ANOVA GAGE R&R METHOD:
The gage R&R study focuses on σms2. In a gage R&R study, you can
break down σms2 into its two components:
σms2 is the measurement system variance.
Repeatability is the ability of the measurement system to repeat the same
measurements on the same sample under the same conditions. It
represents an assessment of the ability to get the same measurement
result each time.
Reproducibility is the ability of measurement system to return consistent
measurements while varying the measurement conditions (different
operators, different parts, etc.) It represents an assessment of the ability
to reproduce the measurement of other operators.
In this series, we will take a look at how the repeatability and
reproducibility are determined using the ANOVA method for Gage R&R.
EXAMPLE DATA
We will re-use the data from our December 2007 newsletter on the
average and range method for Gage R&R. In this example, there were
three operators who tested five parts three times. A picture of part of the
Gage R&R design is shown below.
Operator 1 will test 5 parts three times each. In the figure above, you can
see that Operator 1 has tested Part 1 three times. What are the sources
of variation in these three trials? It is the measurement equipment itself.
The operator is the same and the part is the same. The variation in these
three trials is a measure of the repeatability. It is also called the equipment
variation in Gage R&R studies or the "within" variation in ANOVA studies.
Operator 1 also runs Parts 2 through 5 three times each. The variation in
those results includes the variation due to the parts as well as the
equipment variation. Operator 2 and 3 also test the same 5 parts three
times each. The variation in all results includes the equipment variation,
the part variation, the operator variation and the interaction between
operators and parts. The variation in all results is the reproducibility.
The data from the December 2007 newsletter are shown in the table
below.
Operator Part Results
1 3.29 3.41 3.64
2 2.44 2.32 2.42
A 3 4.34 4.17 4.27
4 3.47 3.5 3.64
5 2.2 2.08 2.16
1 3.08 3.25 3.07
2 2.53 1.78 2.32
B 3 4.19 3.94 4.34
4 3.01 4.03 3.2
5 2.44 1.8 1.72
1 3.04 2.89 2.85
2 1.62 1.87 2.04
C 3 3.88 4.09 3.67
4 3.14 3.2 3.11
5 1.54 1.93 1.55
The operator is listed in first column and the part numbers in the second
column. The next three columns contain the results of the three trials for
that operator and part number. For example, the three trial results for
Operator A and Part 1 are 3.29, 3.41 and 3.64.
We will now take a look at the ANOVA table, which is used as a starting
point for analyzing the results.
THE ANOVA TABLE FOR GAGE R&R
In most cases, you will use computer software to do the calculations.
Since this is a relatively simple Gage R&R, we will show how the
calculations are done. This helps understand the process better. The
software usually displays the results in an ANOVA table. The basic
ANOVA table is shown in the table below for the following:
• k = number of operators
• r = number of replications
• n= number of parts
The first column is the source of variability. Remember that a Gage R&R
study is a study of variation. There are five sources of variability in this
ANOVA approach: the operator, the part, the interaction between the
operator and part, the equipment and the total. Part-to-part variation is the
actual variation between parts produced by the process,
The second column is the degrees of freedom associated with the source
of variation. The degrees of freedom are simply the number of values of a
statistic that are free to vary. For example, suppose you have a sample
that contains n observations. We use the sample to estimate something -
usually an average. When we want to estimate something, it costs us one
degree of freedom. So, if we have n observations and want to estimate
the average, then we have n - 1 degrees of freedom left.
The third column is the sum of squares (SS) associated with the source
of variation. The sum of squares is a measure of variation. It measures
the squared deviations around an average. Remember what the equation
for the variance is? The variance of a set of number is given by:
The sum of squares for the source of variation is very similar to the
numerator. You just take the sum of squares around different averages
depending on the source of variation.
The fourth column is the mean square associated with the source of
variation. The mean square is the estimate of the variance for that source
of variability based on the amount of data we have (the degrees of
freedom). So, the mean square is the sum of squares divided by the
degrees of freedom. Note the similarity to the formula for the variance
above.
The fifth column is the F value. This is the statistic that is calculated to
determine if the source of variability is statistically significant. It is the ratio
of two variances (or mean squares in this case).
THE ANOVA RESULTS
The data above were analyzed using the SPC for Excel software. The
resulting ANOVA table is shown below.
