Southwest Test Conference

Introduction to
Gage R&R Studies
The Key to Understanding
Measurement Systems

By
Hank Scutoski & Chander Sekar, Ph.D.
CERPROBE CORPORATION ®

Gilbert, Arizona
 Speakers

q Hank Scutoski q Chander Sekar, Ph.D.

– VP Quality – Corporate Statistician
– 30 Years Experience – 23 Years Experience
– TI, Motorola, Cerprobe – Professor of Statistics at
– Motorola University’s the University of
Six Sigma Research Institute Madras, India
– Certified Quality Engineer – 3 Degrees in Statistics
– Certified Quality Auditor – Certified Quality Engineer

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 Cerprobe’s Philosophy

We must determine the uncertainty of

our measurement systems before we
can compare, control or optimize our
manufacturing processes.

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 Studies Completed

85 Studies to Date Including:

– Tip Diameter
– Tip Length
– Contact Force
– Probe Tip Alignment
– Planarity
– Contact Resistance
– Leakage

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 Benefits
n Validates consistent results between:
q Cerprobe’s many manufacturing facilities
q Cerprobe & customer sites

n Provides for “Dock to Stock” certification

n Provides feedback to Cerprobe’s suppliers.

n Able to provide customer with quality products

with statistical consulting support.
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 Statistical Applications

Gage
GageR&R
R&R

Comparison
Comparisonof
of Scientific
Scientific
SPC
SPC
Metrology
MetrologyTools
Tools Guard
GuardBanding
Banding

Design
Designof
of
Experiments
Experiments
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 Gage Repeatability

• The variation obtained

from one gage and one PrecisionR = Diameter = 6 Std Dev
operator when
X3
measuring the same True Value X1 X2
part several times.

• Machine Variation

• Only Applies to ATE

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 Gage Reproducibility
• The difference in the
average of the Precision R&R
measurements made by
different operators using Y2
the same gage when Y1 Y3
measuring the same X3
True Value X1 X2
part.

• Operator-to-Operator
Variation

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 R&R Summary Plot
No. of Operators: 3
No. of Parts: 32
No. of Trials: 3

Microscope
0.00030
Deviation from Average

0.00025
0.00020
0.00015
0.00010
0.00005
0.00000
-0.00005
-0.00010
-0.00015
-0.00020
-0.00025
-0.00030
1 2 3
Operators
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 R&R Summary Plot
No. of Operators: 3
No. of Parts: 32
No. of Trials: 3
Study #3

Video System
Deviation from Average

0.00030
0.00025
0.00020
0.00015
0.00010
0.00005
0.00000
-0.00005
-0.00010
-0.00015
-0.00020
-0.00025
-0.00030
1 2 3

Operators
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Total Variation

q Process Variation
q Gage Variation
• Repeatability

• Reproducibility

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 Repeatability

99.73%

-3σ +3σ
o
o
o oooo ooo o ooo o
Nominal

Note: q One Gage

q 1 Operator
®
q Repeated Measurements
 Reproducibility

Operator # 1
Distribution

Operator # 2
Distribution

Note: q One Gage

q 2 Operators
q Repeated Measurements ®

q One Part
 Measurement System Capability

n Precision-to-Tolerance Ratio (P/T)

P/T < 0.1 Acceptable System

0.1 < P/T < 0.3 Marginally Acceptable System

P/T > 0.3 Unacceptable System

Ref.: SEMATECH: Introduction to Measurement Capability Analysis

#91090709A-ENG ®
Interpretation of P/T Ratios

P/T = 0.1
* Measurement system consumes 10%
of tolerance

* Effect of T on P/T

P = 1.2 P = 1.2
T = 4.0 T = 3.0
P/T = 0.3 P/T = 0.4
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 Repeatability Study

n Single operator performs multiple trials

n No change in the setup between trials

n Provides a quick estimate of measurement

capability

n PR/T

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 Repeatability Study - Data

Sample data on Align (x) from a repeatability study

Trial #1 Trial #2 Trial #3 Trial #4 Trial #5 S R

0.0170 0.0180 0.0190 0.0070 0.0930 0.0351 0.0860
0.2090 0.1400 0.1630 0.1540 0.1340 0.0297 0.0750
0.0790 0.1170 0.0600 0.0880 0.0970 0.0211 0.0570
0.0770 0.0750 0.1350 0.0820 0.1380 0.0322 0.0630
0.0840 0.0300 0.0730 0.0780 0.0240 0.0285 0.0600
0.0500 0.0420 -0.0030 0.0380 0.0520 0.0224 0.0550
-0.0480 -0.0510 0.0020 -0.0420 -0.0370 0.0215 0.0530
0.0690 0.0830 0.1360 0.1150 0.0690 0.0299 0.0670

S:Standard Deviation R: Range

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 Repeatability Study

P/T Calculations

_
PR/T = 6 * ( R / d2) / (USL - LSL)

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 Gage R&R Study

n Involves multiple operators and trials

n Total tear down of the setup between trials

n Provides separate estimates of repeatability

and reproducibility

n PR&R /T

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 Gage R&R Study - Data

Sample data on Align (x) from a full gage R & R study

O1-T1 O1-T2 O1-T3 O2-T1 O2-T2 O2-T3

-0.0050 0.0360 0.0330 0.0040 -0.0070 -0.0420
-0.0100 -0.0460 -0.0600 -0.0170 -0.0680 -0.0700
0.0070 0.0110 0.0090 0.0230 -0.0190 -0.0040
-0.0170 -0.0820 -0.1060 -0.0890 -0.0540 -0.0580
-0.0620 -0.1000 -0.1010 -0.0270 -0.1090 -0.1000
-0.0830 -0.1480 -0.1210 -0.1200 -0.1280 -0.1870
-0.1100 -0.1460 -0.1520 -0.1200 -0.1890 -0.1900
-0.0560 -0.1490 -0.1290 -0.0900 -0.1650 -0.1780

O1, O2 - Operators 1 and 2

T1, T2, T3 - Trials 1, 2 and 3

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 Gage R&R Study

n Repeatability

n Reproducibility

n Operator-Part Interaction

n Part-to-Part Variation

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 Operator-to-Part Interaction

Significant
Significant
Operator-to-Part
Operator-to-Part
Interaction
Interaction

Improper
Improper
Poor
PoorOperator
Operator
Bad
BadGage
Gage Measurement
Measurement
Training
Training Study
StudyProcedure
Procedure

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 Data Analysis Methods

n Average Range Method

n Analysis of Variance (ANOVA) Method

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 Gage R&R Study

P/T Calculations

PR&R/T = 6 * ( R&R Sigma) / (USL - LSL)

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 Road Map to Success

Microscope Video
P/T P/T
0.80 0.23

Interaction Feedback Robust Advanced

with to Data Statistical
Suppliers Operators Collection Techniques

Consistent Product Quality ®