Gage R&R Calculations for flexible Test Conditions (3 3 10, 2 2 5, 3 2 5, 3 2 10, 2 2 10)

Please read before use:

This Excel Document calculates % Total Variation, % Contribution, % Tolerance with ANOVA and draws xbar-, R-Cha
Diagrams. The calculations and Graphics are described in more detail in AIAG MSA 4th edition or in my one day MSA
Excel Calculations are validated with statistical Software MiniTab

Select one of the following GRR Situations to jump to the acc. Data Sheet:

1. The Measurement System is used for Process monitoring and the samples reflect the entire pr

2.The Test Parts do not represent the expected process variation the TV (Total Variation) will be ca

3. The Measurement system is used for Product Control --> %GRR will be compared to the spec,

Info or Feedback: ilucka@ford.com

For Process Control situations where the measurement result and

decision criteria determine, process stability, direction and
compliance with the natural process variation (i.e., SPC, process
monitoring, capability, and process improvement), the availability of
samples over the entire operating range becomes very important.
An independent estimate of process variation (process capability
study) is recommended when assessing the adequacy of the
measurement system for process control (i.e., %GRR to process variation)

For Product Control situations where the measurement result and

decision criteria determine, conformance or nonconformance to
the feature specification (i.e., 100% inspection or sampling),
samples (or standards) must be selected, but need not cover the
entire process range. The assessment of the measurement system
is based on the feature tolerance (i.e., %GRR to TOLERANCE).

There are generally four different approaches to determine the process

variation which is used to analyze the acceptability of the measurement
variation:

1) using process variation (GRR_Situation 1)

o process variation, taken from the parts in the GRR study
itself
o use when the selected sample represents the expected
process variation (preferred option)
2) surrogate process variation
o use when sufficient samples to represent the process are not
available but an existing process with similar process
variation is available
3) Pp (or Ppk) target value (GRR_Situation 2)
o use when sufficient samples to represent the process are not
available and an existing process with similar process
variation is not available or the new process is expected to
have less variability then an existing process
4) specification tolerance (GRR_Situation 3)
o When the measurement system is to be used to sort the
process, and the process has a Pp <1.0

IMPORTANT LEGAL NOTICE:

FORD AUS-UND WEITERBILDUNG E.V. MAKES NO REPRESENTATIONS ABOUT THE SUITABILITY OF THE INF
CONTAINED IN THIS DOCUMENT AND RELATED GRAPHICS FOR ANY PURPOSE. ALL SUCH DOCUMENTS AN
GRAPHICS ARE PROVIDED AS IS WITHOUT WARRANTY OF ANY KIND AND ARE SUBJECT TO CHANGE WIT
THE ENTIRE RISK ARISING OUT OF THEIR USE REMAINS WITH THE RECIPIENT. IN NO EVENT FORD AUS-UN
WEITERBILDUNG E.V. IS LIABLE FOR ANY DIRECT, CONSEQUENTIAL, INCIDENTAL, SPECIAL, PUNITIVE OR O
WHATSOEVER (INCLUDING WITHOUT LIMITATION, DAMAGES FOR LOSS OF BUSINESS PROFITS, BUSINESS
OR LOSS OF BUSINESS INFORMATION).
2 2 10)

ANOVA and draws xbar-, R-Chart- and Interaction-

4th edition or in my one day MSA Training.

c. Data Sheet:

amples reflect the entire process range --> %GRR will be compared to TV(Total Variation)

V (Total Variation) will be calculated from the Spec.Just

Limits
clickand
on itrequested Pp (Process Performance).(see page 1
to get more Info about
our
Training & Consulting
l be compared to the spec, Window (Tolerance)

AIAG MSA 4th edition page 73

AIAG MSA 4th edition page 120-121

T THE SUITABILITY OF THE INFORMATION
SE. ALL SUCH DOCUMENTS AND RELATED
RE SUBJECT TO CHANGE WITHOUT NOTICE.
NT. IN NO EVENT FORD AUS-UND
NTAL, SPECIAL, PUNITIVE OR OTHER DAMAGES
USINESS PROFITS, BUSINESS INTERRUPTION,
 www.efaw.de

