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Gage R&R Study Overview and Analysis

This document provides information for calculating gage repeatability and reproducibility (GR&R). It includes data from multiple operators measuring multiple samples over several trials. The data is used to calculate repeatability, reproducibility, and overall GR&R for the measurement process. Key metrics include within-operator variation (repeatability), between-operator variation (reproducibility), and the combined variation (GR&R). The results are also expressed as percentages of the total tolerance to assess the measurement system capability.

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CLEV2010
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347 views7 pages

Gage R&R Study Overview and Analysis

This document provides information for calculating gage repeatability and reproducibility (GR&R). It includes data from multiple operators measuring multiple samples over several trials. The data is used to calculate repeatability, reproducibility, and overall GR&R for the measurement process. Key metrics include within-operator variation (repeatability), between-operator variation (reproducibility), and the combined variation (GR&R). The results are also expressed as percentages of the total tolerance to assess the measurement system capability.

Uploaded by

CLEV2010
Copyright
© Attribution Non-Commercial (BY-NC)
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as XLS, PDF, TXT or read online on Scribd
  • Gage Repeatability and Reproducibility Datasheet
  • Gage Repeatability and Reproducibility Data Collection Sheet
  • Possible Causes for Variation
  • Number of Distinct Categories (NDC)

Gage Repeatability and Reproducibility

Datasheet Long
Operator A B C No. of
Trials
D4
Max X
Sample 1st
2nd
3 rd
1 2
st
3
nd rd
1 2
st
3
nd rd 2 3.27 Min X
Range Range Range
of Trial Trial Trial Trial Trial Trial Trial Trial Trial 3 2.58 X Diff
1
2
RA
3 Tolerance
4
RB
5
6 UCLR
RC
7
(R) x (D4)
8
Sum
9 x
10
R
11
12
13 No. of α
2 3
14 Trials (m)
15 m
Totals α 4.56 3.05

No. of β
2 3
Sum RA Sum RB Sum RC Operators (n)
XA XB XC n
β 3.65 2.70
0

MEASUREMENT UNIT ANALYSIS % TOLERANCE ANALYSIS

Repeatability - Equipment Variation (EV) - [within]

EV = (R) x (α) % EV = 100 x [(EV) / (Tolerance)]

= x = 100 x / ]

= =

Reproducibility - Appraiser Variation (AV) - [Between]

AV = √ { [(X diff
2
) x (β2)] - [(EV2) / (n x m)] } % AV = 100 x [(AV) / (Tolerance)]

= √ {[ x ] - [ / ]} = 100 x / ]

= =

Reproducibility and Reproducibility (R&R)

R&R = √ ((EV ) 2
+ (AV2)) % R&R = 100 x [(R&R) / (Tolerance)

= √ ( + ) = 100 x / ]

= =

Sample Information:
Sample
Date Fill cells
d* Value for the distribution
Sample Operator 1 Operator 2 Operator 3 Operator 4 of the average Range
|Range 1-4|
# # of # of Operators
1 Samples 2 3 4
2 1 1.41 1.91 2.24
3 2 1.28 1.81 2.15
4 3 1.23 1.77 2.12
5 4 1.21 1.75 2.11
6 5 1.19 1.74 2.1
7 6 1.18 1.73 2.09
8 7 1.17 1.73 2.09
9 8 1.17 1.72 2.08
10 9 1.16 1.72 2.08
Sum of Ranges 10 1.16 1.72 2.08
Average Range
Gage Repeatability and Reproducibility
Data Collection Sheet

Part
Appraiser

Average
Trial #

1 2 3 4 5 6 7 8 9 10
1
2
3 Xa
Average Ra
Range
1
2
3 Xb
Average Rb
Range
1
2
3 Xc
Average Rc
Range
Part X
Average Rp

R = (Sum of Ranges / Number of appraisers) =

XDIFF = (Maximum average - Minimum average)

UCLR = (R x D4)

Trials D4 Parts K3 D4 =
2 3.27 2 0.7071
3 2.58 3 0.5231 K1 =
4 0.4467
Constants

Trials K1 5 0.4030 K2 =
2 0.8862 6 0.3742
3 0.5908 7 0.3534 K3 =
8 0.3375 Variables:
Appraiser K2 9 0.3249 n = (parts)
2 0.7071 10 0.3146 r = (trials)
3 0.5231

EV = R x K1 = % EV =

AV =
√ ( XDIFF x K2 )2 - ( EV2 / n x r ) = % AV =

GRR =
√ EV2 + AV2 = % GRR =

PV = Rp x K3 = % PV =

TV =
√ GRR2 + PV2 = ndc =

Sample Information:
Sample
Date
Possible Causes for Variation

Observed Process
Variation

Real
Measurement
Process
Variation
Variation

Long-Term Short-Term Spread Spread Spread


Process Process in the caused by caused by
Variation Variation Sample Operators Gauge

Reproducibility

Accuracy Linearity Stability Repeatabilit

NDC = Number of Distinct Categories


Measurement Instruments have physical limitations to "discriminate" between different parts (i.e. give different value
dimension for parts that are actually different). An example: The discriminative power of the scale that my wife has i
is 5 gr. By using this device it will be impossible for me to "discriminate" between packs of flour wheighing 1.010 gr
1011 gr (eyeballing & rounding is not allowed!). All these three packs will be considered as having the same weight w
it is not true. The three packs are in "the same category". In this way we start to talk about "categories"
NDC = Number of Distinct Categories
Measurement Instruments have physical limitations to "discriminate" between different parts (i.e. give different value
dimension for parts that are actually different). An example: The discriminative power of the scale that my wife has i
is 5 gr. By using this device it will be impossible for me to "discriminate" between packs of flour wheighing 1.010 gr
1011 gr (eyeballing & rounding is not allowed!). All these three packs will be considered as having the same weight w
it is not true. The three packs are in "the same category". In this way we start to talk about "categories"

The NDC tells you how many categories your measurement system (MS) is able to diferenciate considering your pro
variation.

