Gage

R&R (Repeatability & Reproducibility)

Chapter IV: R&R Studies

Plan
IV-1. Generalities
IV-1-1. Objective and principle
IV-1-2. Definitions
IV-1-3. Different methods measuring the suitability of a means of
measure
IV-2. Method of Range
IV-2-1. Principle
IV-2-2. Method: estimation of the R&R variability
IV-2-3. Tolerance analysis

IV-3. Method of the mean and range

IV-3-1. Principle
IV-3-2. Estimation of Repeatability
IV-3-3. Estimation of reproducibility
IV-3-4. Tolerance analysis
 Chapter IV: R&R Studies
IV-1. Generalities

Objective and
principle To improve the quality of production, it is necessary to ensure that
Definitions the characteristics of quality can be measured by
sufficiently accurately to estimate the impact of
Different
methods modifications made to the process

Æ An R&R analysis allows to quantify errors of

measures by estimating the repeatability and reproducibility of
measuring process
Æ Indicate the reliability of the recorded measurements

Chapter IV: R&R Studies

IV-1. Generalities

Objective and

principle Measurement: A set of operations aimed at

Definitions determine a value of a quantity
Different
Measurement: a particular magnitude subject to measurement
methods

Repeatability r (of measurement results): narrowness of

the agreement between the results of successive measurements of the same
measuring, measurements carried out in the entirety of the same
measurement conditions (same operator, same instrument,
same environment, same measurement time

Reproducibility R (of measurement results): narrowness

of the agreement, between the measurement results of the same
measuring, measurements taken by varying the conditions
of measurement
 Chapter IV: R&R Studies
IV-1. Generalities

Objective and
principle 2 main methods
Definitions

Different Æ the range method

methods
Difference between the maximum and minimum value of a series
measure

Æ the method of average and range

Range method)
Takes into account both the trend characteristic
(mean) and the characteristic of dispersion

Chapter IV: Studies R&R

IV-2. Average and Range Method
Prince

Each operator repeats the measurement several times.

Estimation of the
repeatability characteristic on the same piece.
Estimation of her
reproducibility

Analysisofthe
Tolerance

The method of the average and the range allows to

determine separately the dispersion due to Repeatability and to
Reproducibility through the repetition of measurements.
 Chapter IV: R&R Studies
IV-2. Average and Range Method
Prince

Estimation of her
repeatability

Estimation of it
reproducibility

Analysisofthe
Tolerance

Æ A lot of information about the differences between operators

and on the overall measurement process can be obtained

Æ The analysis allows for quantifying the extent of errors on the

measures and compare them to the tolerance

Chapter IV: R&R Studies

IV-2. Average and Range Method
Principle

Estimation of it
Let it beYijm: the observed value
repeatability
the index representing the different pieces
Estimation of it
reproducibility
j: the index referring to the operators
Analysisofthe
the repetition index
Tolerance

Yijm
ijm
= μi+i b + ai+ βi j+ ejijm ijm

μiTrue value
b: bias of the measuring instrument
aIthe dispersion due to the piece
βjeffect of operator j on measurement (reproducibility)
eijmerror due to the measuring instrument itself (repeatability)
 Chapter IV: R&R Studies
IV-2. Average and Range Method
Prince

Estimation of the
repeatability

Estimation of her
Yijm= μi+ b + ai+ βj+ eijm
reproducibility

Analysisofthe
Tolerance

Var(Yijm=var(ai) + var(βj) + var(eijm)

Var(Yijm
ijm
)=σ² + σ²R+
R
σ² rr

Chapter IV: R&R Studies

IV-2. Average and Range Method
Principle

Estimation of her Estimation of repeatability

repeatability

Estimation of the
Æ EV Indicator
reproducibility

Analysisofthe
Tolerance
SoitRijthe extent of the measures for a part and an operator
:
Rij= max(Yij-min(Yij)

Var(R)=
ijij 2σ²
Var(R)= 2σ²
2σ²r=r 2σ² Yijm
Yijm

R R
WithσYijm = =
d2(g,h) d2(n*p,m)
 Chapter IV: R&R Studies
IV-2. Average and Range Method
Principle

Estimation of it
Definition of a confidence interval for dispersion for
repeatability
which has (1-a)% chance that the true value is there
Estimation of her
reproducibility

Analysisofthe
Tolerance
EV=
EV= 22σσYijmUU
Yijm 1-a/2
1-a/2
σσYYiijjmm= R/(d22(n*p,m))
(n*p, m)

2U1-a/2
EV= R
d2(n*p,m)

Chapter IV: R&R Studies

IV-2. Average and Range Method
Prince

Estimation of it Most commonly used case in practice

repeatability

Estimation of her
reproducibility
n=3 (3 operators)
Analysisofthe p=10 (10 pieces)
Tolerance
m=3 (3 repetitions per piece)
99% confidence interval
5.15 d2(30,3) = 1.693
EV= R EV = 3.05 * R
d2(30,3)

EV
EV ==KK
1 *1*R
R

Number of repetitions 2 3

K1 4.56 3.05
 Chapter IV: R&R Studies
IV-2. Average and Range Method
Principle

Estimation of it
Estimation of reproducibility
repeatability
Æ IndicatorAV
Estimation of her
reproducibility
Let Y.j be the average of all measurements for operator j
Analysisofthe
Tolerance etRdiffthe range between these different averages
Rdiff= ( βj- βj’) + (e.j.– e.j’.)

