Gauge R&R Long Form Study

Study Number: Part No.: 421665 Performed By: Nutthapong

Gauge Name: Vernier Part Name: Cyclinder Bowl 68 Operator A: Kalaya
Gauge No.: Operation No.: Total height Operator B: Nisarat
Graduations: Characteristic: - Operator C: Rachanee
Zero Equals: Specification: 404 Area: Bowl line
Unit of Measure: mm. Total Tolerance: 2 Date: 4-Apr-04

Instructions:
1) Verify the gauge can read at least one additional degree of resolution than the part characteristic. Typically, a ten to one
ratio of tolerance to gauge resolution is required.
2) Verify the gauge is calibrated.
3) Perform study per section 5.1 of Instructions
4) Record results below. Type in shaded areas only. Note: "Total Tolerance" and "Operator Names" MUST be filled in for the
form to work properly.
5) Analyze the results to determine variability due to both Repeatability and Reproducibility.

Operator A: Kalaya Operator B: Nisarat Operator C: Rachanee

Sample Trials Sample Trials Sample Trials

Number 1 2 3 R Number 1 2 3 R Number 1 2 3 R
1 404.61 404.43 404.48 0.18 1 404.69 404.60 404.60 0.09 1 404.46 404.42 404.55 0.13
2 404.61 404.64 404.59 0.05 2 404.72 404.67 404.65 0.07 2 404.65 404.62 404.68 0.06
3 404.51 404.78 404.53 0.27 3 404.50 404.79 404.61 0.29 3 404.56 404.43 404.59 0.16
4 404.83 404.78 404.98 0.2 4 404.94 404.75 404.92 0.19 4 404.66 404.73 404.84 0.18
5 404.83 404.79 404.83 0.04 5 404.78 404.78 404.52 0.26 5 404.71 404.78 404.78 0.07
6 404.57 404.54 404.52 0.05 6 404.42 404.53 404.55 0.13 6 404.51 404.55 404.67 0.16
7 404.79 404.7 404.77 0.09 7 404.53 404.75 404.71 0.22 7 404.66 404.79 404.69 0.13
8 404.55 404.53 404.49 0.06 8 404.77 404.58 404.43 0.34 8 404.46 404.36 404.36 0.100
9 404.73 404.71 404.72 0.02 9 404.63 404.70 404.74 0.11 9 404.60 404.75 404.69 0.15
10 404.55 404.73 404.59 0.18 10 404.56 404.64 404.54 0.1 10 404.65 404.58 404.55 0.1
Totals 4046.6 4046.6 4046.5 1.14 Totals 4046.5 4046.8 4046.3 1.8 Totals 4045.9 4046 4046.4 1.24
Means 404.66 404.66 404.65 0.114 Means 404.65 404.68 404.63 0.18 Means 404.59 404.6 404.64 0.124
Xbar1 Xbar2 Xbar3 RbarA Xbar1 Xbar2 Xbar3 RbarB Xbar1 Xbar2 Xbar3 RbarC

XbarA = Xbar1 + Xbar2 + Xbar3 XbarB = Xbar1 + Xbar2 + Xbar3 XbarC = Xbar1 + Xbar2 + Xbar3
Trials Trials Trials

XbarA = 404.6570 XbarB = 404.6533 XbarC = 404.6110

Test for Statistical Control of Ranges

Rbar1 = RbarA + RbarB + RbarC = 0.4180 = 0.1393

Operators 3

UCLR = D4 * Rbar1 = 2.58 * 0.1393 = 0.3595 = Range Upper Control Limit

Note: D4 is based on the number of trials. (See table below)

Repeatability (Gage Variation)

GV = Rbar1 * K1 = 0.1393 * 3.05 = 0.4250

Note: K1 is based on the number of trials. (See table below)

Reproduceability (Between Operator Variation)

 Gauge R&R Long Form Study
Rbar2 = XbarLargest of ABC - XbarSmallest of ABC = 404.6570 - 404.6110 = 0.0460

OV = (Rbar2 * K2)2 - (GV2/(n*r)) = ( 0.046* 2.7) -(

2 2
0.425 / 10 * 3) = 0.0970

Note: K2 is based on the number of Operators. (See table below), n is the number of parts, r is the number of trials

