Beruflich Dokumente
Kultur Dokumente
Reference Manual
Third Edition
First Edition, October 1990 Second Edition, February 1995; Second Printing, June 1998 Third Edition, March 2002 Copyright 1990, 1995, 2002 DaimlerChrysler Corporation, Ford Motor Company, General Motors Corporation
ii
FOREWORD
This Reference Manual was developed by a Measurement Systems Analysis (MSA) Work Group, sanctioned by the DaimlerChrysler Corporation/Ford Motor Company/General Motors Corporation Supplier Quality Requirements Task Force, and under the auspices of the American Society for Quality (ASQ) and the Automotive Industry Action Group (AIAG). The Work Group responsible for this Third Edition were David Benham (DaimlerChrysler Corporation), Michael Down (General Motors Corporation), Peter Cvetkovski (Ford Motor Company), Gregory Gruska (Third Generation, Inc.), Tripp Martin (Federal Mogul) and Steve Stahley (SRS Technical Services). In the past, Chrysler, Ford, and General Motors each had their own guidelines and formats for ensuring supplier compliance. Differences between these guidelines resulted in additional demands on supplier resources. To improve upon this situation, the Task Force was chartered to standardize the reference manuals, procedures, reporting formats, and technical nomenclature used by Chrysler, Ford, and General Motors. Accordingly, Chrysler, Ford, and General Motors agreed in 1990 to develop, and, through AIAG, distribute an MSA manual. That first edition was well received by the supplier community, which offered valuable inputs, based on application experience. These inputs have been incorporated into the Second and this Third edition. This manual, which is approved and endorsed by DaimlerChrysler Corporation, Ford Motor Company, and General Motors Corporation, is a supplemental reference document to QS9000. The manual is an introduction to measurement system analysis. It is not intended to limit evolution of analysis methods suited to particular processes or commodities. While these guidelines are intended to cover normally occurring measurement system situations, there will be questions that arise. These questions should be directed to your customer's Supplier Quality Assurance (SQA) activity. If you are uncertain as to how to contact the appropriate SQA activity, the buyer in your customer's purchasing office can help. The MSA Work Group gratefully acknowledges: the leadership and commitment of Vice Presidents Tom Sidlik at DaimlerChrysler Corporation, Carlos Mazzorin at Ford Motor Company and Bo Andersson of General Motors Corporation; the assistance of the AIAG in the development, production and distribution of the manual; the guidance of the Task Force principals Hank Gryn (DaimlerChrysler Corporation), Russ Hopkins (Ford Motor Company), and Joe Bransky (General Motors Corporation), in association with ASQ represented by Jackie Parkhurst (General Motors Corporation), and the American Society for Testing and Materials (ASTM International). This manual was developed to meet the specific needs of the automotive industry. This Manual is copyrighted by DaimlerChrysler Corporation, Ford Motor Company, and General Motors Corporation, all rights reserved, 2002. Additional manuals can be ordered from AIAG and/or permission to copy portions of this manual for use within supplier organizations may be obtained from AIAG at 248358-3570. March 2002
iii
iv
FOREWORD
This Reference Manual was developed by a Measurement Systems Analysis (MSA) Work Group, sanctioned by the Chrysler/Ford/General Motors Supplier Quality Requirements Task Force, and under the auspices of the Automotive Division of the American Society for Quality Control (ASQC) and the Automotive Industry Action Group (AIAG). The Work Group responsible for this Second Edition was Ray Daugherty (Chrysler), Victor Lowe, Jr. (Ford), Chairperson Michael H. Down (General Motors), and Gregory Gruska (The Third Generation, Inc.). In the past, Chrysler, Ford, and General Motors each had their own guidelines and formats for insuring supplier compliance. Differences between these guidelines resulted in additional demands on supplier resources. To improve upon this situation, the Task Force was chartered to standardize the reference manuals, procedures, reporting formats, and technical nomenclature used by Chrysler, Ford, and General Motors. Accordingly, Chrysler, Ford and General Motors agreed in 1990 to develop, and, through AIAG, distribute an MSA manual. That first edition was well received by the supplier community, which offered valuable inputs, based on application experience. These inputs have been incorporated into this second edition. This manual, which is approved and endorsed by Chrysler, Ford and General Motors, should be used by suppliers implementing MSA techniques in their manufacturing processes and in satisfying the requirements of QS9000. The manual should be considered an introduction to measurement system analysis. It is not intended to limit evolution of analysis methods suited to particular processes or commodities. While these guidelines are intended to cover normally occurring measurement systems situations, there will be questions that arise. These questions should be directed to your customer's Supplier Quality Assurance (SQA) activity. If you are uncertain as to how to contact the appropriate SQA activity, the buyer in your customer's Purchasing office can help. The Task Force gratefully acknowledges: the leadership and commitment of Vice Presidents Thomas T. Stallkamp at Chrysler, Norman F. Ehlers at Ford, and Harold R. Kutner of General Motors; the assistance of the AIAG in the development, production, and distribution of the manual; the guidance of Task Force principals Russell Jacobs (Chrysler), Stephen Walsh (Ford), and Dan Reid (General Motors), and the oversight of ASQC. Therefore, this manual was developed to meet specific needs of the automotive industry. This Manual is copyrighted by AIAG, all rights reserved, 1994. Additional manuals can be ordered from AIAG and/or permission to copy portions of this Procedure for use within supplier organizations may be obtained from AIAG at 810-358-3570.
