AIAG Gage R&R

Average & Range Met

Appraiser 1
Trial 1
Trial2
Trial3
Appraiser 2
Trial 1
Trial2
Trial3
Appraiser 3
Trial 1
Trial2
Trial3

1
0.29
0.41
0.64
0.08
0.25
0.07
0.04
-0.11
-0.15

2
-0.56
-0.68
-0.58
-0.47
-1.22
-0.68
-1.38
-1.13
-0.96

3
1.34
1.17
1.27
1.19
0.94
1.34
0.88
1.09
0.67

4
0.47
0.5
0.64
0.01
1.03
0.2
0.14
0.2
0.11

Part Number
5
6
-0.8
0.02
-0.92
-0.11
-0.84
-0.21
-0.56
-0.2
-1.2
0.22
-1.28
0.06
-1.46
-0.29
-1.07
-0.67
-1.45
-0.49

7
0.59
0.75
0.66
0.47
0.55
0.83
0.02
0.01
0.21

Ford Verification Data

Appraiser 1
Trial 1 3.63957 3.93548 3.84455 4.1651 4.28118 3.43333 3.80442
Trial2
3.57531 3.93015 3.88189 4.22454 4.30886 3.44552 3.84481
Trial3
3.61748 3.89916 3.79324 4.18314 4.25248 3.36779 3.78816
Appraiser 2

Trial 1
Trial2
Trial3

3.58826 3.91847 3.85039 4.16154 4.22682 3.40564 3.80264

3.62865 3.90653 3.84887 4.20828 4.23444 3.39446 3.80366
3.63094 3.94514 3.8509 4.23495 4.27788 3.39599 3.8001

Appraiser 3

Trial 1
Trial2
Trial3

3.57734 3.88087 3.85293 4.17678 4.26467 3.43282 3.81052

3.58268 3.87173 3.78054 4.16129 4.23876 3.37973 3.79959
3.62865 3.87351 3.7968 4.1745 4.19888 3.3998 3.78664

Specification Tolerance = 2
Gage R&R as a percent of tolerance using the ANOVA
Outputs
Method
(See
System
Analysis
Third
Gage
R&R
as Measurement
a percentRequired
of study
variation
using
the
Edition)
ANOVA
Method
(See
Measurement
System
Analysis
Gage R&R as a percent of tolerance using the Average
Third
Edition)
and Range
Method
(Seeof
Measurement
System
Gage
R&R as
a percent
study variation
usingAnalysis
the
Third Edition)
Average
and Range Method (See Measurement System
Analysis Third Edition)
Number of distinct categories

8.23
9.74
8.27
10.28
14

Attribute
8
-0.31
-0.2
-0.17
-0.63
0.08
-0.34
-0.46
-0.56
-0.49

9
2.26
1.99
2.01
1.8
2.12
2.19
1.77
1.45
1.87

10
-1.36
-1.25
-1.31
-1.68
-1.62
-1.5
-1.49
-1.77
-2.16

3.93066 4.14554 4.22784

3.90602 4.15316 4.21844
3.89789 4.19837 4.24714
3.86563 4.14732 4.22073
3.84912 4.09804 4.2187
3.87503 4.1237 4.21311
3.85141 4.14072 4.22352
3.8857 4.15189 4.21133
3.85217 4.12522 4.22454