Combined Reproduceability and Repeatability (Measurement Variation)

R&R = OV2 + GV2 = 0.09702 + 0.42502 = 0.4359

Part Variation

PV = RP * K3 = 0.3222 * 1.62 = 0.5220

Note: K3 is based on the number of parts. (See table below)

Total Variation

TV = R&R2 + PV2 = 0.43592 + 0.52202 = 0.6801

Table of Factors used in calculations from AIAG Manual for Measurement Systems Analysis, Chapter II, Section 4, Figure 19.
r D4 K1 Op. K2 n K3
2 3.27 4.56 2 3.65 9 1.67
3 2.58 3.05 3 2.7 10 1.62

% R&R (as a % of TV)

%R&R = R&R / TV = 0.4359 / 0.6801 = 64%

THE SUM OF THE PERCENT CONSUMED BY EACH FACTOR WILL NOT EQUAL 100%
This result for percent of total GR&R Error shall be evaluated in order to determine if the measurement system as
intended is acceptable for its application.

Guidelines for Judging the acceptance of the GR&R Error are:

-- Under 10% error - the measurement system is acceptable.
-- 10% - 30% error - may be acceptable based on importance of application, cost of gauge, cost to repair, etc.
-- Over 30% error - Measurement system must be improved. Follow the corrective action process to identify the
root cause of the problem and have them corrected.

Note: If Gage R&R as a % of TV fails to meet the above criteria, but the Gage R&R as a % of Tolerance
Range does meet the critera, then the gage is acceptable.

% R&R (as a % of Total Tolerance Range)

%R&R = R&R / Total Tolerance = 0.4359 / 2.0000 = 22%
 Gauge R&R Long Form Study
Study Number: Part No.: 421665 Performed By: Nutthapong
Gauge Name: Vernier Part Name: Cyclinder Bowl 68 Operator A: Kalaya
Gauge No.: Operation No.: Hoop diameter BR1 Operator B: Nisarat
Graduations: Characteristic: - Operator C: Rachanee
Zero Equals: Specification: 570.0 Area: Bowl line
Unit of Measure: mm. Total Tolerance: 0.6 Date: 4-Apr-04

Instructions:
1) Verify the gauge can read at least one additional degree of resolution than the part characteristic. Typically, a ten to one ratio of
tolerance to gauge resolution is required.
2) Verify the gauge is calibrated.
3) Perform study per section 5.1 of Instructions
4) Record results below. Type in shaded areas only. Note: "Total Tolerance" and "Operator Names" MUST be filled in for the form to
work properly.
5) Analyze the results to determine variability due to both Repeatability and Reproducibility.

Operator A: Kalaya Operator B: Nisarat Operator C: Rachanee

Sample Trials Sample Trials Sample Trials

Number 1 2 3 R Number 1 2 3 R Number 1 2 3 R
1 569.71 569.38 569.59 0.33 1 570.00 569.31 569.67 0.69 1 569.16 569.09 569.30 0.21
2 568.53 569.28 568.27 1.01 2 569.40 568.82 569.42 0.60 2 569.69 569.34 569.23 0.46
3 569.74 569.66 569.71 0.08 3 569.19 569.92 569.82 0.73 3 570.61 569.65 569.45 1.16
4 568.93 569.36 569.58 0.65 4 569.09 569.20 569.20 0.11 4 569.22 569.70 569.10 0.60
5 569.60 569.57 569.72 0.15 5 568.21 569.19 569.32 1.11 5 569.76 569.26 569.35 0.50
6 568.88 569.59 569.37 0.71 6 568.77 569.45 569.46 0.69 6 570.53 569.73 569.51 1.02
7 569.82 569.47 569.2 0.62 7 569.29 569.62 569.94 0.65 7 569.40 569.42 569.08 0.34
8 569.20 569.6 568.63 0.97 8 569.57 569.13 569.19 0.44 8 569.94 569.34 569.30 0.64
9 569.27 569.15 569.06 0.21 9 569.90 570.22 569.98 0.32 9 570.08 569.66 569.60 0.48
10 568.47 569.61 569.29 1.14 10 569.10 569.05 569.47 0.42 10 569.00 569.30 569.02 0.30
Totals 5692.2 5694.7 5692.4 5.87 Totals 5692.5 5693.91 5695.47 5.76 Totals 5697.4 5694.5 5692.9 5.71
Means 569.22 569.47 569.24 0.587 Means 569.25 569.391 569.547 0.576 Means 569.74 569.45 569.29 0.571
Xbar1 Xbar2 Xbar3 RbarA Xbar1 Xbar2 Xbar3 RbarB Xbar1 Xbar2 Xbar3 RbarC