February 1995
v
NOTE: Regarding the use of the GRR standard deviation Historically, by convention, a 99% spread has been used to represent the "full" spread of measurement error, represented by a 5.15 multiplying factor (where GRR is multiplied by 5.15 to represent a total spread of 99%). A 99.73% spread is represented by a multiplier of 6, which is 3 and represents the full spread of a "normal" curve. If the reader chooses to increase the coverage level, or spread, of the total measurement variation to 99.73%, please use 6 as a multiplier in place of 5.15 in the calculations. Awareness of which multiplying factor is used is crucial to the integrity of the equations and resultant calculations. This is especially important if a comparison is to be made between measurement system variability and the tolerance.
vi
TABLE OF CONTENTS
CHAPTER I - GENERAL MEASUREMENT SYSTEMS GUIDELINES.....................................................l CHAPTER I -- Section A .............................................................................................................. 3
Introduction, Purpose an Terminology....................................................................................................................3 Quality of Measurement Data .............................................................................................................................. 3 Summary of Terms ................................................................................................................................................ 5 True Value .......................................................................................................................................................... 10
The Measurement Process ....................................................................................................................................11 Statistical Properties of Measurement System.................................................................................................... 12 Source of Variation............................................................................................................................................. 13 The Effects of Measurement System Variability ..................................................................................................16 Effects on Decisions............................................................................................................................................ 16 Effects on Product Decisions .............................................................................................................................. 17 Effects on Process Decisions .............................................................................................................................. 18 New Process Acceptance .................................................................................................................................... 20 Process Setup/Control (Funnel Experiment) ...................................................................................................... 21
CHAPTER I Section C .................................................................................................................... 23
Measurement Strategy and Planning .....................................................................................................................23 Complexity .......................................................................................................................................................... 23 Identify the Purpose of the Measurement Process.............................................................................................. 24 Measurement Life Cycle ..................................................................................................................................... 24 Criteria for a Measurement Process Design Selection....................................................................................... 24 Research Various Measurement Process Methods............................................................................................. 26 Develop and Design Concepts and Proposals.................................................................................................... 26
CHAPTER I-Section D................................................................................................................ 27
Measurement Source Development.......................................................................................................................27 Datum Coordination ........................................................................................................................................... 28 Prerequisites and Assumptions ........................................................................................................................... 29 Gage Source Selection Process .............................................................................................................................29 Detailed Engineering Concept............................................................................................................................ 29 Preventive Maintenance Considerations ............................................................................................................ 30 Specifications ...................................................................................................................................................... 30 Evaluate the Quotations...................................................................................................................................... 31 Documentation Deliverables .............................................................................................................................. 32 Qualification at the Supplier............................................................................................................................... 33 Shipment ............................................................................................................................................................. 34 Qualification at the Customer............................................................................................................................. 34 Documentation Delivery ..................................................................................................................................... 34 Suggested Elements for a Measurement System Development Checklist ........................................................... 36
CHAPTER I Section E .................................................................................................................... 39
Measurement Issues...............................................................................................................................................39 Types of Measurement System Variation ........................................................................................................... 40 Definitions and Potential Sources of Variation .................................................................................................. 40 Measurement Process Variation......................................................................................................................... 48 Location Variation.............................................................................................................................................. 48 Width Variation .................................................................................................................................................. 52 Measurement System Variation .......................................................................................................................... 56 Comments ........................................................................................................................................................... 59
CHAPTER I -Section F ...................................................................................................................... 61
vii
Measurement Uncertainty and MSA.................................................................................................................. 62 Measurement Traceability .................................................................................................................................. 62 ISO Guide to the Expression of Uncertain in Measurement .............................................................................. 63
CHAPTER I Section G................................................................................................................... 65
Background ...........................................................................................................................................................69
CHAPTER II Section B.................................................................................................................. 71