σ² r
Var(Rdiff) = 2 * var(Y.j. ) = 2(σ²R+ p m )

aR
L
nV
ec(adiff
irv is therefore the function of repeatability and
reproducibility andRdiffisanestimateofσy.j
Rdiff Rdiff σ² r
σY.j.= = = σ²R+
d2(g,h) d2(1,m) P*m

Chapter IV: R&R Studies

IV-2. Average and Range Method
Principle
A confidence interval is defined with a threshold of
Estimation of it
repeatability trust.
Estimation of her
reproducibility Rdiff σ² r
Analysisofthe
σ.Yj. = = σ ² R+
Tolerance A
V=2σRU1-a/2 d 2(1,m) P*m

2
2U1- α /2 *Rdiff EV²
AV=
d2(1,m)
P*m
 Chapter IV: R&R Studies
IV-2. Average and Range Method
Principle

Estimation of her
Most commonly used case in practice
repeatability

Estimation of her
reproducibility
n=3 (3 operators)
Analysisofthe
p=10 (10 coins)
Tolerance m=3 (3 repetitions per piece)
99% confidence interval
2
EV squared
AV= 2.70*Rdiff
30
2
K2*RdIff EV ²
AV=
p*m

Operator Number 2 3
K2 3.65 2.70

Chapter IV: R&R Studies

IV-2. Average and Range Method
Principle

Measurement of Repeatability and Reproducibility R&R

Estimation of it
repeatability

Estimation of her
reproducibility

Analysisofthe
Tolerance Æ R&R= AV ² + EV ²

EV
Æ % EV = 100 Tolerance Interval
IT

Æ % AV = 100 AV
IT

Æ %R&R= (%AV)² + (%EV)²

 Chapter IV: R&R Studies
IV-2. Average and Range Method
Principle

Estimation of her
Interpretation
repeatability

Estimation of her
reproducibility Æ%R&R ≤ 10%
Analysisofthe
Tolerance Measuring instrument considered acceptable

Æ10% < %R&R < 30%

Acceptable but must be checked and monitored

Æ%R&R≥ 30%
The measuring device must be modified or improved.

Chapter IV: R&R Studies

IV-2. Average and Range Method
Prince

Example
Estimation of it
repeatability Operator 1 Operator 2 Operator 3
Echantillon Mesure 1 Mesure 2 Etendue Mesure 1 Mesure 2 Etendue Mesure 1 Mesure 2 Etendue
Estimation of it
1 28.92 28.92 28.92 28,92 28,92 28.92
reproducibility
2 28.91 28.91 28.91 28.91 28.9 28.91
Analysisofthe 3 28.91 28.9 28.91 28.91 28.9 28.9
Tolerance 4 28.91 28.92 28.91 28.91 28.91 28,91
5 28,91 28.91 28.92 28.91 28.91 28.91
6 28.9 28.91 28.91 28,91 28,92 28.91
7 28.9 28.91 28.9 28.91 28.9 28.9
8 29.03 29.03 29.03 29.03 29.03 29.02
9 29.04 29.03 29.03 29.02 29.03 29.03
10 29.02 29.02 29.02 29.02 29.02 29.02
 Chapter IV: R&R Studies
IV-2. Average and Range Method
Principle

Example
Estimation of her
Operator 1 Operator 2 Operator 3
repeatability
Echantillon Mesure 1 Mesure 2 Etendue Mesure 1 Mesure 2 Etendue Mesure 1 Mesure 2 Etendue
1 28.92 28.92 0 28.92 28,92 0 28.92 28.92 0
Estimation of it
reproducibility 2 28.91 28,91 0 28.91 28.91 0 28.9 28.91 0.01
3 28,91 28.9 0.01 28.91 28.91 0 28.9 28.9 0
Analysisofthe 4 28.91 28.92 0.01 28.91 28.91 0 28.91 28.91 0
Tolerance 5 28.91 28.91 0 28,92 28.91 0.01 28.91 28.91 0
6 28.9 28.91 0.01 28.91 28.91 0 28.92 28.91 0.01
7 28.9 28.91 0.01 28.9 28.91 0.01 28.9 28.9 0
8 29.03 29.03 0 29.03 29.03 0 29.03 29.02 0.01
9 29.04 29.03 0.01 29.03 29.02 0.01 29.03 29.03 0
10 29.02 29.02 0 29.02 29.02 0 29.02 29.02 0
average 28,945 28,946 average 28,946 28,945 average 28,944 28,943