XbarA = Xbar1 + Xbar2 + Xbar3 XbarB = Xbar1 + Xbar2 + Xbar3 XbarC = Xbar1 + Xbar2 + Xbar3
Trials Trials Trials

XbarA = 569.3080 XbarB = 569.3967 XbarC = 569.4940

Test for Statistical Control of Ranges

Rbar1 = RbarA + RbarB + RbarC = 1.7340 = 0.5780

Operators 3

UCLR = D4 * Rbar1 = 2.58 * 0.5780 = 1.4912 = Range Upper Control Limit

Note: D4 is based on the number of trials. (See table below)

Repeatability (Gage Variation)

GV = Rbar1 * K1 = 0.5780 * 3.05 = 1.7629

Note: K1 is based on the number of trials. (See table below)

Reproduceability (Between Operator Variation)

Rbar2 = XbarLargest of ABC - XbarSmallest of ABC = 569.4940 - 569.3080 = 0.1860

2
/
 Gauge R&R Long Form Study
OV = (Rbar2 * K2) - (GV /(n*r)) =
2 2 ( 0.186* )2-(
2.7 2
1.763 / 10 * 3) = 0.3855

Note: K2 is based on the number of Operators. (See table below), n is the number of parts, r is the number of trials

Combined Reproduceability and Repeatability (Measurement Variation)

R&R = OV2 + GV2 = 0.38552 + 1.76292 = 1.8046

Part Variation

PV = RP * K3 = 0.6411 * 1.62 = 1.0386

Note: K3 is based on the number of parts. (See table below)

Total Variation

TV = R&R2 + PV2 = 1.80462 + 1.03862 = 2.0821

Table of Factors used in calculations from AIAG Manual for Measurement Systems Analysis, Chapter II, Section 4, Figure 19.
r D4 K1 Op. K2 n K3
2 3.27 4.56 2 3.65 9 1.67
3 2.58 3.05 3 2.7 10 1.62

% R&R (as a % of TV)

%R&R = R&R / TV = 1.8046 / 2.0821 = 86.67%

THE SUM OF THE PERCENT CONSUMED BY EACH FACTOR WILL NOT EQUAL 100%
This result for percent of total GR&R Error shall be evaluated in order to determine if the measurement system as
intended is acceptable for its application.

Guidelines for Judging the acceptance of the GR&R Error are:

-- Under 10% error - the measurement system is acceptable.
-- 10% - 30% error - may be acceptable based on importance of application, cost of gauge, cost to repair, etc.
-- Over 30% error - Measurement system must be improved. Follow the corrective action process to identify the root
cause of the problem and have them corrected.

Note: If Gage R&R as a % of TV fails to meet the above criteria, but the Gage R&R as a % of Tolerance Range
does meet the critera, then the gage is acceptable.

% R&R (as a % of Total Tolerance Range)

%R&R = R&R / Total Tolerance = 1.8046 / 0.6000 = 301%
 Gauge R&R Long Form Study
Study Number: Part No.: 421665 Performed By: Nutthapong
Gauge Name: Vernier Part Name: Cyclinder Bowl 68 Operator A: Kalaya
Gauge No.: Operation No.: Hoop diameter BB1 Operator B: Nisarat
Graduations: Characteristic: - Operator C: Rachanee
Zero Equals: Specification: 570.0 Area: Bowl line
Unit of Measure: mm. Total Tolerance: 0.6 Date: 4-Apr-04

Instructions:
1) Verify the gauge can read at least one additional degree of resolution than the part characteristic. Typically, a ten to one ratio of
tolerance to gauge resolution is required.
2) Verify the gauge is calibrated.
3) Perform study per section 5.1 of Instructions
4) Record results below. Type in shaded areas only. Note: "Total Tolerance" and "Operator Names" MUST be filled in for the form
to work properly.
5) Analyze the results to determine variability due to both Repeatability and Reproducibility.

