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Dilshod Achilov Gage R&R

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Information about Dilshod Achilov Gage R&R

Published on November 7, 2008

Author: ahmad1957

Source: slideshare.net

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Dilshod Achilov Gage R&R
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Gage R&R: The key to understanding measuring systems Dilshod Achilov MBA 530, Section 1

Agenda What is the Measurement Systems Analyses? Definition of GR&R Benefits of implementing GR&R Example of practical application of Gauge R&R Common Misconceptions Conducting GR&Rs Quiz Summary

What is the Measurement Systems Analyses?

Definition of GR&R

Benefits of implementing GR&R

Example of practical application of Gauge R&R

Common Misconceptions

Conducting GR&Rs

Quiz

Summary

Measurement Systems analyses We must determine the uncertainty of our measurement systems before we can compare, control or optimize our manufacturing processes. - Cerprobe 1 1 Hank Scutoski & Chander Sekar, Ph.D. CERPROBE CORPORATION; Gilbert, Arizona

We must determine the uncertainty of

our measurement systems before we

can compare, control or optimize our

manufacturing processes.

- Cerprobe 1

What is Measurement Systems analyses? A Measurement System Analysis , abbreviated MSA , is a specially designed experiment that seeks to identify the components of variation in the measurement.

A Measurement System Analysis , abbreviated MSA , is a specially designed experiment that seeks to identify the components of variation in the measurement.

What is Measurement Systems analyses ? The Measurement Systems Analysis process is defined in a number of published documents including the AIAG's MSA (Measurement Systems Analysis) Manual, which is part of a series of inter-related documents the AIAG controls and publishes. These manuals include: The FMEA and Control Plan Manual The SPC (Statistical process control) Manual The MSA (Measurement Systems Analysis) Manual The Production Part Approval Process (PPAP) Manual

The Measurement Systems Analysis process is defined in a number of published documents including the AIAG's MSA (Measurement Systems Analysis) Manual, which is part of a series of inter-related documents the AIAG controls and publishes. These manuals include:

The FMEA and Control Plan Manual

The SPC (Statistical process control) Manual

The MSA (Measurement Systems Analysis) Manual

The Production Part Approval Process (PPAP) Manual

Definition of GR&R Gauge R&R (or ANOVA Gauge Repeatability & Reproducibility) is a Measurement Systems Analysis technique which uses Analysis of Variance (ANOVA) to assess a measurement system.

Gauge R&R

(or ANOVA Gauge Repeatability & Reproducibility) is a Measurement Systems Analysis technique which uses Analysis of Variance (ANOVA) to assess a measurement system.

Definition of GR&R There are four components affecting measurement system : Measurement devices (machine) Measurement instructions (method) Specification Parts

There are four components affecting measurement system :

Measurement devices (machine)

Measurement instructions (method)

Specification

Parts

Definition of GR&R There are two important aspects of a Gauge R&R: Repeatability - the ability of the device to provide consistent results. Reproducibility - the variability created by the operators

There are two important aspects of a Gauge R&R:

Repeatability - the ability of the device to provide consistent results.

Reproducibility - the variability created by the operators

Definition of GR&R 1 Repeatability conditions include the same measurement procedure, the same observer, the same measuring instrument used under the same conditions, the same location and repetition over a short period of time. 1 The Chart comes from Quality America Inc web-site, free quality encyclopedia

Repeatability conditions include the same measurement procedure, the same observer, the same measuring instrument used under the same conditions, the same location and repetition over a short period of time.

Definition of GR&R 1 Reproducibility is one of the main principles of the scientific method, and refers to the ability of a test or experiment to be accurately reproduced, or replicated , by someone else working independently. 1 The Chart comes from Quality America Inc web-site, free quality encyclopedia

Reproducibility is one of the main principles of the scientific method, and refers to the ability of a test or experiment to be accurately reproduced, or replicated , by someone else working independently.