MSA 3rd

USL=0.545
LSL=0.45

Appraiser A
Part #

Appraiser B

Trial 1

Trial 2

Trial 3

Trial 1

Trial 2

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
32
33

1
1
0
0
0
1
1
1
0
1
1
0
1
1
1
1
1
1
1
1
1
0
1
1
1
1

1
1
0
0
0
1
1
1
0
1
1
0
1
1
1
1
1
1
1
1
1
0
1
1
1
1

1
1
0
0
0
0
1
1
0
1
1
0
1
0
1
1
1
1
1
1
0
1
1
1
1
1

1
1
0
0
0
1
1
1
0
1
1
0
1
1
1
1
1
1
1
1
1
0
1
1
1
1

1
1
0
0
0
1
1
1
0
1
1
0
1
1
1
1
1
1
1
1
0
1
1
1
1
1

25
26
27
28
29
30
31
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48

0
0
1
1
1
0
1
0
1
1
0
1
0
1
1
0
1
1
0
1
1
0

0
1
1
1
1
0
1
0
1
1
0
1
0
1
1
0
0
1
0
1
1
0

0
0
1
1
1
0
1
1
1
0
0
1
0
1
1
0
1
1
0
1
1
0

0
0
1
1
1
0
1
0
1
1
0
1
0
1
1
0
1
1
0
1
1
0

0
0
1
1
1
0
1
0
1
1
0
1
0
1
1
0
1
1
0
1
1
0

49
50

1
0

1
0

1
0

1
0

1
0

Appraiser B

Appraiser C

Appraiser A

Trial 3

Trial 1

Trial 2

Trial 3

1
1
0
0
0
0
1
1
0
1
1
0
1
1
1
1
1
1
1
1
1
0
1
1
1
1

1
1
0
0
0
1
1
1
0
1
1
0
1
1
1
1
1
1
1
1
0
1
1
1
1
1

1
1
0
0
0
0
0
1
0
1
1
1
1
0
1
1
1
1
1
1
1
1
1
1
1
1

1
1
0
0
0
0
1
1
0
1
1
0
1
0
1
1
1
1
1
1
0
0
1
1
1
1

Ref Value
0.476901
0.509015
0.5736459
0.566152
0.57036
0.544951
0.465454
0.502295
0.437817
0.515573
0.488905
0.559918
0.541704
0.454518
0.517377
0.531939
0.519694
0.484167
0.520496
0.477236
0.45231
0.545604
0.529065
0.514192
0.50585
0.487613

0
0
1
1
1
1
1
1
1
1
0
1
0
1
1
0
1
1
0
1
1
0

0
0
1
1
1
0
1
0
1
1
0
1
0
1
1
0
1
1
0
1
1
0

0
0
1
1
1
0
1
1
1
0
0
1
0
1
1
0
1
1
0
1
1
0

0
1
1
1
1
0
1
1
1
1
0
1
0
1
1
0
0
1
0
1
1
0

0.599581
0.547204
0.502436
0.521642
0.523754
0.561457
0.503094
0.449696
0.498698
0.543077
0.409238
0.488184
0.427687
0.501132
0.513779
0.566575
0.46241
0.470832
0.412453
0.493441
0.486379
0.587893