Operator A: Kalaya Operator B: Nisarat Operator C: Rachanee

Sample Trials Sample Trials Sample Trials

Number 1 2 3 R Number 1 2 3 R Number 1 2 3 R
1 569.40 569.68 569.44 0.28 1 568.19 569.93 569.89 1.74 1 569.53 570.10 569.24 0.86
2 569.11 570.23 570.22 1.12 2 569.62 570.25 569.30 0.95 2 570.69 569.72 569.94 0.97
3 569.78 568.3 568.61 1.48 3 568.41 568.41 568.43 0.02 3 569.04 569.21 569.20 0.17
4 570.44 570.08 570.26 0.36 4 570.32 570.58 570.80 0.48 4 570.71 569.70 570.91 1.21
5 571.71 570.58 570.83 1.13 5 569.87 570.62 570.31 0.75 5 570.66 570.02 570.58 0.64
6 569.52 570.44 570.35 0.92 6 568.82 570.19 570.75 1.93 6 570.38 570.19 570.77 0.58
7 568.38 567.71 567.93 0.67 7 570.56 569.61 568.31 2.25 7 569.11 568.87 568.10 1.01
8 568.44 567.98 568.21 0.46 8 569.07 568.70 568.77 0.37 8 569.64 568.52 568.81 1.12
9 571.45 570.15 570.95 1.3 9 571.16 570.87 570.89 0.29 9 570.80 570.95 570.45 0.50
10 570.28 570.95 570.63 0.67 10 570.34 569.60 569.65 0.74 10 570.67 570.37 570.58 0.30
Totals 5698.5 5696.1 5697.4 8.39 Totals 5696.4 5698.76 5697.1 9.52 Totals 5701.2 5697.7 5698.6 7.36
Means 569.85 569.61 569.74 0.839 Means 569.64 569.876 569.71 0.952 Means 570.12 569.77 569.86 0.736
Xbar1 Xbar2 Xbar3 RbarA Xbar1 Xbar2 Xbar3 RbarB Xbar1 Xbar2 Xbar3 RbarC

XbarA = Xbar1 + Xbar2 + Xbar3 XbarB = Xbar1 + Xbar2 + Xbar3 XbarC = Xbar1 + Xbar2 + Xbar3
Trials Trials Trials

XbarA = 569.7347 XbarB = 569.7407 XbarC = 569.9153

Test for Statistical Control of Ranges

Rbar1 = RbarA + RbarB + RbarC = 2.5270 = 0.8423

Operators 3

UCLR = D4 * Rbar1 = 2.58 * 0.8423 = 2.1732 = Range Upper Control Limit

Note: D4 is based on the number of trials. (See table below)

Repeatability (Gage Variation)

GV = Rbar1 * K1 = 0.8423 * 3.05 = 2.5691

Note: K1 is based on the number of trials. (See table below)

Reproduceability (Between Operator Variation)

 Gauge R&R Long Form Study
Rbar2 = XbarLargest of ABC - XbarSmallest of ABC = 569.9153 - 569.7347 = 0.1807

OV = (Rbar2 * K2)2 - (GV2/(n*r)) = ( 0.181* )2-(

2.7 2
2.569 / 10 * 3) = 0.1339

Note: K2 is based on the number of Operators. (See table below), n is the number of parts, r is the number of trials

Combined Reproduceability and Repeatability (Measurement Variation)

R&R = OV2 + GV2 = 0.13392 + 2.56912 = 2.5726

Part Variation

PV = RP * K3 = 2.1700 * 1.62 = 3.5154

Note: K3 is based on the number of parts. (See table below)

Total Variation

TV = R&R2 + PV2 = 2.57262 + 3.51542 = 4.3562

Table of Factors used in calculations from AIAG Manual for Measurement Systems Analysis, Chapter II, Section 4, Figure 19.
r D4 K1 Op. K2 n K3
2 3.27 4.56 2 3.65 9 1.67
3 2.58 3.05 3 2.7 10 1.62

% R&R (as a % of TV)

%R&R = R&R / TV = 2.5726 / 4.3562 = 59%

THE SUM OF THE PERCENT CONSUMED BY EACH FACTOR WILL NOT EQUAL 100%
This result for percent of total GR&R Error shall be evaluated in order to determine if the measurement system as
intended is acceptable for its application.

