Professional Documents
Culture Documents
Learning Objectives
Measurement Systems
Measurement systems are like eyeglasses, when the
lenses are incorrect, the vision is blurred.
A measurement system allows us to see the process.
When a measurement system is poor, we lose the ability to
make good decisions about how to improve the process
In the Measure Phase of the DMAIC process, the MSA
should be conducted on the Y or KPOV
In the Control Phase of the DMAIC process, the MSA
should be conducted on the critical few Xs or KPIV
Basic Concepts
Every process produces a product or service
Every product or service possesses requirements
Every requirement can be measured
The total observed variation is equal to the real product
variation plus the variation due to the measurement system
Note: We want most of the variation coming from the
Product/Part and very little coming from the Measuring
System
2
2
2
Total
= Process/ + Measurement System
Part/
Service
Process
Measurement
Measurement
LSL
Target
USL
Accuracy
Current
Desired
LSL
9
Target
USL
Precision
10
True
Value
Bias
Mean
11
Mean
Instrument 1
Instrument 2
12
Precision
In addition to accuracy, it is important for a measurement
system to be precise
Precision
True
Value
Bias
Mean
13
Discrimination
Discrimination is the capability of detecting small changes in the characteristic
The instrument may not be appropriate to identify process variation or quantify
individual part characteristic values if the discrimination is unacceptable
If an instrument does not allow differentiation between common variation in the
process and special cause variation, it is unsatisfactory
A common cause to MSA failure can be attributed to rounding up or down
measurements
.28
.279
.2794
14
.28
.282
.2822
Ruler
Caliper
Micrometer
.28
.282
.2819
.28
.279
.2791
Stability
If measurements do not change or drift over time, the
instrument is considered to be stable
Time One
Time Two
15
Linearity
A measure of the difference in bias (or offset) over the range of
the sample characteristic the instrument is expected to see
determines linearity. If the bias is constant over the range of
measurements, then linearity is good
Over what range of values for a given characteristic can the
device be used?
When the measurement equipment is used to measure a wide range of values, linearity is a
concern
Measurement
Variation
Low
End
16
Measurement Scale
High
End
2
2
Measurement = Repeatability
+ Reproducibility
System
2
MS
2
rpt
2
rpd
17
= +
2
rpd
Operator B
Operator C
%R&R = 20%
Measurement
System Variation
%R&R = 75%
%R&R = 100%
20
Rule of Thumb:
We want
%R&R < 30%
21
Usually
expressed
as
percent
22
Acceptability Summary
% Contribution
% Study
Variation
% Tolerance
10%
30%
30%
1%
10%
10%
10
Process
Control
Product
Control
Number of
Distinct
Categories
Gage R&R
The objective of a Gage R&R study is to learn as much as possible
about the measurement process in a short amount of time
The strategy is to include equipment, operators, parts, and other factors
that will usually be elements of the measurement process
Make careful selection of parts (or samples) representing the entire
range of process variation. (Good and Bad to the entire specification)
The parts should be labeled in such a way to preclude operator
identification and therefore remove possible operator bias
Each part will then be measured multiple times in random sequence by
each operator using the same equipment. This can be replicated for
each equipment set
Verify that an on-going calibration, maintenance, and metrology
program exists and is current on the measurement system
24
25
26
27
28
2. R Chart by Operator
Repeatability is checked by using a special Range Chart where the
differences in the measurements by each operator on each part is
charted. If the difference between the largest value of a measured part
and the smallest value of the same part does not exceed the UCL,
then that gage and operator are considered to be Repeatable
It is desirable to see plots that consistently go outside the UCL and LCL because
limits are determined by gage variance and these plots should show that gage
variance is much smaller than variability between the parts
If the samples chosen do not represent the total variability of the process, the
gage (repeatability) variance may be larger than the part variance and invalidate
the distinct categories calculation
If the patterns of the operators are not comparable, there may be significant
operator and part interactions (discussed on another slide)
30
4. Response by Part
This graph shows the data for all ten parts for all operators plotted
together. It should show plots that vary from the smallest dimensions
for the parts made by the process to the largest dimensions for the
same parts. Parts should be both in tolerance and out of tolerance if the
process makes them
If a part shows a large spread, it may be a poor candidate for the test
because the feature may not be clear on that part
31
5. Response by Operator
This graph shows the data for all ten parts for plotted by each operator.
The line connecting the averages (shown as the circle with crosshairs)
of all 10 parts measured by each operator should be horizontal
Any significant slope is an indication that this operator has a general
bias to measure large or small when compared to the other operators
32
33
Minitab Sixpack
34
Case Study # 1
Selection of parts to be tested
10 parts randomly selected
Good, bad & average parts used
Instructions to operators
Perform tests as normal
Report variance
Tests conducted
10 parts tested
2 operators
3 checks on each of the 10 parts
given to the operator in random order
37
MSA
Tree
MSA
Part 1
Part 2
Part 3
Operator
1
Repeat 1
38
Repeat 2
Part 4
Part 5
Part 6
Part 7
Operator
2
Operator
1
Repeat 3
Repeat 1
Part 8
Part 9
Operator
2
Repeat 2
Repeat 3
Part 10
39
<30%
>5
40
Case Study # 2
MSA Bolt Torque
41
42
Operator
Part 1
Part 2
Part 3
Part 4
Part 5
Part 6
Part 7
Part 8
Part 9
Part
10
Operator
1
Sample
1
43
Part
11
Part
12
Operator
2
Sample
2
Sample
1
Sample
2
Part
13
Part
14
Part
15
Part
16
Minitab Data
44
45
Minitab Data
46
Minitab Data
47
Minitab Data
48
Q & A Session