Chapter IV: R&R Studies

IV-2. Average and Range Method
Principle

Example
Estimation of it
repeatability Operator 1 Operator 2 Operator 3
Echantillon Mesure 1 Mesure 2 Etendue Mesure 1 Mesure 2 Etendue Mesure 1 Mesure 2 Etendue
Estimation of it 1 28.92 28.92 0 28.92 28,92 0 28,92 28,92 0
reproducibility 2 28.91 28,91 0 28.91 28.91 0 28.9 28.91 0.01
3 28.91 28.9 0.01 28,91 28,91 0 28,9 28.9 0
Analysisofthe 4 28.91 28.92 0.01 28.91 28.91 0 28.91 28.91 0
Tolerance 5 28,91 28.91 0 28.92 28.91 0.01 28.91 28.91 0
6 28.9 28.91 0.01 28.91 28.91 0 28.92 28.91 0.01
7 28.9 28,91 0.01 28.9 28,91 0.01 28.9 28.9 0
8 29.03 29.03 0 29.03 29.03 0 29.03 29.02 0.01
9 29.04 29.03 0.01 29.03 29.02 0.01 29.03 29.03 0
10 29.02 29.02 0 29.02 29.02 0 29.02 29.02 0
average 28,945 28,946 average 28,946 28,945 average 28,944 28,943
28,945 28,946 28,944
28,946 28,945 28,943
R1 0.005 R2 0.003 R3 0.003
Xbar 28,9455 Xbar 28.9455 Xbar 28.9435
 Chapter IV: R&R Studies
IV-2. Average and Range Method
Prince

Example
Estimation of it
Operator 1 Operator 2 Operator 3
repeatability
Echantillon Mesure 1 Mesure 2 Etendue Mesure 1 Mesure 2 Etendue Mesure 1 Mesure 2 Etendue
Estimation of her 1 28.92 28,92 0 28.92 28,92 0 28,92 28.92 0
reproducibility 2 28.91 28.91 0 28.91 28,91 0 28.9 28.91 0.01
3 28.91 28.9 0.01 28.91 28,91 0 28.9 28.9 0
Analysisofthe 4 28.91 28.92 0.01 28.91 28,91 0 28,91 28.91 0
Tolerance 5 28.91 28,91 0 28,92 28.91 0.01 28.91 28.91 0
6 28.9 28.91 0.01 28.91 28.91 0 28.92 28.91 0.01
7 28.9 28.91 0.01 28.9 28,91 0.01 28.9 28.9 0
8 29.03 29.03 0 29.03 29.03 0 29.03 29.02 0.01
9 29.04 29.03 0.01 29.03 29.02 0.01 29.03 29.03 0
10 29.02 29.02 0 29.02 29.02 0 29.02 29.02 0
average 28,945 28,946 average 28,946 28,945 average 28,944 28,943
28,945 28,946 28,944
28,946 28,945 28,943
R1 0.005 R2 0.003 R3 0.003
Xbar 28.9455 Xbar 28.9455 Xbar 28.9435

Rbarbar0.003667 Tolerance 0.021

K1 4.56 E.V 0.01672% E.V. 79,61905
K2 2.7 A.V 0.003896%A.V 18.55438
R&R 0.017168% R&R 81,75242
R diff 0.002

Chapter IV: R&R Studies

IV-2. Average and Range Method
Prince

Note: control chart

Estimation of the
repeatability

Estimation of it
reproducibility Operator1 Operator2 Operator3
LSC
Analysisofthe
Tolerance

LIC

Æ Control chart of ranges

Æ Control chart of averages

 Chapter IV: R&R Studies
IV-2. Average and Range Method
Prince

Æ Control chart of expanses

Estimation of her
repeatability

Estimation of it LSCR= D4*R

reproducibility
LICR= D3*R
Analysisofthe
Tolerance

Interpretation:

Æ If all the points are within the control limits,

So the measurement method is common to all operators.

Æ If an operator has one or more points outside the

the limits of her measurement method differ from the other two

Æ If all operators present values outside of

control limits, the measurement method is too sensitive to
operators. In this case, we must absolutely take a close look at the
method and measurement instrument

Chapter IV: R&R Studies

IV-2. Average and Range Method
Prince

Estimation of it
Æ Control chart of the averages
repeatability

Estimation of it LSCx= X + A2*R

reproducibility
LICx= X - A2*R
Analysisofthe
Tolerance

Interpretation:

Æ If all measurements are within the limits of

control, the dispersion of the measuring instrument is much
more important than the dispersion due to the process

Æ If half or more of the values are outside the limits of

control, we can judge that the measurement system is capable