Guidelines for Judging the acceptance of the GR&R Error are:

-- Under 10% error - the measurement system is acceptable.
-- 10% - 30% error - may be acceptable based on importance of application, cost of gauge, cost to repair, etc.
-- Over 30% error - Measurement system must be improved. Follow the corrective action process to identify the root
cause of the problem and have them corrected.

Note: If Gage R&R as a % of TV fails to meet the above criteria, but the Gage R&R as a % of Tolerance Range
does meet the critera, then the gage is acceptable.

% R&R (as a % of Total Tolerance Range)

%R&R = R&R / Total Tolerance = 2.5726 / 0.6000 = 429%
 Gauge R&R Long Form Study
Study Number: Part No.: 421665 Performed By: Nutthapong
Gauge Name: Vernier Part Name: Cyclinder Bowl 68 Operator A: Kalaya
Gauge No.: Operation No.: Flamge height BB1 Operator B: Nisarat
Graduations: Characteristic: - Operator C: Rachanee
Zero Equals: Specification: 11.5 Area: Bowl line
Unit of Measure: mm Total Tolerance: 1 Date: 4-Apr-04

Instructions:
1) Verify the gauge can read at least one additional degree of resolution than the part characteristic. Typically, a ten to one ratio
of tolerance to gauge resolution is required.
2) Verify the gauge is calibrated.
3) Perform study per section 5.1 of Instructions
4) Record results below. Type in shaded areas only. Note: "Total Tolerance" and "Operator Names" MUST be filled in for the
form to work properly.
5) Analyze the results to determine variability due to both Repeatability and Reproducibility.

Operator A: Kalaya Operator B: Nisarat Operator C: Rachanee

Sample Trials Sample Trials Sample Trials

Number 1 2 3 R Number 1 2 3 R Number 1 2 3 R
1 10.58 10.45 10.12 0.46 1 10.4 10.59 10.65 0.25 1 10.64 10.24 10.25 0.40
2 10.78 10.62 10.46 0.32 2 10.71 10.89 10.75 0.18 2 10.67 10.3 10.11 0.56
3 10.29 10.26 10.06 0.23 3 10.35 10.54 10.54 0.19 3 10.32 10.35 10.41 0.09
4 10.46 10.64 10.42 0.22 4 10.36 10.37 10.32 0.05 4 10.57 10.43 10.47 0.14
5 10.63 10.81 10.72 0.18 5 10.72 10.68 10.67 0.05 5 10.78 10.79 10.81 0.03
6 10.27 10.43 10.13 0.30 6 10.53 10.5 10.55 0.05 6 10.24 10.58 10.4 0.34
7 10.56 10.73 10.77 0.21 7 10.73 10.65 10.87 0.22 7 10.51 10.43 10.53 0.10
8 10.25 10.31 10.21 0.10 8 10.68 10.49 10.58 0.19 8 10.58 10.5 10.35 0.23
9 10.47 10.49 10.39 0.10 9 10.6 10.65 10.64 0.05 9 10.35 10.19 10.31 0.16
10 10.14 10.15 10.18 0.04 10 10.32 10.48 10.48 0.16 10 10.13 10.07 10.07 0.06
Totals 104.43 104.89 103.46 2.16 Totals 105.4 105.84 106.05 1.39 Totals 104.79 103.88 103.71 2.11
Means 10.443 10.489 10.346 0.216 Means 10.54 10.584 10.605 0.139 Means 10.479 10.388 10.371 0.211
Xbar1 Xbar2 Xbar3 RbarA Xbar1 Xbar2 Xbar3 RbarB Xbar1 Xbar2 Xbar3 RbarC

XbarA = Xbar1 + Xbar2 + Xbar3 XbarB = Xbar1 + Xbar2 + Xbar3 XbarC = Xbar1 + Xbar2 + Xbar3
Trials Trials Trials