Part #

Trial 1

Trial 2

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26

1
1
0
0
0
1
1
1
0
1
1
0
1
1
1
1
1
1
1
1
1
0
1
1
0
0

1
1
0
0
0
1
1
1
0
1
1
0
1
1
1
1
1
1
1
1
1
0
1
1
0
1

27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48

1
1
1
0
1
1
1
0
1
1
0
1
0
1
1
0
1
1
0
1
1
0

1
1
1
0
1
1
1
0
1
1
0
1
0
1
1
0
0
1
0
1
1
0

1
0

1
0

1
0

1
0

0.483803
0.446697

49
50

1
0

1
0

Appraiser A
Trial 3

Trial 1

Appraiser B
Trial 2

Trial 3

Trial 1

Appraiser C
Trial 2

Trial 3

1
1
0
0
0
0
1
1
0
1
1
0
1
0
1
1
1
1
1
1
0
1
1
1
0
0

1
1
0
0
0
1
1
1
0
1
1
0
1
1
1
1
1
1
1
1
1
0
1
1
0
0

1
1
0
0
0
1
1
1
0
1
1
0
1
1
1
1
1
1
1
1
0
1
1
1
0
0

1
1
0
0
0
0
1
1
0
1
1
0
1
1
1
1
1
1
1
1
1
0
1
1
0
0

1
1
0
0
0
1
1
1
0
1
1
0
1
1
1
1
1
1
1
1
0
1
1
1
0
0

1
1
0
0
0
0
0
1
0
1
1
1
1
0
1
1
1
1
1
1
1
1
1
1
0
0

1
1
0
0
0
0
1
1
0
1
1
0
1
0
1
1
1
1
1
1
0
0
1
1
0
1

Reference Results
Ref Value
0.476901
0.509015
0.576459
0.566152
0.57036
0.544951
0.465454
0.502295
0.437817
0.515573
0.488905
0.559918
0.542704
0.454518
0.517377
0.531939
0.519694
0.484167
0.520496
0.477236
0.45231
0.545604
0.529065
0.514192
0.599581
0.547204

1
1
1
0
1
1
1
1
1
0
0
1
0
1
1
0
1
1
0
1
1
0

1
1
1
0
1
1
1
0
1
1
0
1
0
1
1
0
1
1
0
1
1
0

1
1
1
0
1
1
1
0
1
1
0
1
0
1
1
0
1
1
0
1
1
0

1
1
1
1
1
1
1
1
1
1
0
1
0
1
1
0
1
1
0
1
1
0

1
1
1
0
1
1
1
0
1
1
0
1
0
1
1
0
1
1
0
1
1
0

1
1
1
0
1
1
1
1
1
0
0
1
0
1
1
0
1
1
0
1
1
0

1
1
1
0
1
1
1
1
1
1
0
1
0
1
1
0
0
1
0
1
1
0

0.502436
0.521642
0.523754
0.561457
0.503094
0.50585
0.487613
0.449696
0.498698
0.543077
0.409238
0.488184
0.427687
0.501132
0.513779
0.566575
0.46241
0.470832
0.412453
0.493441
0.486379
0.587893

1
0

1
0

1
0

1
0

1
0

1
0

1
0

0.483803
0.446697

erence Results
MSA 4th Ed

Gage R&R2

Gage R&R
Average & Range M
Enya
Trial 1
Trial2
Trial3
Trial4
Lucy
Trial 1
Trial2
Trial3
Trial4

1
21.24
21.33
21.29
21.34
21.19
21.29
21.24
21.21

2
21.65
21.67
21.6
21.56
21.5
21.51
21.55
21.55

3
22.28
22.34
22.31
22.31
22.17
22.14
22.23
22.18

Page 11

4
23.28
23.23
23.34
23.27
23.14
23.09
23.02
23.19

Part Number
5
21.85
21.84
21.93
21.89
21.78
21.84
21.76
21.81

Gage R&R2

From Six Sigma for Greenbelts and Champions

Pg 115

Page 12

Operator/Part
A

1 2
45 13
48 13
B
46 13
46 14
C
49 13
48 16
Quality Toolbox (2nd),

3 4 5 6 7 8 9 10
21 64 23 61 34 41 30 52
19 62 19 60 35 39 30 57
20 63 23 63 33 41 31 53
17 64 18 61 35 40 32 50
18 61 23 62 36 38 34 53
22 65 20 64 38 40 35 56
pg 182, ASQ Press, Tague