If your NDC = 1 then your MS is useless.


If the NDC = 2 then your MS can only distinguish between two categories ("small" and "big", for example). (useles
If NDC = 3 then you have small, medium and big, and so on...

Automotive industries recomend a value equal or greather than five, if I remember well... The greatest the NDC the b

Of course the term "category" is not physical or tangible. It is an "abstract category".


ment
n

d Spread
by caused by
rs Gauge

bility

Repeatability

fferent parts (i.e. give different values of a


power of the scale that my wife has in the kitchen
en packs of flour wheighing 1.010 gr, 1.007 or
nsidered as having the same weight when actually
alk about "categories"
fferent parts (i.e. give different values of a
power of the scale that my wife has in the kitchen
en packs of flour wheighing 1.010 gr, 1.007 or
nsidered as having the same weight when actually
alk about "categories"

to diferenciate considering your process

mall" and "big", for example). (useless too)

er well... The greatest the NDC the better.

ory".

Common questions

Powered by AI

A larger 'Spread caused by Gauge Repeatability' indicates higher inconsistency in repeated measurements taken by the same instrument, leading to decreased accuracy and potentially allowing defective products to pass unchecked. This spread can result in a lack of confidence in the measurement system's output, affecting overall product quality and requiring additional resources to correct .

% Tolerance is calculated as part of the measurement system's repeatability and reproducibility analysis to quantify how much variation is present compared to the allowable tolerance. It helps determine if the measurement system can consistently produce results within the acceptable limits. This is crucial for assessing the effectiveness and capability of the system in maintaining quality control .

EV or Equipment Variation measures within-appraiser consistency and is critical for understanding the precision of a measurement system. It reflects the inherent variability of the measurement instrument itself, independent of the operator. By minimizing EV, we can improve the precision and ensure the measurement system provides more reliable and repeatable results, which is key for quality assurance .

Measurement Unit Analysis involves calculating variations attributed to appraisers by using statistics such as % AV, which is the percentage of appraiser variation relative to tolerance. This analysis helps identify the extent to which differences between operators affect measurement consistency, thereby contributing crucial information for improving inter-operator reliability .

The relationship between GRR and PV is used to assess if the measurement system's variability is significant compared to the inherent process variation. A high GRR relative to PV indicates that measurement variability could overshadow actual process insights. As a result, improving measurement efficiency involves reducing GRR to ensure any process changes are accurately monitored and managed, enhancing overall system capability .

Identifying possible causes of variation, such as 'Spread caused by Operators,' is significant because it allows for targeted improvement actions to increase measurement accuracy and consistency. Understanding these causes helps in isolating human factors that contribute to measurement errors, thus helping in the development of training and standardization efforts to minimize variance and enhance the reliability of the measurement process .

Differentiating between short-term and long-term process variations is essential as it helps in identifying and addressing different factors affecting the process stability and capability over time. Short-term variations could indicate immediate issues with equipment or appraiser procedures, while long-term variations may suggest systemic issues needing deeper investigation. This differentiation aids in improving process reliability and product quality .

A low NDC value implies that the measurement system cannot adequately differentiate between different categories of product dimensions, leading to potential quality control issues. To rectify this, the measurement system needs to be improved, either by adopting more precise instruments, recalibrating existing equipment, or enhancing operator training to ensure more distinct and reliable measurement outcomes .

Constants like D4, K1, and K2 are used as multipliers in statistical equations to adjust for sample size and enhance the accuracy of variation calculations. For instance, D4 is used in control chart applications, while K1 and K2 are utilized to adjust the standard deviation based on sample sizes. These constants ensure the calculated measurement variations accurately reflect the true variability of the system .

NDC, or Number of Distinct Categories, is used to evaluate the discriminating power of a measurement system to differentiate between distinct categories of parts. In automotive industries, a higher NDC value is crucial as it indicates the measurement system's ability to accurately discern small differences in part dimensions, which is essential for ensuring product quality. A minimum NDC value of 5 is recommended to ensure reliability and effectiveness of the measurement system .

Gage Repeatability and Reproducibility Datasheet Long Operator A B C Max X Range Range Range 2 3.27 Min X 3 2.58 1 2 3 Tole
Operator 1 Operator 2 Operator 3 Operator 4 |Range 1-4| # of Operators 1 2 3 4 2 1 1.41 1.91 2.24 3 2 1.28 1.81 2.15 4 3 1.23
Gage Repeatability and Reproducibility Data Collection Sheet Appraiser Trial # Part Average 1 2 3 4 5 6 7 8 9 10 1 2 3 Avera
Possible Causes for Variation Observed Process Variation Real Process Variation Measurement Variation Short-Term Process Vari
NDC = Number of Distinct Categories Measurement Instruments have physical limitations to "discriminate" between different par
ment n d by rs Spread caused by Gauge Repeatability bility fferent parts (i.e. give different values of a power of the scale
fferent parts (i.e. give different values of a power of the scale that my wife has in the kitchen en packs of flour wheighi

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