Gage Repeatability & Reproducibility
Introduction
What is a Gage R&R Definitions Standards that companies use Examples of Gage R&Rs
What will not be covered
The Equations for Gage R&R
There are many statistics programs Go to [Link] and type in Gage R&R and there are work sheets
Example
Thickness
0.0440
0.0430
Reading
0.0420
0.0410
0.0400 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Count 17 18 19 20 21 22 23 24 25 26 27 28 29 30
What is a Gage R&R?
A method to check whether a gage is capable of making the appropriate measurements. Doing an Analysis of Variation (ANOVA) of a group of readings to ensure measurement precision and reliability The gage is a constant
What is a Gage R&R?
A measurement is characterized by Location (accuracy, stability and linearity metrics) and Spread (repeatability and reproducibility). A Gage R&R measures spread
Definitions
Variation
the differences within a piece, from piece to piece, measurement to measurement, and other variation such as process step to process step, etc.
Every process has variation including in the measuring gage Want to make sure that variation in the gage is acceptable
Definitions
Accuracy
Bias. Difference between an average of a number of measurements and the true value
Gage must be accurate Test for accuracy is calibration The Gage must be calibrated
Definitions
Repeatability
Precision. The ability to repeat the measurements by the same operator at or near the same time
Reproducibility
Reliability. The ability to reproduce the measurements by different operators at different times.
Methodology
Standards
What are some standards that companies such as GE are using for acceptable gages?
Standards
For gages that are used to make pass/fail decisions < 30% of the process variation can come from the gage For gages that are used to measure improvements in the process < 10% of the process variation can come from the gage
Any Questions?
Examples from the simplest measuring gages to more complicated equipment
Example of a simple Gage R&R
A micrometer is tested by having 3 people measure 5 to 10 parts 3 times each in random order
Part Inspector Nick Number 1 2 3 4 5 6 7 8 9 10
Individual 1st set 4.822 4.81 4.808 4.796 4.818 4.811 4.816 4.809 4.809 4.811
Readings 2nd set 4.823 4.811 4.814 4.795 4.817 4.815 4.801 4.817 4.808 4.802 3rd set 4.826 4.813 4.81 4.813 4.816 4.812 4.813 4.81 4.811 4.808
Part Inspector Roy Number 1 2 3 4 5 6 7 8 9 10
Individual Readings 1st set 4.826 4.803 4.834 4.8 4.816 4.804 4.821 4.814 4.811 4.806 2nd set 4.827 4.811 4.812 4.808 4.834 4.796 4.806 4.827 4.815 4.816 3rd set 4.817 4.815 4.794 4.803 4.811 4.812 4.813 4.824 4.813 4.81
Part Inspector Greg Number 1 2 3 4 5 6 7 8 9 10
Individual 1st set 4.845 4.831 4.808 4.814 4.812 4.828 4.812 4.799 4.804 4.809
Readings 2nd set 4.821 4.819 4.815 4.807 4.81 4.82 4.81 4.79 4.809 4.791 3rd set 4.813 4.812 4.819 4.814 4.816 4.813 4.809 4.819 4.801 4.8
Results
Gage R&R
Source Total Gage R&R Repeatability Reproducibility Operator Operator*Sample Part-To-Part Total Variation
Sigma2 7.29E-05 6.20E-05 1.09E-05 0.00E+00 1.09E-05 1.92E-05 9.21E-05
%Contribution (of Sigma2) 79.12 67.27 11.85 0.00 11.85 20.88 100.00
Results
Gage R&R (ANOVA) for Measurement
Com ponents of Variation
100 %Contribution 4.85 4.84 4.83 50 4.82 4.81 4.80 0 Gage R&R Repeat Reprod Part-to-Part 4.79
Gage name: Date of study: Reported by: Tolerance: Misc:
Micrometer Dav Potty e
By Sam ple
Percent
Sample
4.85 UCL=0.03183 4.84 4.83 4.82 R=0.01237 LCL=0 4.81 4.80 4.79
10
R Chart by Operator
Sample Range
0.04 0.03 0.02 0.01 0.00 0
Greg Nick Roy
By Operator
Operator
Greg
Nick
Roy
Xbar Chart by Operator
4.83
Greg Nick Roy
Operator*Sam Interaction ple
UCL=4.825
Operator
Greg Nick Roy
Sample M ean
4.81 4.80 0
M ean=4.812
Average
4.82
4.82 4.81 4.80
LCL=4.800
Sample
10
Example of a more complicated Gage R&R
We had a continuous measurement of width of a flat wire We measure a standard 10 times and compared the measurements
Calculation
T W i t h i n p a r t V a r i a t i o n
t a l o f o b s e V a r i a t i o n
r v e
s u
r e
r i a
t i o
Data
Average SD Count 4.7473 0.0309 990 4.7479 0.0058 1008 4.7485 0.0064 983 4.7484 0.0055 979 4.7483 0.0065 986 4.7484 0.0056 984 4.7477 0.0067 987 4.7480 0.0056 979 4.7493 0.0060 987 4.7486 0.0056 976
Width
Grand Average = 4.748 Grand SD = 0.011 Wire variation = 0.005 Measurement variation = 0.010 99% CB = 5.15 * measurement variation 99% CB = 0.051
Summary
Width Measurement variation Tolerance GRR (tolerance) 0.051 0.250 20.4%
Review
What is a Gage R&R Definitions Standards that companies use Examples of Gage R&Rs
Any Questions?
Thank You!
