REFERENCE VALUE
2.492
0.492
4.125
0.125
6.025
0.025
7.708
-0.292
9.383
-0.617
1
2
3
4
5
6
7
8
9
12.706
4.303
3.182
2.776
2.571
2.447
2.365
2.306
2.262
10
2.228
11
2.201
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
40
60
2.179
2.160
2.145
2.131
2.120
2.110
2.101
2.093
2.086
2.080
2.074
2.069
2.064
2.060
2.056
2.052
2.048
2.045
2.042
2.021
2.000
120
alpha(L)=0.05
v=gm -2=
58
t(v,L/2)=
1.980
2.000
0.473
0.21
-0.053
-0.317
-0.58
0.393
0.167
-0.069
-0.359
-0.661
S q r(d )
U =B +Q
0.554
0.253
-0.04
-0.27
-0.5
40
G = S u m (S q r(d ))=
F = S u m (S q r(y))=
E = S u m (S q r(x))=
Conclusion/ Remarks:
16
4
0
4
16
L=B -Q
Q =Kst
-0.132
0.723
-4
-2
0
2
4
B =b +a x
K=S q rt(J)
H =S q r(d )/S u m (S q r(d ))
J=(1 /g m )+H
-0.053
220
0.242
0.016
6E-04
0.085
0.38
d =x -x b a r
a=[S(xy)-(S(x)S(y)/g)]/[E-(Sqr(S(x)/g)]=
s=Sqrt[(F-b S(y)- a S(xy))/(g-1)] =
-6.867
4
16
36
64
100
S q r(y)
0.081
0.043
0.016
0.043
0.081
S q r(x)
0.645
0.342
0.129
0.342
0.645
-0.267
x bar y bar
6
0.417
0.117
0.017
0.117
0.417
0.983
0.5
0.15
-2.333
-6.167
S (y)= S u m (y)=
S (x)= S u m (x)=
30
0.4
0.1
0
0.1
0.4
0.492
0.125
0.025
-0.292
-0.617
S (xy)= S u m(xy )=
2
4
6
8
10
xy
B ia s (y)
R ef. va lu e (x )
0.063
b=y bar- a x bar= 0.737

t statistic=mod(a)/[s/Sqrt(G)=
13.306

1.
2.
3.
4.
R & R Evaluation Study

Decide no. of operators , no. of sample parts &
no. of trials in advance
Optimum condition for carrying out MSA is : 03
Operators , 03 Trials & 10 Parts
For other combinations :
No. of operators ( r ) x No. of Parts ( n ) > 15
No. of parts chosen must represent entire
operating range of process .

5.
6.
7.
8.
R & R Evaluation Study :

Select appraisers from those who normally
operate the gauge.
One Observer should be appointed to record the
measurements.
Each part must be identified because the same
part will be used several times for measurement.
Ensure that the instrument should have a least
count of 1 / 10th of the expected process variation
or the tolerance.

R & R Evaluation Study :
9. Measurement should be done in random order.
10. Operator should be unaware which numbered
part is being checked in order to avoid any
possible knowledge bias.
11. Each appraiser should use the same method to
obtain the measurements.

GAUGE REPEATABILITY & REPRODUCIBILITY DAT A SHEET
Part No. :
Part Name :
Characteristic
Specification
1
Appraiser
Observer Name :
Date :
PART
3
R = ( Ra + Rb + Rc ) / No. of Appraiser
Trial 1
Trial 2
Trial 3
Xa=Average
Ra=Range
Appraiser
Trial 1
Trial 2
Trial 3
Xb=Average
Rb=Range
Appraiser
Trial 1
Trial 2
Trial 3
Xc=Average
PART
Rp =
Rc=Range
Xp = Avg.
(Xa,Xb,Xc)
Max Xp - Min Xp =
Xa = Average Xa
Xdiff = Max ( Xa , Xb , Xc ) - Min ( Xa , Xb , Xc )
Xb = Average Xb
UCL r = R x D4
Xc = Average Xc
LCL r = R x D3
Ra = Average Ra
UCL x = Xp + A 2 R =
Rb = Average Rb
LCL x = Xp
Rc = Average Rc
Xp = Average Xp
=
=
- A2 R =
A2
D3
D4
n= 2
1.88
3.27
n= 3
1.023
2.58
10