Source df SS MS F p Value
Operator 2 1.630 0.815 100.322 0.0000
Part 4 28.909 7.227 889.458 0.0000
Operator by
8 0.065 0.008 0.142 0.9964
Part
Equipment 30 1.712 0.057
Total 44 32.317
Let's see where the numbers come from.
TOTAL SUM OF SQUARES AND DEGREES OF FREEDOM
The total sum of squares (SST) is the sum of the other sources of
variability. So,
SST = SS0 + SSP + SS0*P + SSE
The total sum of squares is the squared deviation of each individual result
from the overall average - the average of all results. The overall average
of the 45 results is:
The total sum of squares is then given by:
where Xijm is the result for the ith operator running the jth part for the
mth trial. This equation is simply a fancy way of saying that you subtract
the average from an individual result and square that result. This is shown
in the figure below for the squared deviation of the first result.
If you do this for each point and add up the results, you will obtain the
following:
SST = 32.317
The calculations are shown in the table below.
Squared Squared Squared
Operator Part Trial 1 Trial 2 Trial 3 Deviation Deviation Deviation
Trial 1 Trial 2 Trial 3
1 3.29 3.41 3.64 0.120 0.217 0.485
2 2.44 2.32 2.42 0.254 0.389 0.274
A 3 4.34 4.17 4.27 1.949 1.504 1.759
4 3.47 3.5 3.64 0.277 0.309 0.485
5 2.2 2.08 2.16 0.553 0.746 0.614
1 3.08 3.25 3.07 0.019 0.094 0.016
2 2.53 1.78 2.32 0.171 1.354 0.389
B 3 4.19 3.94 4.34 1.553 0.992 1.949
4 3.01 4.03 3.2 0.004 1.180 0.066
5 2.44 1.8 1.72 0.254 1.308 1.498
1 3.04 2.89 2.85 0.009 0.003 0.009
2 1.62 1.87 2.04 1.752 1.153 0.817
C 3 3.88 4.09 3.67 0.877 1.314 0.527
4 3.14 3.2 3.11 0.039 0.066 0.028
5 1.54 1.93 1.55 1.971 1.028 1.943
Sum 32.317
e.g.
Trial 1 mean for operator A = 3.148
The first trial observation is 3.29
Squared deviation= (3.29-3.148)^2
There were a total of 45 results. We calculated the overall average for
these results. So the degrees of freedom associated with the total sum of
squares are 45 - 1 = 44. This can also be calculated as nkr - 1.
OPERATOR SUM OF SQUARES AND DEGREES OF FREEDOM
As mentioned before, you obtain the sum of squares by determining the
squared deviations between two numbers. With the operator source of
variability, you will obtain the squared deviations between the operator
average and the overall average. Algebraically, this is given by:
where nr represents the number of results for operator i and the "i.."
subscript means over all parts and trials for operator i.
In this example, n = 5 and r = 3, so there are 15 results for each operator.
The table below shows how the calculations are done:
Operator Squared Deviation
Operator Parts Trial 1 Trial 2 Trial 3
Average for Operator
1 3.29 3.41 3.64 3.1567 0.0453
2 2.44 2.32 2.42 =(3.1567-2.944)^2
A 3 4.34 4.17 4.27
4 3.47 3.5 3.64
5 2.2 2.08 2.16
1 3.08 3.25 3.07 2.9800 0.0013
2 2.53 1.78 2.32 =(2.98-2.944)^2
B 3 4.19 3.94 4.34
4 3.01 4.03 3.2
5 2.44 1.8 1.72
1 3.04 2.89 2.85 2.6947 0.0621
2 1.62 1.87 2.04
C 3 3.88 4.09 3.67
4 3.14 3.2 3.11
5 1.54 1.93 1.55
Sum of Deviations 0.1087
15(Sumof Deviations) 1.6304
Thus,
SSO = 1.6304
So, you can see that the sum of squares due to the operators is based on
how the operator averages deviate from the overall average. There are
three operator averages. Since we calculated the overall average, we lost
one degree of freedom. The degrees of freedom associated with the
operators are 3 - 1 = 2, or k -1 = 2.