Benefits of implementing Gage R&R Gage R&R can improve understanding of the products that companies produce. Better understanding leads to a reduction in the unnecessary scrapping of finished product. Gage R&R study can help identify problems with measurement system, allowing us to trust our data and affect real improvements in our business processes.

Gage R&R can improve understanding of the products that companies produce. Better understanding leads to a reduction in the unnecessary scrapping of finished product.

Gage R&R study can help identify problems with measurement system, allowing us to trust our data and affect real improvements in our business processes.

Benefits of implementing Gage R&R Gage R&R can tell you if inconsistencies in your measurements are too large to ignore—whether due to a faulty tool or to inconsistent operation of a tool. Reveal an inconsistent tool* Although the average measurements are not far apart, the spread of the measurements is huge!

Gage R&R can tell you if inconsistencies in your measurements are too large to ignore—whether due to a faulty tool or to inconsistent operation of a tool.

Reveal an inconsistent tool*

Although the average measurements

are not far apart, the spread of the

measurements is huge!

Benefits of implementing Gage R&R Highlight operator differences* The measurements of the new hires do not agree with the measurements of more experienced operators.

Highlight operator differences*

The measurements of the new hires

do not agree with the measurements

of more experienced operators.

Example of practical application of Gauge R&R Suppose we have 3 financial analysts and 7 projects. Each analyst calculates NPVs 1 for all 7 projects independently. 1 Net Present Value of future cash flows

Suppose we have 3 financial analysts and 7 projects. Each analyst calculates NPVs 1 for all 7 projects independently.

Example of practical application of Gauge R&R After performing all the calculations, analysts submit their reports to a CFO. CFO carefully examines each report and notices that all three reports yield different results Before taking next step, CFO needs to know, where these variations come from: the projects, method of calculation, or the analysts

After performing all the calculations, analysts submit their reports to a CFO.

CFO carefully examines each report and notices that all three reports yield different results

Before taking next step, CFO needs to know, where these variations come from: the projects, method of calculation, or the analysts

Example of practical application of Gauge R&R One of the ways CFO can find the source of variations is by using ANOVA analyses. Performing ANOVA (analyses of variability) using Excel: Enter all the data into an Excel spreadsheet Click on Tools; Choose Data analyses Tool-Pak Specify input range; put 2 for rows per sample Press Ok

One of the ways CFO can find the source of variations is by using ANOVA analyses.

Performing ANOVA (analyses of variability) using Excel:

Enter all the data into an Excel spreadsheet

Click on Tools; Choose Data analyses Tool-Pak

Specify input range; put 2 for rows per sample

Press Ok

Example of practical application of Gauge R&R ANOVA analyses shows gauge measurement is repeatable and reproducible

Common Misconceptions Misconception #1 1 : Statement: Need only one GR&R per family of gauges Why false?: It is usual to say "There is an acceptable GRR for this caliper". This statement is false, as a GRR is for the measurement system, which includes the part, specification, operator and method. 1 These misconceptions come from Wikipedia, free encyclopedia

Misconception #1 1 :

Statement:

Need only one GR&R per family of gauges

Why false?:

It is usual to say "There is an acceptable GRR for this caliper". This statement is false, as a GRR is for the measurement system, which includes the part, specification, operator and method.

Common Misconceptions Misconception #2: Statement: The GRR will not pass using parts, so it has to be done with standard weights and blocks Why false?: The GRR done on this way will assess the precision while measuring standard weights. The device might not be suitable to measure that specific type of parts. If the part "changes" while being measured, this has to be counted as a measurement system error.

Misconception #2:

Statement:

The GRR will not pass using parts, so it has to be done with standard weights and blocks

Why false?:

The GRR done on this way will assess the precision while measuring standard weights. The device might not be suitable to measure that specific type of parts. If the part "changes" while being measured, this has to be counted as a measurement system error.

Common Misconceptions Misconception #3: Statement: Need to report on PPAP documentation GRR results for everything that is measured Why false?: This is not necessarily a requirement. The Quality Engineer usually makes an educated assessment. If the characteristic is critical to safety, a valid GRR is required. Instead, if there is enough understanding that some particular part is easy to measure with acceptable precision, a formal GRR is not required.

