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JR Karandikar

Consultant

Introduction, Purpose and Terminology

Standards and Traceability

Quality of Measurement Data


Purpose
Terminology
Summary of Terms

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National Measurement Institutes


Traceability
Calibration Systems
True Value

The Measurement Process

Measurement Systems
Statistical Properties of Measurement Systems
Sources of Variation
SWIPE
ISHIKAWA MSA

Effect on Decisions
Effect on Product Decisions
Effect on Process Decisions
New Process Acceptance
Process Setup/ Control (Funnel Experiment)

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The Effects of Measurement System Variability

Measurement Strategy and Planning

Measurement Source Development

Measurement Issues

Complexity
Identify the Purpose of the Measurement Process
Measurement Life Cycle
Criteria for a Measurement Process Design Selection
Develop and Design Concepts and Proposals

Datum Coordination
Prerequisites and Assumptions

Types of Measurement System Variation


Definitions and Potential Sources of Variation
Measurement Process Variation
Location Variation
Width Variation

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Measurement System Variation

Comments

Measurement Uncertainty

Measurement Problem Analysis

Measurement Uncertainty and MSA


Measurement Traceability
ISO Guide to the Expression of Uncertainty in Measurement

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Step 1 -- Identify the Issues


Step 2 -- Identify the Team
Step 3 -- Flowchart of Measurement System and Process
Step 4 -- Cause and Effect Diagram
Step 5 -- Plan-Do-Study-Act (PDSA)
Step 6 -- Possible Solution and Proof of the Correction
Step 7 -- Institutionalize the Change

Type of Measurement
System
Basic Variable
Basic Attribute
Non-Replicable
(e.g., Destructive Tests)

Page

Range, Average & Range, ANOVA,


Bias, Linearity, Control Charts
Signal Detection,
Hypothesis Test Analyses
Alternate Approaches
Range, Average & Range, ANOVA,
Bias, Linearity, Control Charts

Multiple Systems, Gages or


Test Stands

Control Charts, ANOVA, Regression


Analysis

Miscellaneous

Alternate Approaches

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Complex Variable

MSA Methods

Introduction:

MSA stands for Measurement System Analysis


Measurement system analysis (MSA) is an experimental
and mathematical method of determining how much the
variation within the measurement process contributes to
overall process variability.
There are five parameters to investigate in an MSA:

Bias,
Linearity,
Stability,
Repeatability and
Reproducibility.

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BIAS:

Bias is the difference between the true value (reference


value) and the observed average of measurements on the
same characteristic on the same part. Bias is the measure
of the systematic error of the measurement system.

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Linearity:

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The difference
of bias
throughout the
expected
operating
(measurement)
range of the
equipment is
called
linearity.
Linearity can
be thought of
as a change of
bias with respect
to size.

Stability:

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Stability (or drift) is the total


variation in the measurements
obtained with a measurement
system on the same master or
parts when measuring a single
characteristic over an extended
time period. That is, stability is
the change in bias over time.

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Repeatability

Reproducibility

Gage R&R or GRR

Reproducibility is typically defined as the variation in the


average of the measurements made by different appraisers
using the same measuring instrument when measuring the
identical characteristic on the same part.

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Gage R&R is an estimate of the combined variation of


repeatability and reproducibility. Stated another way, GRR is
the variance equal to the sum of within-system and betweensystem variances.

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Repeatability is the variation in measurements obtained with


one measurement instrument when used several times by one
appraiser while measuring the identical characteristic on the
same part.

Quality of Measurement Data

The quality of measurement data is defined by the statistical


properties of multiple measurements obtained from a
measurement system operating under stable conditions.
A general rule of thumb for measurement system acceptability
is:
depending on the importance of application, cost of measurement
device, cost of repair, and other factors.
Over 30 percent error is considered unacceptable, and you should
improve the measurement system. AIAG also states that the
number of distinct categories the measurement systems divides a
process into should be greater than or equal to 5.

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Under 10 percent error is acceptable.


10 percent to 30 percent error suggests that the system is acceptable

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Purpose:

Terminology

Measurement is defined as the assignment of numbers [or


values] to material things to represent the relations among
them with respect to particular properties.
Gage is any device used to obtain measurements,
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.

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To present guidelines for assessing the quality of a


measurement system.

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Summary of Terms

Operational Definition

An operational definition is one that people can do business with


same meaning to vendor
same meaning to purchaser
Same meaning yesterday and today to production worker
Example:

A specific test of a piece of material or an assembly

A criteria for judgment

Decision Yes or No, Acceptable Not acceptable

Standard

Reference Standards

A standard is anything taken by general consent as a basis for comparison; an

accepted model.