Variable Measurement System Study Guidelines ............................................................................................83 Guidelines for Determining Stability .................................................................................................................. 83 Guidelines for Determining Bias Independent Sample Method ..................................................................... 85 Guidelines for Determining Bias Control Chart Method.............................................................................. 88 Guidelines for Determining Linearity................................................................................................................. 92 Guidelines for Determining Repeatability and Reproducibility ......................................................................... 97 Range Method .......................................................................................................................................................97 Average and Range Method ..................................................................................................................................99 Average Chart........................................................................................................................................................... 102 Range Charts ............................................................................................................................................................ 104 Run Chart.................................................................................................................................................................. 105 Scatter Plot ............................................................................................................................................................... 106 Whiskers Char .......................................................................................................................................................... 107 Error Charts ............................................................................................................................................................. 108 Normalized Histogram.............................................................................................................................................. 109 X-Y Plot of Averages by Size..................................................................................................................................... 110 Comparison X-Y Plots ............................................................................................................................................. 110 Numerical Calculations ............................................................................................................................................ 111 Analysis of Results Numerical ............................................................................................................................ 115 Analysis of Variance (ANOVA) Method.................................................................................................................... 117 Randomization and Statistical Independence ........................................................................................................... 117
CHAPTER III Section C .............................................................................................................. 125
Attribute Measurement Systems Study ...............................................................................................................125 Risk Analysis Methods ...................................................................................................................................... 125 Analytic Method................................................................................................................................................ 135
CHAPTER IV PRACTICES FOR COMPLEX MEASUREMENT SYSTEMS ....................................... 141 CHAPTER IV Section A .............................................................................................................. 143
Stability Studies...................................................................................................................................................145 S1: Single Part, Single Measurement per Cycle ....................................................................................................... 145 S2: n Parts, Single Measurement per Cycle per Part............................................................................................ 146 S3: Large Sample from a Stable Process.................................................................................................................. 147 S4: Split Specimens (General), Single Specimen per Cycle...................................................................................... 148 S5: Test Stands .................................................................................................................................................. 148
CHAPTER IV Section C .............................................................................................................. 151
viii
V2: Multiple Readings with p 2 Instruments....................................................................................................151 V3: Split Specimens (m = 2)................................................................................................................................152 V4. Split Specimens (General)............................................................................................................................153l V5: Same as VI with Stabilized Parts ..................................................................................................................153 V6: Time Series Analysis .....................................................................................................................................154 V7. Linear Analysis .............................................................................................................................................154 V8: Time versus Characteristic (Property) Degradation....................................................................................155 V9: V2 with Simultaneous Multiple Readings and p > 3 Instruments.................................................................155
CHAPTER V OTHER MEASUREMENT CONCEPTS....................................................................... 157 CHAPTER V Section A ............................................................................................................... 159
Impact of GRR on the Capability Index Cp .............................................................................................................191 Formulas ...................................................................................................................................................................191 Analysis ...................................................................................................................................................................191 Graphical Analysis ..................................................................................................................................................193
Appendix C .................................................................................................................................... 195
d2 Table ....................................................................................................................................................................195
Appendix D .................................................................................................................................... 197
Gage R Study............................................................................................................................................................197
Appendix E..................................................................................................................................... 199
ix
LIST OF TABLES
Number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Title Page
Control Philosophy and Driving Interest ................................................................................17 Bias Study Data .....................................................................................................................87 Bias Study Analysis of Bias Study ....................................................................................88 Bias Study Analysis of Stability Study for Bias .................................................................90 Linearity Study Data ..............................................................................................................94 Linearity Study Intermediate Results ................................................................................95 Gage Study (Range Method) .................................................................................................98 ANOVA Table ......................................................................................................................120 ANOVA Analysis Percent Variation and Contribution .....................................................121 Comparison of ANOVA and Average and Range Methods .................................................122 GRR ANOVA Method Report ..............................................................................................122 Attribute Study Data Set ......................................................................................................127 Examples of Measurement Systems ...................................................................................143 Methods Based on Type of Measurement System ..............................................................144 Pooled Standard Deviation Analysis Data Set ....................................................................181 Estimate of Variance Components ......................................................................................187 5.15 Sigma Spread ..............................................................................................................188 Analysis of Variance ............................................................................................................189 Tabulated ANOVA Results (Parts a & b) .............................................................................190 Comparison of Observed to Actual Cp ................................................................................193