37.2
37.8
37.1
37.8

36.9
37.9
38.2
38.1

38.1
38.2
37.2
37.2

37.5
36.8
37.5
37.3

37.7
37.8
37.7
37.5

36.2 35.8 35.8 35.5

36

Subgroup Size
Upper Specification Lim
Lower Specification Lim

5
39.0 Part specification: 37.0 2.0
35.0

Required Outputs from Statistical Sofware

36.5 35.9 35.9 36.4 36.4

36.6
36.3
36.5
36.6
36.2
36.9

36.1
36.8
36.9
37.2
37.2
36.8

36.4
36.5
36.8
37.1
36.1
36.7

36.9
36.7
36.7
37.4
36.3
36.6

36
36.3
37.5
37.3
36.2
36.3

AIAG
(defined on p.80 of the SPC manual 1st edition
using RMethod
bar divided

37.1
37.6
36.8
37.3
36.1
36.5
36.3
35.8
37.1
36.8
35.9
36.3
36.1
36.8

37.9
38.2
37.5
37.1
37.2
36.7
36.2
36.5
37.9
37.2
36.1
37.4
37.1
36.2

38.1
38.1
37.1
36.7
37.1
36.8
36.5
36.4
36.5
37.3
37
36.6
36.9
36.6

37.6
37.8
37.4
37.5
36.9
36.9
36.5
36
36.9
37.4
36.6
36.3
36.8
36.8

37.5
37.2
36.5
37.6
36.2
36.7
35.8
36
36.9
36.6
36.1
36
36.7
37.1

Other
Acceptable
(unbiasing
constant)Values
to estimate "within"
sigma
standard deviation to
estimate "within"
sigma
(unbiasing constant)
to estimate "overall"
sigma

by d2 to estimate
"within" sigma
standard
deviation to
estimate "overall"
sigma

Cpk
Cp
Ppk
Pp

1.55
1.67
0.98
1.06

Using Different Estimates of Sigma

Cpk
Cp
Cpk
Cp
Ppk
Pp

1.60
1.73
1.61
1.73
0.98
1.05

cation: 37.0 2.0

C manual 1st edition)

Estimates of Sigma

Subgroup 1
2
3
4
5
6
7
8
9
x1
5.4
4.8
7.2
4.7 4.5 5.7 4.9 6.0 5.9
x2
6.2
6.3
4.6
4.3 5.7 4.2 3.7 3.0 3.9
x3
5.5
4.0
5.6
6.9 5.3 2.7 4.3 5.3 6.5
x4
5.1
6.0
5.1
6.8 5.4 5.1 4.1 3.9 2.7
x5
4.8
4.1
6.6
4.4 5.3 5.9 5.4 5.3 4.6
Diameter 1 DiametDiametDiametDiameter 5
22.30 22.54 22.01 22.62 22.65 pg 186 AIAG SPC (2nd)
22.86 22.68 22.43 22.58 22.73
22.88 22.68 22.46 22.30 22.61 USL
22.44 22.66 22.48 22.37 22.56 23.5
22.59 22.65 22.78 22.58 22.33 LSL
22.37 22.34 22.75 22.71 22.51 21.5
22.23 22.36 22.90 22.45 22.48
22.60 22.72 22.35 22.51 22.69
22.61 22.52 22.52 22.49 22.31
22.42 22.64 22.52 22.40 22.63
22.28 22.55 22.38 22.65 22.56
22.54 22.25 22.40 22.72 22.90
22.31 22.57 22.38 22.58 22.30
22.42 22.21 22.45 22.24 22.55
22.25 22.36 22.25 22.34 22.67
22.65 22.50 22.41 22.39 22.48
22.50 22.86 22.60 22.60 22.66
22.79 22.61 22.91 22.66 22.37
22.65 22.75 21.92 22.00 22.45
22.51 22.58 22.46 22.76 22.56
22.48 22.38 22.28 22.72 22.96
22.53 22.52 22.61 22.62 22.60
22.54 22.56 22.36 22.46 22.71
22.84 22.52 22.88 22.68 22.54
22.76 22.65 22.51 22.77 22.43

10
3.5
5.7
3.2
3.6
5.2

11
3.9
4.2
6.2
6.3
4.0

12
5.6
4.5
5.4
4.4
6.6

13
3.8
3.2
4.9
5.0
6.4

14
5.3
6.3
2.7
4.4
4.5

15
3.9
4.7
5.2
4.3
4.1

16
6.5
4.7
3.7
4.2
5.5

17
7.5
6.4
4.7
6.7
4.7

18
6.4
4.2
4.6
5.5
4.0

19
5.6
6.7
4.9
5.4
6.9

20
6.3
8.1
5.1
5.5
7.7

21
4.6
5.8
4.7
4.1
7.0

22
3.5
5.0
5.9
3.0
3.2

23
5.2
6.1
3.8
4.3
4.1

24
4.2
4.4
5.0
5.0
3.9

25
5.2
5.1
3.5
6.9
5.2

26
6.4
6.4
5.9
4.9
5.9

27
4.5
5.2
4.9
4.0
5.5

28 pg 78 AIAG SPC (2nd)