A standard, generally of the highest metrological quality available at a given

location, from which measurements made at that location are derived.

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Calibration Standard

Transfer Standard

Master

Working Standard

Check Standard

A standard that serves as a reference in the performance of routine

calibrations.

A standard used to compare a separate standard of known value to the

unit being calibrated.

A standard used as a reference in a calibration process. May also be

termed as reference or calibration standard.


within the laboratory

A measurement artifact that closely resembles what the process is

designed to measure, but is inherently more stable than the


measurement process being evaluated.

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A standard whose intended use is to perform routine measurements

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Reference Value

A reference value, also known as the accepted reference value or


master value, is a value of an artifact or ensemble that serves as an
agreed upon reference for comparison. Accepted reference values are
based upon the following:
Determined by averaging several measurements with a higher level (e.g.,

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metrology lab or layout equipment) of measuring equipment


Legal values: defined and mandated by law
Theoretical values: based on scientific principles
Assigned values: based on experimental work (supported by sound
theory) of some national or international organization
Consensus values: based on collaborative experimental work under the
auspices of a scientific or engineering group; defined by a consensus of
users such as professional and trade organizations
Agreement values: values expressly agreed upon by the affected parties

True Value

Discrimination

The true value is the actual measure of the part.


Unknown and Unknowable"

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Discrimination is the amount of change from a reference


value that an instrument can detect and faithfully
indicate.

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Accuracy: difference between the observed


measurement and the actual measurement.
Precision: variation that occurs when measuring the
same part with the same instrument.

Precise but not


accurate

Accurate but not


precise

Not accurate or
precise

Accurate and
precise

Broken down into three components:


1. Stability: the consistency of measurements over
time.
2. Accuracy: a measure of the amount of bias in the
system.
3. Linearity: a measure of the bias values through
the expected range of measurements.

Precision, aka Measurement Variation, can be


broken down into two components:
1. Repeatability (Equipment variation): variation in
measurements under exact conditions.
2. Reproducibility (Appraiser variation): variation
in the average of measurements when different
operators measure the same part.

National Measurement Institutes

Traceability:

Calibration Systems:

True Value:

The property of a measurement or the value of a standard whereby it can


be related to stated references, usually national or international
standards, through an unbroken chain of comparisons all having stated
uncertainties.
A calibration system is a set of operations that establish, under specified
conditions, the relationship between a measuring device and a traceable
standard of known reference value and uncertainty.
The actual population value that would be obtained with perfect
measuring instruments and without committing any error of any type,
both in collecting the primary data and in carrying out mathematical
operations. It is always unknown and unknowable.

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Ultimate Authority in any country for providing reference standard for


all measurements.

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Master

Transfer Standard
Calibration Standard
Transfer Standard
Working Standard

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Check Standard

Master

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Measurement & Test Equipment

Reference Standard

Measurement Systems

The measurement and analysis activity is a process a


measurement process. Any and all of the management,
statistical, and logical techniques of process control can be
applied to it.

Measurement

Analysis
Value

Decision

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Process to be
Managed

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Fundamental properties of a GOOD measurement


system

It should have adequate discrimination and sensitivity,


The measurement system ought to be in statistical control,
Variability of the measurement system must be small
compared to the specification limits,
The variability of the measurement system ought to
demonstrate effective resolution and be small compared
to manufacturing process variation.

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Statistical Properties of Measurement Systems

An ideal measurement system would produce only correct


measurements each time it is used. Each measurement would always
agree with a standard. A measurement system that could produce
measurements like that would be said to have the statistical
properties of zero variance, zero bias, and zero probability of
misclassifying any product it measured.
Operational definitions:

variation in system must be only due to "Common Causes".


For product control -- Variability of measurement system must be
small compared to the specification limits.
For process control -- the variability of measurement system ought to
demonstrate effective resolution and be small compared to
manufacturing process variation.

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Adequate discrimination and sensitivity


The measurement system ought to be in statistical control i.e. all

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Sources of Variation

What do we do with it?

Similar to all processes, the measurement system is


impacted by both random and systematic sources of
variation.

Identify the potential sources of variation,


Eliminate (whenever possible) or monitor these sources of
variation.