Misconception #3:

Statement:

Need to report on PPAP documentation GRR results for everything that is measured

Why false?:

This is not necessarily a requirement. The Quality Engineer usually makes an educated assessment. If the characteristic is critical to safety, a valid GRR is required. Instead, if there is enough understanding that some particular part is easy to measure with acceptable precision, a formal GRR is not required.

Common Misconceptions Misconception #4: Statement: Performing a GRR is very expensive Why false?: In order to perform a GRR usually a number of parts (sometimes between 5 to 10) is required to be measured by 2 to 3 operators 2 to 3 times. So the measurement costs are the ones associated with those additional measurements

Misconception #4:

Statement:

Performing a GRR is very expensive

Why false?:

In order to perform a GRR usually a number of parts (sometimes between 5 to 10) is required to be measured by 2 to 3 operators 2 to 3 times. So the measurement costs are the ones associated with those additional measurements

Common Misconceptions Misconception #5: Statement: GRRs must be within 10% to pass Why false?: There are AIAG guidelines for GRR errors relative to the specification, and what to report on a PPAP process. The final call is between the supplier and customer, and it is a function of the critically of the characteristic and the assessed measurement error. GRR is a tool that helps making this assessment, but it does not gives you the answer.

Misconception #5:

Statement:

GRRs must be within 10% to pass

Why false?:

There are AIAG guidelines for GRR errors relative to the specification, and what to report on a PPAP process. The final call is between the supplier and customer, and it is a function of the critically of the characteristic and the assessed measurement error. GRR is a tool that helps making this assessment, but it does not gives you the answer.

Conducting GR&Rs The key to a good GR&R study lies in the upfront planning. A GR&R study can be planned using the following 5 steps: Define the objective of the study. Define the components of the study. Make the measurements. Calculate the %GR&R. Take action to improve the measurement process .

The key to a good GR&R study lies in the upfront planning. A GR&R study can be planned using the following 5 steps:

Define the objective of the study.

Define the components of the study.

Make the measurements.

Calculate the %GR&R.

Take action to improve the measurement process .

Conducting GR&Rs Step 1: Define the objective of the GR&R study: This step involves defining both what instrument (or family of instruments) will be studied as well as the product or product features to be studied.

Step 1: Define the objective of the GR&R study:

This step involves defining both what instrument (or family of instruments) will be studied as well as the product or product features to be studied.

Conducting GR&Rs Step 2: Define the components of the study: The components to consider include the people (testers or appraisers), the (test) method, the materials (or samples to test), the (testing) equipment, and the environment (such as conditioning requirements and the ambient temperature). Use 2 or 3 people who routinely conduct the test as the appraisers; do not replace the typical users with engineers or quality professionals. The test method used should be exactly as documented. Do not add new steps or precautions.

Step 2: Define the components of the study:

The components to consider include the people (testers or appraisers), the (test) method, the materials (or samples to test), the (testing) equipment, and the environment (such as conditioning requirements and the ambient temperature).

Use 2 or 3 people who routinely conduct the test as the appraisers; do not replace the typical users with engineers or quality professionals.

The test method used should be exactly as documented.

Do not add new steps or precautions.

Conducting GR&Rs Step 3: Make the measurements: It is best for each appraiser to take all the measurements (including replicate measurements) for the study before having the next appraiser start taking measurements. The samples measured should be randomly selected and preferably “anonymous” to the appraiser to reduce bias.

Step 3: Make the measurements:

It is best for each appraiser to take all the measurements (including replicate measurements) for the study before having the next appraiser start taking measurements.

The samples measured should be randomly selected and preferably “anonymous” to the appraiser to reduce bias.