xi
LIST OF FIGURES
Number 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 27 28 29 30 31 32 33 34 35 36 37 38 39 40 Title Page
Example of a Traceability Chain for a Length Measurement ............................................10 Measurement System Variability Cause and Effect Diagram ........................................15 Relationships Among the Various Standards ...................................................................42 Discrimination ...................................................................................................................44 Impact of Number of Distinct Categories (ndc) of the Process Distribution on Control and Analysis Activities ......................................................................................................45 Process Control Charts .....................................................................................................47 Characteristics of the Measurement Process Variation ....................................................48 Relationship Between Bias and Repeatability ..................................................................60 Control Chart Analysis for Stability ...................................................................................84 Bias Study Histogram of Bias Study ..............................................................................87 Linearity Study Graphical Analysis ................................................................................95 Gage Repeatability and Reproducibility Data Collection Sheet ......................................101 Average Chart "Stacked" .............................................................................................103 Average Chart "Unstacked" .........................................................................................103 Range Chart "Stacked" ................................................................................................104 Range Chart "Unstacked" ............................................................................................105 Run Chart by Part ...........................................................................................................105 Scatter Plot ......................................................................................................................106 Whiskers Chart ...............................................................................................................107 Error Charts .....................................................................................................................108 Normalized Histogram ....................................................................................................109 X-Y Plots of the Averages by Size ..................................................................................110 Comparison X-Y Plots .....................................................................................................111 Completed GR&R Data Collection Sheet .......................................................................113 Gage Repeatability and Reproducibility Report ..............................................................114 Interaction Plot .................................................................................................................119 Residual Plot ...................................................................................................................119 Example Process ............................................................................................................126 The Gray Areas Associated with the Measurement System ...........................................126 Example Process with Pp=Ppk=1.33 ..............................................................................133 Attribute Gage Performance Curve Plotted on Normal Probability Paper ......................139 Attribute Gage Performance Curve ................................................................................140 (33a & b) Measurement Evaluation Control Chart ............................................... 164 & 165 (34a & b) Computations for the Control Chart Method of Evaluating a Measurement Process .......................................................................................... 166 &167 Gage Performance Curve Without Error .........................................................................172 Gage Performance Curve - Example ..............................................................................173 Gage Performance Plotted on Normal Probability Paper ...............................................174 (38a, b & c) Pooled Standard Deviation Study Graphical Analysis ............... 180, 183, 184 Observed Vs. Actual Cp (Process Based) ......................................................................193 Observed Vs. Actual Cp (Tolerance Based) ...................................................................194
12
ACKNOWLEDGEMENTS
There have been many individuals responsible for the creation of this document over the years. The following are but a few who have given much of their time and effort in the development of this manual. The ASQ and the AIAG have contributed time and facilities to aid in the development of this publication. Greg Gruska, as a representative of the Automotive Division of the ASQ, and John Katona as the past chairman of the Revision Work Group have been major contributors to the development and the past publication of this manual. The techniques described in Chapter III of this document were first investigated and developed by Kazem Mirkhani from Chevrolet Product Assurance under the direction and motivation of Barney Flynn. The variable gage study, based on a paper by R.W. Traver of General Electric (1962 ASQC Transactions), was validated by Jim McCaslin. The concepts were extended to attribute studies and gage performance curves by Jim McCaslin, Gregory Gruska and Torn Bruzell from Chevrolet (1976 ASQC Transactions). These techniques were consolidated and edited by Bill Wiechec in June, 1978 resulting in the publication of the Chevrolet Measurement System Analysis Book. Over the past few years, supplemental materials were developed. In particular, Sheryl Hansen and Ray Benner of Oldsmobile documented the ANOVA approach and the confidence intervals. In the 1980's Larry Marruffo and John Lazur of Chevrolet updated the Chevrolet manual. John Lazur and Kazem Mirkhani have organized the sections for the manual and enhanced some of the concepts such as stability, linearity, and ANOVA. Jothi Shanker of EDS contributed to the preparation of the update for the Supplier Development Staff. Additional updates included the concept of identification and qualification of with-in part variation, as well as more thorough description of statistical stability, both of which were contributed by the GM Corporate Statistical Review Committee. The latest improvements were updating the format to conform to the current QS-9000 documentation, more clarification and examples to make the manual more user friendly, discussion on the concept of measurement uncertainty, and additional areas which where not included or did not exist when the original manual was written. This update also includes the concept of measurement system life cycle and moves toward a measurement analysis similar to conventional process analysis. Portions of the GM Powertrain internal Measurement Processes: Planning, Use and Improvement manual, printed April 28, 1993, were included in this revision. The current re-write subcommittee is chaired by Mike Down from General Motors Corporation and consists of David Benham from DaimlerChrysler Corporation, Peter Cvetkovski from Ford Motor Company, ,Greg Gruska, as a representative of the Automotive Division of the ASQ, Tripp Martin from Federal Mogul, and Steve Stahley from SRS Technical Services. There were also significant contributions from Yanling Zuo of Minitab, Neil Ullman of ASTM International and Gordon Skattum of Rock Valley College Technology Division. The AIAG has contributed time and facilities to aid in the development of this publication. Finally, the joint consensus on the contents of this document was effected through the MSA Work Group members representing General Motors Corporation, DaimlerChrysler Corporation and Ford Motor Company.
