Measurement System

Analysis
March 2016
MEASUREMENT SYSTEM DISCRIMINATION
Discrimination, sometimes called resolution, refers to the ability of the
measurement system to divide measurements into data categories. All
parts within a particular data category will measure the same. For example,
if a measurement system has a resolution of 0.001 inches, then items measuring
1.0002, 1.0003, 0.9997 would all be placed in the data category 1.000, i.e.,
they would all measure 1.000 inches with this particular measurement system.
A measurement systems discrimination should enable it to divide the region
of interest into many data categories. In Six Sigma, the region of interest is
the smaller of the tolerance (the high specification minus the low specification)
or six standard deviations. A measurement system should be able to
divide the region of interest into at least five data categories
STABILITY
Measurement system stability is the change in bias over time when using a
measurement system to measure a given master part or standard. Statistical stability
is a broader term that refers to the overall consistency of measurements
over time, including variation from all causes, including bias, repeatability,
reproducibility, etc. A systems statistical stability is determined through the
use of control charts. Averages and range charts are typically plotted on measurements
of a standard or a master part. The standard is measured repeatedly
over a short time, say an hour; then the measurements are repeated at predetermined
intervals, say weekly. Subject matter expertise is needed to determine
the subgroup size, sampling intervals and measurement procedures to be followed.
Control charts are then constructed and evaluated.A(statistically) stable
system will show no out-of-control signals on an X-control chart of the averages
readings. No stability number is calculated for statistical stability; the system
either is or is not statistically stable.
Once statistical stability has been achieved, but not before, measurement system
stability can be determined. One measure is the process standard deviation
based on the R or s chart.
BIAS
Bias is the difference between an observed average measurement result and a
reference value. Estimating bias involves identifying a standard to represent
the reference value, then obtaining multiple measurements on the standard.
The standard might be amaster part whose value has been determined by ameasurement
system with much less error than the system under study, or by a standard
traceable to NIST. Since parts and processes vary over a range, bias is
measured at a point within the range. If the gage is non-linear, bias will not be
the same at each point in the range (see the definition of linearity above).
Bias can be determined by selecting a single appraiser and a single reference
part or standard. The appraiser then obtains a number of repeated measurements
on the reference part. Bias is then estimated as the difference between
the average of the repeated measurement and the known value of the reference
part or standard.
REPEATABILITY
A measurement system is repeatable if its variability is consistent. Consistent
variability is operationalized by constructing a range or sigma chart based on
repeated measurements of parts that cover a significant portion of the process
variation or the tolerance, whichever is greater. If the range or sigma chart is
out of control, then special causes are making the measurement system inconsistent.
If the range or sigma chart is in control then repeatability can be estimated
by finding the standard deviation based on either the average range or the average
standard deviation.

REPRODUCIBILITY
A measurement system is reproducible when different appraisers produce
consistent results. Appraiser-to-appraiser variation represents a bias due to
appraisers. The appraiser bias, or reproducibility, can be estimated by comparing
each appraisers average with that of the other appraisers. The standard
deviation of reproducibility (o) is estimated by finding the range between
appraisers (Ro) and dividing by d2 . Reproducibility is then computed as 5.15o.
PART-TO-PART VARIATION
The X-bar charts show the part-to-part variation. To repeat, if the measurement
system is adequate, most of the parts will fall outside of the X -bar chart control
limits. If fewer than half of the parts are beyond the control limits, then
the measurement system is not capable of detecting normal part-to-part variation
for this process.
Part-to-part variation can be estimated once the measurement process is
shown to have adequate discrimination and to be stable, accurate, linear (see
below), and consistent with respect to repeatability and reproducibility.

Linearity
Linearity can be determined by choosing parts or standards that cover all or
most of the operating range of the measurement instrument. Bias is determined
at each point in the range and a linear regression analysis is performed.
Linearity is defined as the slope times the process variance or the slope times
the tolerance, whichever is greater. A scatter diagram should also be plotted
from the data.
ATTRIBUTE MEASUREMENT ERROR ANALYSIS
Attribute data consist of classifications rather than measurements.
Attribute inspection involves determining the classification of an item, e.g., is
it good or bad? The principles of good measurement for attribute inspection
are the same as for measurement inspection (Table 10.7). Thus, it is possible
to evaluate attribute measurement systems in much the same way as we
evaluate variable measurement systems. Much less work has been done on
evaluating attribute measurement systems. The proposals provided in this
book are those Ive found to be useful for my employers and clients. The
ideas are not part of any standard and you are encouraged to think about
them critically before adopting them