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

Required
Method (See Measurement
SystemOutputs
Analysis Third
Edition)
ANOVA Method (See Measurement System Analysis Third
Edition)
and Range Method (See Measurement System Analysis
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

Trial 3

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

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

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

1
0

1
0

1
0

1
0

0.483803
0.446697

49
50

1
0

1
0

1
0

Appraiser B

Appraiser C

Reference Results
Ref Value MSA 4th Ed
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

Trial 1

Trial 2

Trial 3

Trial 1

Trial 2

Trial 3

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

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

0.483803
0.446697

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 9

Part Number
4
5
23.28
21.85
23.23
21.84
23.34
21.93
23.27
21.89
23.14
21.78
23.09
21.84
23.02
21.76
23.19
21.81

From Six Sigma for Gree

Pg 115

Gage R&R2

From Six Sigma for Greenbelts and Champions

Page 10

Operator/Part
A

1 2 3 4 5 6 7 8 9 10
45 13 21 64 23 61 34 41 30 52
48 13 19 62 19 60 35 39 30 57
B
46 13 20 63 23 63 33 41 31 53
46 14 17 64 18 61 35 40 32 50
C
49 13 18 61 23 62 36 38 34 53
48 16 22 65 20 64 38 40 35 56
Quality Toolbox (2nd), 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 Li
Lower Specification Li

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 Using
Cpk
to estimate "within"
sigma
Cp
standard deviation to
Cpk
estimate "within"
sigma
Cp
(unbiasing constant)
Ppk
to estimate "overall"
sigma
Pp

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

Cpk
Cp
Ppk
Pp

1.55
1.67
0.98
1.06

Different Estimates of Sigma

1.60
1.73
1.61
1.73
0.98
1.05

fication: 37.0 2.0

PC manual 1st edition)

nt Estimates of Sigma

Subgroup 1
2
3
4
5
6
7
8
9
10 11 12 13 14 15 16 17
x1
5.4
4.8
7.2
4.7 4.5 5.7 4.9 6.0 5.9 3.5 3.9 5.6 3.8 5.3 3.9 6.5 7.5
x2
6.2
6.3
4.6
4.3 5.7 4.2 3.7 3.0 3.9 5.7 4.2 4.5 3.2 6.3 4.7 4.7 6.4
x3
5.5
4.0
5.6
6.9 5.3 2.7 4.3 5.3 6.5 3.2 6.2 5.4 4.9 2.7 5.2 3.7 4.7
x4
5.1
6.0
5.1
6.8 5.4 5.1 4.1 3.9 2.7 3.6 6.3 4.4 5.0 4.4 4.3 4.2 6.7
x5
4.8
4.1
6.6
4.4 5.3 5.9 5.4 5.3 4.6 5.2 4.0 6.6 6.4 4.5 4.1 5.5 4.7
Diameter 1DiametDiametDiametDiameter 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

18 19 20 21 22 23 24 25 26 27 28 pg 78 AIAG SPC (2nd)

6.4 5.6 6.3 4.6 3.5 5.2 4.2 5.2 6.4 4.5 5.4 DIOUEW Length
4.2 6.7 8.1 5.8 5.0 6.1 4.4 5.1 6.4 5.2 5.6 Part: Qubic Release
4.6 4.9 5.1 4.7 5.9 3.8 5.0 3.5 5.9 4.9 3.3
USL
10.0
5.5 5.4 5.5 4.1 3.0 4.3 5.0 6.9 4.9 4.0 5.4
LSL
0.0
4.0 6.9 7.7 7.0 3.2 4.1 3.9 5.2 5.9 5.5 3.8

279005105.xlsx

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 16

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 17

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

pg 84
AIAG SPC
4 (2nd)
17
14
USL
18
LSL
13
16

19
11

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 20

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

Total pg 88 AIAG SPC (2nd)

6 162
5 113
6 125
1
5

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

Page 21

Constant control limits apply when:

Min(n)/Max(n) < 0.75

p chart

s apply when:

Page 22

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 23

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 24

np chart

Total pg 92 AIAG SPC (2nd)

92
2
4
1
3
6

4 2 3 7
62 62 62 62

Page 25

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

Page 26

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

Page 27

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

5
5

Total pg 94 AIAG SPC (2nd)

17
6
23
9
27
2
11
1
19
19
1
17
3
23
22
34

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 28

Constant control limits apply when:

Min(n)/Max(n) < 0.75

u chart

G SPC (2nd)

ontrol limits apply when:

Page 29