Conducting GR&Rs Step 4: Calculate the %GR&R: This is the heart of the GR&R study. There are several techniques for calculating the %GR&R. Part of the planning involves deciding what type of analysis technique will be used. R&R Analysis techniques include: Analysis for Non-Destructive Measurements Analysis using ANOVA Analysis for Destructive Measurements Analysis for Attribute Measurements Analysis Using Graphical Techniques

Step 4: Calculate the %GR&R:

This is the heart of the GR&R study. There are several techniques for calculating the %GR&R. Part of the planning involves deciding what type of analysis technique will be used.

R&R Analysis techniques include:

Analysis for Non-Destructive Measurements

Analysis using ANOVA

Analysis for Destructive Measurements

Analysis for Attribute Measurements

Analysis Using Graphical Techniques

Conducting GR&Rs Step 5: Take action: If the measurement system is validated as “good,” additional action may not be necessary. If it is “poor,” action to improve the measurement system is needed.

Step 5: Take action:

If the measurement system is validated as “good,” additional action may not be necessary.

If it is “poor,” action to improve the measurement system is needed.

Quiz How repeatability and reproducibility determine whether a measurement system is trustworthy? Give an example from your work experience of how Gage R&R can improve data reliability.

How repeatability and reproducibility determine whether a measurement system is trustworthy? Give an example from your work experience of how Gage R&R can improve data reliability.

Summary Gage R&R is a technique used to assess measurement system Gage R&R has two important aspects: Repeatability & Reproducibility Repeatability : the ability of the device to provide consistent results. Reproducibility : the variability induced by the operator Gage R&R can improve understanding of the products companies produce and help identify problems with measurement system Gage R&R can be planned using 5 steps: Define the objective of the study. Define the components of the study. Make the measurements. Calculate the %GR&R. Take action to improve the measurement process.

Gage R&R is a technique used to assess measurement system

Gage R&R has two important aspects: Repeatability & Reproducibility

Repeatability : the ability of the device to provide consistent results.

Reproducibility : the variability induced by the operator

Gage R&R can improve understanding of the products companies produce and help identify problems with measurement system

Gage R&R can be planned using 5 steps:

Define the objective of the study.

Define the components of the study.

Make the measurements.

Calculate the %GR&R.

Take action to improve the measurement process.

Bibliography Design and Analysis of Gauge R&R Studies, Author: Michael J Mazu Journal: Technometrics ( Alexandria ), Pub.: 2006-05 Gage R&R IMPROVES QUALITY AND PROFITABILITY Author: William D Kappele, John Raffaldi; Journal: Quality ( Troy ) Improve Gage R&R Results, Author: Merwan Mehta, Paul Kauffmann, Journal: ASQ Six Sigma Forum Magazine MilwaukeePub.: 2006-08 Wikipedia, the free encyclopedia; http://en.wikipedia.org/wiki/Gage_R%26R Isixsima; http://www.isixsigma.com/dictionary/Gage_R&R-147.htm

Design and Analysis of Gauge R&R Studies, Author: Michael J Mazu Journal: Technometrics ( Alexandria ), Pub.: 2006-05

Gage R&R IMPROVES QUALITY AND PROFITABILITY Author: William D Kappele, John Raffaldi; Journal: Quality ( Troy )

Improve Gage R&R Results, Author: Merwan Mehta, Paul Kauffmann, Journal: ASQ Six Sigma Forum Magazine MilwaukeePub.: 2006-08

Wikipedia, the free encyclopedia; http://en.wikipedia.org/wiki/Gage_R%26R

Isixsima; http://www.isixsigma.com/dictionary/Gage_R&R-147.htm

Bibliography Managing quality, S.Thomas Foster, BYU; Pearson, third edition Introduction to Gage R&R Studies, Hank Scutoski & Chander Sekar, Ph.D. CERPROBE CORPORATION; Gilbert, Arizona http://www.swtest.org/swtw_library/1998proc/PDF/T1_Hank.PDF

Managing quality, S.Thomas Foster, BYU; Pearson, third edition

Introduction to Gage R&R Studies, Hank Scutoski & Chander Sekar, Ph.D. CERPROBE CORPORATION; Gilbert, Arizona

http://www.swtest.org/swtw_library/1998proc/PDF/T1_Hank.PDF

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