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Gage R&R Studies on

CMM Accuracy
6/14/2005
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What is a GR&R ?
GR&R is an abbreviation for Gage
Repeatability and Reproducibility
A GR&R is one component of a
Measurement System Evaluation
A Measurement System Evaluation is
a component of a Statistical Process
Control system
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Gage Accuracy
Gage Accuracy* is the difference between
the observed average of measurements and
the true average.
*Definition from the ASQC Automoti ve Division SPC Manual, 1986
ACCURACY
True
Average
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Gage Repeatability
Gage Repeatability* is the variation in
measurements obtained when one operator
uses the same gage for measuring the
identical characteristics of the same parts.
True
Average
*Definition from the ASQC Automoti ve Division SPC Manual, 1986
REPEATABILITY
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Gage Reproducibility
Gage Reproducibility* is the variation in the
average of measurements made by different
operators using the same gage when
measuring identical characteristics of the same
parts.
True
Average
*Definition from the ASQC Automoti ve Division SPC Manual, 1986
REPRODUCIBILITY
A
C
B
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Gage Stability
Gage Stability* is the difference in the average
of at least two sets of measurements obtained
using the same gage on the same parts taken
at different times.
*Definition from the ASQC Automoti ve Division SPC Manual, 1986
True
Average
STABILITY
Time 1
Time 2
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Gage Linearity
Gage Linearity* is the difference in the
accuracy values through the expected
operating range.
*Definition from the ASQC Automoti ve Division SPC Manual, 1986
True
Average
10mm
Accuracy over
short distance
Accuracy over
long distance
True
Average
1000mm
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The Purpose of a GR&R
Designed to provide a user with an
assurance that the measurement
system will repeat and reproduce to
acceptable levels
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Why is it needed
EARLY AND CORRECT RECOGNITION OF PROCESS TRENDS
TOLERANCE
UCL
LCL
FREQUENT, UNNECESSARY
PROCESS INTERVENTION
POOR REPEATABILITY
GOOD REPEATABILITY
LESS FREQUENT, NECESSARY
PROCESS INTERVENTION
- PROCESS CHANGE INDICATED
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Long Method Parameters
NUMBER OF PARTS:
5 10
NUMBER OF TRIALS:
2 3
NUMBER OF OPERATORS:
2 - 3
TYPICAL
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Typical GR&R Procedure
DECIDE ON NUMBER OF PARTS, TRIALS
AND OPERATORS
OPERATOR A MEASURES ALL PARTS AS
TRIAL 1
REPEAT THE ABOVE STEP FOR THE
TOTAL NUMBER OF OPERATORS
REPEAT THE ABOVE TWO STEPS FOR
THE TOTAL NUMBER OF TRIALS
SELECTED
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Mathematically Reduce Results to:
REPEATABILITY - EQUIPMENT VARIATION
(EV)
THE AVERAGE AVERAGE RANGE - R-double bar
REPRODUCIBILITY - APPRAISER
VARIATION (AV)
DIFFERENCE BETWEEN AVERAGE VALUES FROM
EACH OPERATOR - X bar difference
USE THE ABOVE VALUES IN SOME
NASTY LOOKING FORMULAS WITH
STATISTICAL CONSTANTS BASED ON
THE NUMBER OF OPERATORS AND
TRIALS
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SIMPLY TAKE BETWEEN 20 AND 90 OBSERVATIONS
ON MULTIPLE PARTS
WITH MORE THAN ONE OPERATOR
AND PERFORM THE FOLLOWING
CALCULATION:
GR&R= 100 X
(R x K1)
= 2
+ [Xdiff x K2] - (R x K1) / (n x r)
=
2
( )
2
OF A FEATURE ,
TOLERANCE
Gage R&R Made Simple
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Acceptable Limits
LESS THAN 10% - Very Good
Measurement System
10 to 30% - May be acceptable based
upon the importance of the application,
cost of gage, cost of repair, etc..