XbarA = 10.4260 XbarB = 10.5763 XbarC = 10.4127

Test for Statistical Control of Ranges

Rbar1 = RbarA + RbarB + RbarC = 0.5660 = 0.1887

Operators 3

UCLR = D4 * Rbar1 = 2.58 * 0.1887 = 0.4868 = Range Upper Control Limit

Note: D4 is based on the number of trials. (See table below)

Repeatability (Gage Variation)

GV = Rbar1 * K1 = 0.1887 * 3.05 = 0.5754

Note: K1 is based on the number of trials. (See table below)

Reproduceability (Between Operator Variation)

 Gauge R&R Long Form Study
Rbar2 = XbarLargest of ABC - XbarSmallest of ABC = 10.5763 - 10.4127 = 0.1637

OV = (Rbar2 * K2)2 - (GV2/(n*r)) = ( 0.164* 2.7) -(

2 2
0.575 / 10 * 3) = 0.4292

Note: K2 is based on the number of Operators. (See table below), n is the number of parts, r is the number of trials

Combined Reproduceability and Repeatability (Measurement Variation)

R&R = OV2 + GV2 = 0.42922 + 0.57542 = 0.7179

Part Variation

PV = RP * K3 = 0.5100 * 1.62 = 0.8262

Note: K3 is based on the number of parts. (See table below)

Total Variation

TV = R&R2 + PV2 = 0.71792 + 0.82622 = 1.0945

Table of Factors used in calculations from AIAG Manual for Measurement Systems Analysis, Chapter II, Section 4, Figure 19.
r D4 K1 Op. K2 n K3
2 3.27 4.56 2 3.65 9 1.67
3 2.58 3.05 3 2.7 10 1.62

% R&R (as a % of TV)

%R&R = R&R / TV = 0.7179 / 1.0945 = 66%

THE SUM OF THE PERCENT CONSUMED BY EACH FACTOR WILL NOT EQUAL 100%
This result for percent of total GR&R Error shall be evaluated in order to determine if the measurement system as
intended is acceptable for its application.

Guidelines for Judging the acceptance of the GR&R Error are:

-- Under 10% error - the measurement system is acceptable.
-- 10% - 30% error - may be acceptable based on importance of application, cost of gauge, cost to repair, etc.
-- Over 30% error - Measurement system must be improved. Follow the corrective action process to identify the
root cause of the problem and have them corrected.

Note: If Gage R&R as a % of TV fails to meet the above criteria, but the Gage R&R as a % of Tolerance
Range does meet the critera, then the gage is acceptable.

% R&R (as a % of Total Tolerance Range)

%R&R = R&R / Total Tolerance = 0.7179 / 1.0000 = 72%
 Gauge R&R Long Form Study
Study Number: Part No.: 421665 Performed By: Nutthapong
Gauge Name: Vernier Part Name: Cyclinder Bowl 68 Operator A: Kalaya
Gauge No.: Operation No.: Flamge height BB1 Operator B: Nisarat
Graduations: Characteristic: - Operator C: Rachanee
Zero Equals: Specification: 11.5 Area: Bowl line
Unit of Measure: mm Total Tolerance: 1 Date: 4-Apr-04

Instructions:
1) Verify the gauge can read at least one additional degree of resolution than the part characteristic. Typically, a ten to one ratio
of tolerance to gauge resolution is required.
2) Verify the gauge is calibrated.
3) Perform study per section 5.1 of Instructions
4) Record results below. Type in shaded areas only. Note: "Total Tolerance" and "Operator Names" MUST be filled in for the
form to work properly.
5) Analyze the results to determine variability due to both Repeatability and Reproducibility.