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The acronym S.W.I.P.E. is used to represent the six essential


elements of a generalized measuring system to assure
attainment of required objectives. S.W.I.P.E. stands for
Standard, Work piece, Instrument, Person and Procedure,
and Environment. This may be thought of as an error model
for a complete measurement system.
Standard
Work piece (i.e. part)
Instrument
Person / Procedure
Environment

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S
W
I
P
E

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Elastic
Deformation
Elastic
Properties

Calibration

Work-piece

Mass

Interrelated
Characteristics

Stability

Standard

Cycles
Std Vs Ambient

Lights

Environment

Contact
Geometry

Sensitivity

Deformation
Effects
Consistency
Uniformity

Repeatability
Reproducibility

Experience

Variability

Measurement
system Variability
Training

Operational
Definitions

Visual
Standard
Procedure
Attitude

Person
Appraiser

Experience
Training
Understanding

Skill

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Environment

Lights

Lights

Educational

Amplification

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Temperature

Components

Calibration

Design

Limitations

Air Pollution

Artificial

EqualizationSystem
Components

Maintenance

Physical

Geometric
compatibility
Air
Drafts
Thermal
Sun
Lights
Expansion
People

Bias

Robustness

Linearity

P.M.

Elastic
Properties

Use
Assumptions

Stability

-Location
-Measurement
points
-Measurement
Probes

Operational
Definition

Traceability

CTE

Design
Validation
-Clamping

Adequate
Datums

Hidden
Geometry

Build
Tolerance

Build

Cleanliness
Supporting
Features

Instrument
Gage

Build
variation

Effect on Decisions

Effect on Product Decisions


Effect on Process Decisions

Product Control
Process control

Interest

Is the part in a specific category?

Is the process variation stable and


acceptable?

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Philosophy

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Effect on Decisions

New Process Acceptance:

Care has to be taken to ensure that process acceptance is

based on instruments to be used and vice versa.

Process Setup/ Control


Funnel Experiment

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The Measurement Life Cycle concept expresses the belief


that the measurement methods may change over time as
one learns and improves the process.

Criteria for a Measurement Process Design


Selection
Develop and Design Concepts and Proposals

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Complexity
Identify the Purpose of the Measurement Process
Measurement Life Cycle

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Datum Coordination

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Ideally, with the current prevalence in the use of


Geometric Dimensioning & Tolerancing (GD&T), datum
need to be coordinated (i.e., made identical) throughout
the manufacturing process and the measurement system
and this needs to be established very early in the APQP
process.

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Prerequisites and Assumptions :

Engineering Product Design is correct,

Process Design is Correct:

Datum references are coordinated

Process allows for measurement at the proper time and

location in the process.

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Three fundamental issues must be addressed when


evaluating a measurement system:
The measurement system must demonstrate adequate
sensitivity.
The measurement system must be stable.
The statistical properties (errors) are consistent over the
expected range and adequate for the purpose of
measurement (product control or process control).

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Types of Measurement System Variation


Definitions and Potential Sources of Variation
Measurement Process Variation
Location Variation
Width Variation

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Comments

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Measurement Uncertainty and MSA


Measurement Traceability
ISO Guide to the Expression of Uncertainty in
Measurement

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Step 1 -- Identify the Issues


Step 2 -- Identify the Team
Step 3 -- Flowchart of Measurement System and
Process
Step 4 -- Cause and Effect Diagram
Step 5 -- Plan-Do-Study-Act (PDSA)
Step 6 -- Possible Solution and Proof of the
Correction
Step 7 -- Institutionalize the Change

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1. Preparation for study


2. Evaluate stability
3. Evaluate resolution
4. Determine accuracy
5. Calibration
6. Evaluate linearity
7. Determine repeatability and reproducibility

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Objective: Establish process parameter for the


study.

Determine which measurement system will be studied.


Establish test procedure.
Establish the number of sample parts, the number of
repeated readings, and the number of operators that will
be used.
Choose operators and sample parts.

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Process:

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Objective: evaluate measurement system to


determine if the system is in statistical control.

Procedure:

Analysis:

Determine if process is in control.


If process is unstable determine and correct the cause.

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Choose sample standards.


Measure sample standards three to five times.
Plot data on a x-bar and R chart.

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Objective: determine if the measurement system


can identify and differentiate between small
changes in the given characteristic.
Process:

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Choose a sample standard.


Measure the sample standard three to five times.
Repeat the process 10 to 25 times.
Plot data on a R chart.

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Analysis:

1. The resolution is inadequate if:

There are only one, two, or three possible values for the

range, or
There are only four possible values for the range when n >=
3.