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The Other Meaning of 10%
ALTHOUGH IT IS BASED ON 10% OF
TOLERANCE, IT IS A STATISTICAL 10%.
FOR THE DATA SAMPLE RECORDED
DURING THE STUDY, THE GAGE MUST
REPEAT ON AVERAGE TO ONLY 2.2 to 3.3 %
OF TOLERANCE !
STATISTICAL MULTIPLIERS ARE USED TO
PREDICT LONG TERM VARIATION TO A 5.15
SIGMA LEVEL
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Did He J ust Say Approximately 2-3% ?
YOU HEARD IT CORRECTLY
JUST 2-3% OF TOLERANCE
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10% GR&R - Dont Confuse It
DO NOT CONFUSE 10% GR&R WITH THE
OLD 10:1 METROLOGY RULE.
IN CASE YOU FORGOT, THATS THE RULE
WHICH STATES A GAGE SHOULD BE 10
TIMES MORE ACCURATE THAN THE
TOLERANCE IT WILL BE USED TO CHECK.
REMEMBER - 10% GR&R MEANS THAT
THE GAGING SYSTEM NEEDS TO
REPEAT AND REPRODUCE TO
APPROXIMATELY 3% OF THE
TOLERANCE DURING THE STUDY
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So Whats the Big Deal ?
ALL CMMs THESE DAYS REPEAT TO 80
MILLIONTHS OR BETTER, RIGHT ?
THE BIG DEAL IS THAT THIS IS NOT SIMPLE
B89 REPEATABILITY.
YOU WILL SEE THAT
MANY SOURCES OF ERROR COME INTO
PLAY.
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Influences on Results
CMM MECHANICS (Stability)
PROBE SYSTEM - Type of Probe Head
CONTROLLER ACCURACY AND
REPEATABILITY
PROBE STYLUS CONFIGURATION
FIXTURE - Design and Stability
PART PROGRAM
WHAT CAN INFLUENCE THE RESULTS ?
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Influences on Results
CLEANLINESS OF PARTS
SURFACE FORM AND FINISH OF PARTS
PROJ ECTED TOLERANCES
OPERATOR
TEMPERATURE VARIATION
WHAT CAN INFLUENCE THE RESULTS ?
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Top Four Influences
FIXTURES R US
Cleanliness
Temperature
Form and Finish of the
Workpiece
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Survival Tools - CMM Selection
Best to use the ISO 10360 E
1
st
term as a starting point for
predicting GR&R
performance
Compare the E value to the
target R-double bar required
to meet the 10% GR&R
Predicting GR&R is not an
exact science
Remember the 3%
rule
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Survival Tools - Temperature Effects
Temperature - one of the single
biggest factors in metrology
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Survival Tools - Fixturing
Use a 3 - 2 - 1 Nest concept
Use clamps in sequence to nest the
part
Assure stability of fixture
Avoid locating on cast surfaces where
possible
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Survival Tools - Form
Understand the allowable level of Form
error to be expected in the part
Consider most advantageous probing
strategy and data density
The higher the Form error, the more
critical the fixture
Use Scanning if possible
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Survival Tools - Cleanliness
Provide Clean and Dry parts for the
study
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Survival Tools - Feature Projection
Be aware of feature projections
Eliminate them all, except those cases
where the projection is per the design
intent
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Feature Projection - not possible
-A-
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Feature Projection - possible
-A-
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Run Preliminary Tests
A GR&R can be time consuming
10x3x3 on a 10 minute inspection cycle equates
to 15 hours of run time
Run 1 part 10 times leaving it in the fixture
Compare range to the target R-double bar
Run 1 part 10 times removing it from the
fixture
Compare range to target R-double bar
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What About Accuracy?
Leave the absolute accuracy certification to
known traceable standards such as Gage
Blocks and Ring Gages
XXX
Ring Gages
Gage Blocks