Evaluate Range of each sample by an individual
appraiser. Draw a Range Chart , then find out the
cause & take necessary corrective actions , then
retake the data.
Average Chart Gap at B Pillar RHL-B
0.90
A ve rage
0.80
0.70
0.60
0.50
0.40
0.30
0.20
0.10
0.00
Sam ple No.
UCL

GAUGE REPEATABILITY & REPRODUCABILITY ANALYSIS SHEET
Part No. :
Part Name :
Characteristic
Specification
Gauge Name
Gauge No.
Least Count
Observer Name
Appraiser A
Appraiser B
Appraiser C
Date :
R =
Xdiff =
Rp =
Measurement unit analysis

Repeatability --- Equipment Variation ( Ev )
Ev
= R x K1
=
Trials
2
3
% Of Total Variation
K1
0.8862
0.5908
Reproducability --- Appraiser Variation

Av =
(( Xdiff x K 2 )2 - (Ev / nr)2)1/2
=
n = no. of part , r = no. of trials
Appraiser
K2
2
0.707
3
0.5231
% EV
=
= 100(EV/TV)
%AV
=
= 100(AV/TV)
% R&R
= 100(R&R/TV)
=
Repeatability & Reproducibility (R & R)
R&R = (EV2 + AV 2 )1/2
=
Part Variation
Parts(n)
PV
= Rp x K 3
=
Total Variation
TV = (R&R2 + PV 2)
=
1/2
5
6
7
8
9
10
K3
0.403
0.3742
0.3534
0.3375
0.3249
0.3146
%PV
= 100(PV/TV)
ndc
Prepared By
=1.41(PV/GRR)
Verified By

If Average Chart is not in control , I.e. , if average chart
is not meeting the conditions then find out the cause &
take corrective actions & retake the data.
After the charts are OK , the evaluate the Gauge R & R
by :
Ist evaluating Equipment Variation EV
Then Appraiser Variation AV
Find out R & R as ( EV2 +AV2 )
Evaluate Parts Variation PV
Evaluate Total Variation TV as ( PV2 + R & R2 )
Evaluate % R & R

If Range Chart is in control , draw Average Chart. The
area within the control limits represent the measurement
error, if 50% or more of the averages fall outside the
limits then measurement system is adequate to detect part
to part variation , hence measurement system can be used
for controlling the process.
Ave ra ge Cha rt Ga p a t BL -13-A
A ve rage
4.00
3.50
3.00
2.50
2.00
1.50
1.00
0.50
0.00
Sam ple No.

Acceptance criteria For Bias & Linearity
The bias & linearity error of the system is
unacceptabl if it is significantly different from
zero or exceeds the maximum permissible error
established by the gage calibration procedure.
In such cases measurement system should be
recalibrated or an offset correction applied toi
minimize this error.

Acceptance criteria For GRR
Under 10 %
Accepted
10 % to 30 %
May be accepted based upon

the importance of application ,
cost of the gauge , etc.
Over 30 %
Gauge not acceptable &

measurement system needs
improvement.

Most Important
1. Product Control Situations
For Product Control Situations where measurement
result & decision criteria determine Conformance or
Non conformance to the feature specification the
assessment of the measuement sytem is based on the
feature tolerance (%GRR to Tolerance).
Samples need not to cover entire process range.

Most Important
2. Process Control Situations
For Process Control Situations where measurement
result & decision criteria determine Process Stability,
direction & compliance with natural process variation
I.e. SPC,process monitoring, capability & process
improvement, the assessment of the measurement sytem
is based on the feature Process Variation (%GRR to
Process Variation).
Samples need to cover entire process range.

Principals of MSA Study
Principal of randomness.
Principal of confidentiality.
Samples must be collected in such a way that they
represent entire production operating range.
Instruments discrimination must allow atleast one
tenth of the process variation.

Post Training Test on Measurement System Analysis
Name :
Department :
1.
What is MSA ?
2.
What is Repeatability ?
3.
What is Reproducibility ?
4.
What is R & R ?
5.
What is the role of observer ?
6.
What is the acceptance criteria of R & R ?
7.
What is Bias ?
8.
What is Stability ?
9.
What is Linearity ?

Measurement System Analysis

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