The variability chart below shows the results by operator by part. The
horizontal blue line is the average for the operator. The horizontal green
line is the overall average. The difference between those two lines is the
deivation.
PARTS SUM OF SQUARES AND DEGREES OF FREEDOM
The sum of square due to the parts is done in the same manner as for the
operators except the average you are focusing on are the part averages.
Algebraically, the equation for SSP is:
where kr is the number of results for a given part (3 operators, 3 trials) and
the subscript ".j." is the average of the results for part j across all
operators and trials. The table below shows the calculations. The original
data has been sorted by part.
Part Trial 1 Trial 2 Trial 3 Part Average Squared Deviation for Part
1 3.29 3.41 3.64 3.1689 0.0507
1 3.08 3.25 3.07 =(3.1689-2.944)^2
1 3.04 2.89 2.85
2 2.44 2.32 2.42 2.1489 0.6318
2 2.53 1.78 2.32
2 1.62 1.87 2.04
3 4.34 4.17 4.27 4.0989 1.3343
3 4.19 3.94 4.34
3 3.88 4.09 3.67
4 3.47 3.5 3.64 3.3667 0.1788
4 3.01 4.03 3.2
4 3.14 3.2 3.11
5 2.2 2.08 2.16 1.9356 1.0165
5 2.44 1.8 1.72
5 1.54 1.93 1.55
Sum of Deviations 3.2122
9(Sum of Deviations) 28.9094
Thus,
SSP = 28.9094
Again, you can see how the sum of square due to parts is based on how
the part averages deviate from the overall average. There are five
parts. Again, we calculated the overall average, so one degree of
freedom is lost. There are n - 1 = 5 -1 = 4 degrees of freedom associated
with the parts sum of squares.
EQUIPMENT (WITHIN) SUM OF SQUARE AND DEGREES OF
FREEDOM
The equipment sum of squares uses the deviation of the three trials for a
given part and a given operator from the average for that part and
operator. This can be expressed as:
The calculations are shown in the table below.
Squared
Average Squared Squared
Trial Trial Trial Deviation
Operator Parts of 3 Deviation Deviation
1 2 3 Trial 1
Trials Trial 2 Trial 3
1 3.29 3.41 3.64 3.447 0.025 0.001 0.037
2 2.44 2.32 2.42 2.393 0.002 0.005 0.001
A 3 4.34 4.17 4.27 4.260 0.006 0.008 0.000
4 3.47 3.5 3.64 3.537 0.004 0.001 0.011
5 2.2 2.08 2.16 2.147 0.003 0.004 0.000
1 3.08 3.25 3.07 3.133 0.003 0.014 0.004
2 2.53 1.78 2.32 2.210 0.102 0.185 0.012
B 3 4.19 3.94 4.34 4.157 0.001 0.047 0.034
4 3.01 4.03 3.2 3.413 0.163 0.380 0.046
5 2.44 1.8 1.72 1.987 0.206 0.035 0.071
1 3.04 2.89 2.85 2.927 0.013 0.001 0.006
2 1.62 1.87 2.04 1.843 0.050 0.001 0.039
C 3 3.88 4.09 3.67 3.880 0.000 0.044 0.044
4 3.14 3.2 3.11 3.150 0.000 0.003 0.002
5 1.54 1.93 1.55 1.673 0.018 0.066 0.015
Sum 1.712
Thus,
SSE = 1.712
Again, note that the sum of squares is examining variation around an
average. For the within variation, it is the variation in the three trials
around the average of those three trials.
We calculated an average for each set of three trials. So, we lost one
degree of freedom for each set of three trials or r - 1. There were nk set
of three trials, so the degrees of freedom associated with the equipment
variation is nk(r-1) = 30.
The variability chart below shows the results by part by operator.
INTERACTION SUM OF SQUARE AND DEGREES OF FREEDOM
We will make use of the equality stated earlier to find the interaction sum
of squares. This equality was:
SST = SS0 + SSP + SS0*P + SSE
SS0*P = SST- (SS0 + SSP + SSE)
SS0*P = 32.317 - (1.63 + 28.909 + 1.712)
SS0*P = 0.065
The same equality holds for the degrees of freedom:
df0*P = dfT - (df0 + dfP + dfE)
df0*P =44 - (2 + 4 + 30)
df0*P = 8