xiii
xiv
Chapter I
GENERAL MEASUREMENT SYSTEM GUIDELINES
The quality of measurement data is defined by the statistical properties of multiple measurements obtained from a measurement system operating under stable conditions. For instance, suppose that a measurement system, operating under stable conditions, is used to obtain several measurements of a certain characteristic. If the measurements are all "close" to the master value for the characteristic, then the quality of the data is said to be "high." Similarly, if some, or all, of the measurements are "far away" from the master value, then the quality of the data is said to be "low." The statistical properties most commonly used to characterize the quality of data are the bias and variance of the measurement system. The property called bias refers to the location of the data relative to a reference (master) value, and the property called variance refers to the spread of the data. One of the most common reasons for low-quality data is too much variation. Much of the variation in a set of measurements may be due to the interaction between the measurement system and its environment. For instance, a measurement system used to measure the volume of liquid in a tank may be
sensitive to the ambient temperature of the environment in which it is used. In that case, variation in the data may be due either to changes in the volume or to changes in the ambient temperature. That makes interpreting the data more difficult and the measurement system, therefore, less desirable. If the interaction generates too much variation, then the quality of the data may be so low that the data are not useful. For example, a measurement system with a large amount of variation may not be appropriate for use in analyzing a manufacturing process because the measurement system's variation may mask the variation in the manufacturing process. Much of the work of managing a measurement system is directed at monitoring and controlling variation. Among other things, this means that emphasis needs to be placed on learning how the measurement system interacts with its environment so that only data of acceptable quality are generated.
Purpose
The purpose of this document is to present guidelines for assessing the quality of a measurement system. Although the guidelines are general enough to be used for any measurement system, they are intended primarily for the measurement systems used in the industrial world. This document is not intended to be a compendium of analyses for all measurement systems. Its primary focus is measurement systems where the readings can be replicated on each part. Many of the analyses are useful with other types of measurement systems and the manual does contain references and suggestions. It is recommended that competent statistical resources be consulted for more complex or unusual situations not discussed here. Customer approval is required for measurement systems analysis methods not covered in this manual.
Terminology
The discussion of the analysis of measurement system can become confusing and misleading without an established set of terms to refer to the common statistical properties and related elements of the measurement system. This section provides a summary of such terms which are used in this manual. In this document, the following terms are used: Measurement is defined as "the assignment of numbers [or values] to material things to represent the relations among them with respect to particular properties." This definition was first given by C. Eisenhart (1963). The process of assigning the numbers is defined as the measurement process, and the value assigned is defined as the measurement value.
Gage is any device used to obtain measurements; frequently used to refer specifically to the devices used on the shop floor; includes go/no-go devices. Measurement system is the collection of instruments or gages, standards, operations, methods, fixtures, software, personnel, environment and assumptions used to quantify a unit of measure or fix assessment to the feature characteristic being measured; the complete process used to obtain measurements.
Basic equipment
Discrimination, readability, resolution Alias: smallest readable unit, measurement resolution, limit, or detection limit An inherent property fixed by design Smallest scale unit of measure or output for an instrument Always reported as a unit of measure 10 to 1 rule of thumb Effective resolution The sensitivity of a measurement system to process variation for a particular application
scale