5.4 DIOUEW Length
5.6 Part: Qubic Release
3.3
USL
10.0
5.4
LSL
0.0
3.8

315959417.xls

Date/time
6/8 8am
10am
12pm
2pm
6/9 8am
10am
12pm
2pm
6/10 8am
10am
12pm
2pm
6/11 8am
10am
12pm
2pm
6/12 8am
10am
12pm
2pm
6/15 8am
10am
12pm
2pm
6/16 8am

S1
0.65
0.75
0.75
0.6
0.7
0.6
0.75
0.6
0.65
0.6
0.8
0.85
0.7
0.65
0.9
0.75
0.75
0.75
0.65
0.6
0.5
0.6
0.8
0.65
0.65

S2
0.7
0.85
0.8
0.7
0.75
0.75
0.8
0.7
0.8
0.7
0.75
0.75
0.7
0.7
0.8
0.8
0.7
0.7
0.65
0.6
0.55
0.8
0.65
0.6
0.7

S3
0.65
0.75
0.8
0.7
0.65
0.75
0.65
0.8
0.85
0.6
0.9
0.85
0.75
0.85
0.8
0.75
0.85
0.6
0.85
0.65
0.65
0.65
0.75
0.65
0.7

S4
0.65
0.85
0.7
0.75
0.85
0.85
0.75
0.75
0.85
0.8
0.5
0.65
0.75
0.75
0.75
0.8
0.7
0.7
0.65
0.6
0.8
0.65
0.65
0.6
0.6

S5 Juran QC Handbook pg 24.16

0.85 AIAG SPC pg 34
0.65 Bend Clip "Gap"
0.75
0.65
USL .90mm
0.8
LSL .50mm
0.7
0.7
0.75
0.75
0.65
0.8
0.7
0.7
0.6
0.85
0.65
0.8
0.6
0.7
0.65
0.8
0.75
0.65
0.7
0.65

Page 18

XmR

11-2 2pm

11-2 3pm

11-3 1pm

11-3 2pm

11-3 3pm

11-4 1pm

Acid Concentration
pg 86 AIAG SPC (2nd)
8.0
8.5
USL none
7.4
LSL 9
10.5
9.3
11.1
10.4
10.4
9.0
10.0
11.7
10.3
16.2
11.6
11.5
11.0
12.0
11.0
10.2
10.1
10.5
10.3
11.5
11.1

Page 19

Length
x1
x2
x3
x4
x5

2/9
7am
16
14
13
12
17

8
16
15
13
15
17

9
16
13
16
15
15

10
15
13
13
13
14

11
16
15
16
14
17

12
13
13
14
17
18

1
13
11
15
17
13

2
14
16
17
14
14

3
13
17
14
17
13

4
15
14
17
20
18

5
11
19
14
15
17

6
17
16
11
14
16

7
20
19
18
19
16

8
18
16
13
15
13

9
12
13
15
12
13

10
11
20
14
17
9

2/10
7
17
17
15
13
15

8
13
15
18
11
13

9
19
13
10
12
14

10
14
14
16
14
13

11
13
17
17
16
14

12
16
15
14
17
16

1
18
18
17
17
13

2
14
15
16
15
14

3
15
14
16
14
14

4 pg 84 AIAG SPC (2nd)

17
14
USL
19
18
LSL
11
13
16

p chart

Final Test
Under Torque
Non-start
Leaker
Smoker
Final Test Discrepancies
Sample (n)

2
6
4

4
4
7

8
7
3
1

5
5
3

5
2
2

9
8
9

9
4
4
1

7
3
4

8
2
6
1

5
5
8

8
4
4

7
9
8

6
3
2

14
8
9

12 15 19 13
9 26 18 14 17 18 16 24 11 31
500 500 500 500 500 500 500 500 500 500 500 500 500 500