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Objective: Determine the variation between the


observed measurement and the actual
measurement of a part.
Process:

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Choose sample standards.


Measure sample standards 15 to 25 times using the same
measuring device, the same operator, and the same setup.
Calculate x-bar
Calculate bias (Bias = Average Reference Value )
Calculate the upper and lower 95% confidence limit (CL).

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Analysis:

If reference value is within the 95% CL then the bias is


insignificant.
If reference value is outside the 95% CL then the bias is
significant and measurement system must be recalibrated.

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Objective: To ensure the instrument is accurate, and


measurement bias is minimized.
Process: Calibrate instrument IAW manufacturers
instructions.

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Objective: Determine the difference between the


obtained value and a reference value using the same
instrument over the entire measurement space.
Process:

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Choose three to five sample standards that cover the


measurement space.
Measure sample standards 15 to 25 times.
Calculate the average of the readings.
Calculate bias.
Plot reference values on x-y graph.
Calculate slope of the linear regression line.
Calculate linearity and percent linearity.
Calculate R2.

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Analysis:

The closer the slope is to zero, the better the instrument,


R2 gives indication of how well the best-fit line accounts
for variability in the x-y graph.

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Objective: Determine variation in a set of


measurement, using a single instrument, that can
be credited to the instrument itself, and to the entire
measurement system.
Process:

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Generate random order for operators and parts to


complete the run.
Repeat process for subsequent runs.
Have operators take measurements.

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Analysis:

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Plot data,
Run ANOVA (analysis of variance) on data.
Calculate total variance.
Calculate % Contribution and determine if acceptable.
Calculate % Contribution (R&R)
Calculate Process to Tolerance ratio (P/T) for
repeatability.
Determine if P/T is acceptable.

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Case study performed by Tirthankar Dasgupta and


S.V.S.N Murthy, Indian Statistical Institute, 2001.
- Gauge R&R study of automobile radiator
manufacturer.
- After studying four characteristics of radiator
components the following results were obtained:

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EV -- Equipment Variation
AV Appraiser Variation
TV -- Total Variation
%R&R Repeatability & Reproducibility

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Any system having greater than 30% gauge R&R is


considered inadequate. As seen in Table 1, all four
characteristics %R&R is inadequate.
Investigation of the measurement system led to a
subsequent reduction of %R&R in three of the four
characteristics to between 12% and 23%.

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Further investigation of the fourth characteristic,


inlet hole diameter, led the examiners to a
manufacturing problem. The team discovered high
ovality in the inlet hole, which was caused by the
cutting tool. The tool was modified to reduce
ovality.

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Benefits of the study:

Reduced measurement variation.


Increased operator confidence regarding their aptitude
for conducting gauge R&R studies.
Paved the way for further studies within the firm.

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Given: EV = 5.15(s0) , AV = 5.25(s1)


R&R = (EV2 + AV2)
TV = (EV2 + AV2 + PV2)
Where: s0 = gauge standard deviation = 0.05
s1 = true appraiser standard deviation = 0.1
PV = part-to-part variation = 0.02

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Calculate R&R and TV

Is the calculated R&R acceptable?

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MSA studies are a tool that aid in ensuring quality


at all levels of a process.

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MSA studies are required for ISO 16949:2008


certification. However, MSA can prove beneficial
to any firm that uses measurement systems
whether they are seeking ISO 16949:2008
certification, or not.

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According to David C. Crosby, If you dont know


the capability of your measurement system, you
dont know if your measurements, or your
products, are good or bad.

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Error Source

Alias or Component

Factor or Parameter

Means of comparison

Part

Production part, sample, measurand, Unit Under Test


(UUT), artefact, check standard

Instrument

Gage, unit of M&TE, master gage, measuring machine,


test stand

Standard

Scale, reference, artefact, check standard, intrinsic


standard, consensus, Standard Reference Materials
(SRM), class, acceptance criteria

Method

On-the-job training, verbal, work instruction, control


plan, inspection plan, test program, part program

Operator

Appraiser, calibration or test technician,


assessor, inspector

E
A

Environment
Assumptions

Temperature, humidity, contamination, housekeeping,


lighting, position, vibration, power, Electromagnetic
Interference (EMI), noise, time, air
Statistical, operational, calibration, constants,
handbook values, thermal stability, modulus of
elasticity, laws of science

Known value accepted as


truth *, reference value, or
acceptance criteria
How
Who
Conditions of measurement,
noise
Criteria, constant, or
supposition for reliable
measurement

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Unknown

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