Operator A: Kalaya Operator B: Nisarat Operator C: Rachanee

Sample Trials Sample Trials Sample Trials

Number 1 2 3 R Number 1 2 3 R Number 1 2 3 R
1 11.29 11.18 11.19 0.11 1 11.41 11.43 11.49 0.08 1 11.46 11.26 11.31 0.20
2 11.35 11.38 11.33 0.05 2 11.41 11.36 11.44 0.08 2 11.60 11.04 11.1 0.56
3 11.68 11.61 11.71 0.10 3 11.64 11.73 11.7 0.09 3 11.80 11.81 11.75 0.06
4 11.77 11.8 11.8 0.03 4 11.57 11.82 11.62 0.25 4 11.69 11.77 11.7 0.08
5 11.46 11.23 11.35 0.23 5 11.31 11.35 11.37 0.06 5 11.24 11.19 11.14 0.10
6 11.49 11.27 11.25 0.24 6 11.48 11.45 11.44 0.04 6 11.45 11.63 11.63 0.18
7 11.28 11.26 11.29 0.03 7 11.33 11.28 11.18 0.15 7 11.40 11.27 11.16 0.24
8 11.22 11.59 11.47 0.37 8 11.48 11.3 11.45 0.18 8 11.60 11.55 11.53 0.07
9 11.46 11.18 11.52 0.34 9 11.41 11.57 11.55 0.16 9 11.33 11.38 11.52 0.19
10 11.84 11.76 11.79 0.08 10 11.71 11.74 11.73 0.03 10 11.57 11.76 11.53 0.23
Totals 114.84 114.26 114.7 1.58 Totals 114.75 115.03 114.97 1.12 Totals 115.14 114.66 114.37 1.91
Means 11.484 11.426 11.47 0.158 Means 11.475 11.503 11.497 0.112 Means 11.514 11.466 11.437 0.191
Xbar1 Xbar2 Xbar3 RbarA Xbar1 Xbar2 Xbar3 RbarB Xbar1 Xbar2 Xbar3 RbarC

XbarA = Xbar1 + Xbar2 + Xbar3 XbarB = Xbar1 + Xbar2 + Xbar3 XbarC = Xbar1 + Xbar2 + Xbar3
Trials Trials Trials

XbarA = 11.4600 XbarB = 11.4917 XbarC = 11.4723

Test for Statistical Control of Ranges

Rbar1 = RbarA + RbarB + RbarC = 0.4610 = 0.1537

Operators 3

UCLR = D4 * Rbar1 = 2.58 * 0.1537 = 0.3965 = Range Upper Control Limit

Note: D4 is based on the number of trials. (See table below)

Repeatability (Gage Variation)

GV = Rbar1 * K1 = 0.1537 * 3.05 = 0.4687

Note: K1 is based on the number of trials. (See table below)

Reproduceability (Between Operator Variation)

 Gauge R&R Long Form Study
Rbar2 = XbarLargest of ABC - XbarSmallest of ABC = 11.4917 - 11.4600 = 0.0317

2
( 0.032* 2.7) -( 0.469 / 10 * 3)
2
OV = (Rbar2 * K2)2 - (GV2/(n*r)) = = 0.0000

Note: K2 is based on the number of Operators. (See table below), n is the number of parts, r is the number of trials

Combined Reproduceability and Repeatability (Measurement Variation)

R&R = OV2 + GV2 = 0.00002 + 0.46872 = 0.4687

Part Variation

PV = RP * K3 = 0.4544 * 1.62 = 0.7362

Note: K3 is based on the number of parts. (See table below)

Total Variation

TV = R&R2 + PV2 = 0.46872 + 0.73622 = 0.8727

Table of Factors used in calculations from AIAG Manual for Measurement Systems Analysis, Chapter II, Section 4, Figure 19.
r D4 K1 Op. K2 n K3
2 3.27 4.56 2 3.65 9 1.67
3 2.58 3.05 3 2.7 10 1.62

% R&R (as a % of TV)

%R&R = R&R / TV = 0.4687 / 0.8727 = 54%

THE SUM OF THE PERCENT CONSUMED BY EACH FACTOR WILL NOT EQUAL 100%
This result for percent of total GR&R Error shall be evaluated in order to determine if the measurement system as
intended is acceptable for its application.

Guidelines for Judging the acceptance of the GR&R Error are:

-- Under 10% error - the measurement system is acceptable.
-- 10% - 30% error - may be acceptable based on importance of application, cost of gauge, cost to repair, etc.
-- Over 30% error - Measurement system must be improved. Follow the corrective action process to identify the
root cause of the problem and have them corrected.

Note: If Gage R&R as a % of TV fails to meet the above criteria, but the Gage R&R as a % of Tolerance
Range does meet the critera, then the gage is acceptable.

% R&R (as a % of Total Tolerance Range)

%R&R = R&R / Total Tolerance = 0.4687 / 1.0000 = 47%