Page 22

p chart

6
4
6

3
3
4

4
3
9

8
5
4

8
5
6
1

5
5
5

5
2
1

5
4
4

6
4
2

9
3
5

6
5
6
1

16 10 16 17 20 15
8 13 12 17 18
500 500 500 500 500 500 500 500 500 500 500

Page 23

Total pg 88 AIAG SPC (2nd)

162
113
125
5
Constant control limits apply when:
Min(n)/Max(n) < 0.75

p chart

apply when:

Page 24

p chart var

1/17
1/18
1/19
1/22
1/23
1/24
1/25
1/26
1/29
1/30
1/31
2/1
2/2
2/5
2/6
2/7
2/8
2/9
2/12
2/13
2/14
2/15
2/16
2/19
2/20

Non-Conforming Sample (n) Defect Rate

8
968
0.83%
13
1216
1.07%
13
804
1.62%
16
1401
1.14%
14
1376
1.02%
15
995
1.51%
13
1202
1.08%
10
1028
0.97%
24
1184
2.03%
18
542
3.32%
16
1325
1.21%
17
1066
1.59%
19
1721
1.10%
9
1305
0.69%
14
1190
1.18%
9
2306
0.39%
13
1365
0.95%
5
973
0.51%
15
1058
1.42%
19
1244
1.53%
10
392
2.55%
17
1433
1.19%
13
1255
1.04%
15
1352
1.11%
21
1187
1.77%

Page 25

np chart

Spot Weld Flaws

Undersize
Cold Weld
Missing
Off-Location

Spot Weld Flaws

Sample

4
1

1
1

2
1

3
1

5
1

2 5 4 3 3 6 5 0 7 5 4 1 2 3 6 3 8 4 4 4 6
62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62 62

Page 26

np chart

Total pg 92 AIAG SPC (2nd)

6
92
2
4
1
3

4 2 3 7
62 62 62 62

Page 27

c chart

Date/Bolt
vr721'
vr1050
vr1901
vr1942
vr3017

11-9
11-10
11-16
1
2 3 4 5
1
2 3
1
2 3 4
4 1
6
4
4
4 3
1
1 3
1
1 2 1
1 1
1
2 7
1
2
3
3 3 4
4 4
8
1
1
1
1 5
2
7 8 1
3 3 2
4
5 5

Date/Bolt
Number

11-9
11-10
11-16
11-18
2 3 4 5
2 3
2 3 4 5 11-17 1 2 3 4
2 3 4 5
1
1
1
1
9 15 11 8 17
11 5 11
13 7 10 12 4
3 7 2 3
3 7 2 7 9

Page 28

5 11-17 1 2 3 4
1
1
1 3 2
1
2
2
4
2

11-18
1
2 3 4 5
1
1 1 2 1 1
1 2
3 3
3
1 1
1
2 4

c chart

11-19
1
2 3 pg 96 AIAG SPC (2nd)
1
1
4
3
5
11-19
2 3
1
1 5 8

Page 29

u chart

Dock Audit
nd013
nd018
nd043
nd050
nd084
vr721
vr1050
vr1901
vr1942
vr3017
Number
Sample (n)

1
1
2
3

1
1
3
1
3
4
1
1

1
7
2
1
3
4

4
4
7

3
1
1
2
1 6
1
2 1
5
8 1

3
7
2
1
1 3
1 1
1 2
2
1

1
1
2
1
1
1
1
3
1
2

3
1
2
1
1
1
3
1
4

2
1
1
1
1
3
1
3

6
1
1
1
1
1
4
1
5

6
9
2
1
1
3
5
5

8 17 18 15 23 9 19 6 14 17 13 15 16 22
8 8 9 8 8 7 7 8 8 8 7 8 9 9

Page 30

Total pg 94 AIAG SPC (2nd)

17
23
27
11
19
19
17
23
22
34
Constant control limits apply when:
Min(n)/Max(n) < 0.75

u chart

ontrol limits apply when:

Page 31