GAGE REPEATABILITY AND REPRODUCIBILITY DATA SHEET (%GRR -->Total Variation)

Part Number Gage Name Operator A A

Part Name Requested Pp Operator B B

please fill the light Specification

Gage Use Process Control
Product Control
Operator C C
BACK to
yellow cells !
yes No Read Before
Trials Parts Operators Date Performed Use
Parts do represent entire Process Variation ? Yes
3 10 3
Part No. 1 2 3 4 5 6 7 8 9 10
A 3.6396 3.9355 3.8446 4.1651 4.2812 3.4333 3.8044 3.9307 4.1455 4.2278
3.5753 3.9302 3.8819 4.2245 4.3089 3.4455 3.8448 3.9060 4.1532 4.2184
3.6175 3.8992 3.7932 4.1831 4.2525 3.3678 3.7882 3.8979 4.1984 4.2471
Range Check 0.06 0.04 0.09 0.06 0.06 0.08 0.06 0.03 0.05 0.03 0.055
B 3.5883 3.9185 3.8504 4.1615 4.2268 3.4056 3.8026 3.8656 4.1473 4.2207
3.6287 3.9065 3.8489 4.2083 4.2344 3.3945 3.8037 3.8491 4.0980 4.2187
3.6309 3.9451 3.8509 4.2350 4.2779 3.3960 3.8001 3.8750 4.1237 4.2131
Range Check 0.04 0.04 0.00 0.07 0.05 0.01 0.00 0.03 0.05 0.01 0.031
C 3.5773 3.8809 3.8529 4.1768 4.2647 3.4328 3.8105 3.8514 4.1407 4.2235
3.5827 3.8717 3.7805 4.1613 4.2388 3.3797 3.7996 3.8857 4.1519 4.2113
3.6287 3.8735 3.7968 4.1745 4.1989 3.3998 3.7866 3.8522 4.1252 4.2245
Range Check 0.05 0.01 0.07 0.02 0.07 0.05 0.02 0.03 0.03 0.01 0.037
Red Range Number indicates "Out of Range" --> Measurement needs to be replicated or removed and re-averaged and recomputed.
0.041

%Total Variation %Contribution

[Std.Dev] [Variance] 0.105
EV 8.63% 0.75%
Op 4.49% 0.20%
Op*Part 0.00% 0.00%
R&R 9.73% 9.73% 0.95% 0.95%
Parts 99.53% 99.05%
Gage system O.K
Number of
distinct categories 14 ###

prepared by ilucka@ford.com Seite 5

This should be 50% out
of Control.
Look for similar shapes Xbar Chart By OPERATOR (TV)
across operators.
Inside Control limits:
4.40of the gage
Blind spot
(Measurement
Variation)
SAMPLE MEAN

4.20

4.00

Values
UCL
3.80 Mean
LCL

3.60

3.40

Scale Y-axis to your

need
3.20
A B C
Operator
This should be in Control.
R Chart helps to identify
unusual measurements R Chart by Operator (TV)
Resolution/Repeatability
and Stability Issues.
0.12

0.10
Sample Range

0.08

Ind. R
Mean R
0.06
UCL R
LCL R

0.04

0.02

Scale Y-axis to your

need

0.00
A B C
Operator
Ideally:
the lines will follow the same
pattern OP * Part Interaction
otherwise it indicates OP *
4.40
Part Interaction

the part averages will vary

enough that differences
between parts are clear
4.20

4.00
Average

A
3.80 B
_
C

3.60

3.40

3.20
1 2 3 4 5 6 7 8 9 10
Part
 www.efaw.de

GAGE REPEATABILITY AND REPRODUCIBILITY DATA SHEET (% GRR --> Expected Total Variation)
Part Number Gage Name Operator A Benjamin

Part Name Requested Pp 1.67 Operator B Kathrin

please fill the light Gage Use Process Control

Product Control
Specification Operator C Jean Luc
yellow cells !
3 5 Yes No BACK to
Trials Parts Operators Date Performed Read Before
Parts do represent entire Process Variation ? No Use
3 10 3
Part No. 1 2 3 4 5 6 7 8 9 10
Benjamin 3.6396 3.9355 3.8446 4.1651 4.2812 3.4333 3.8044 3.9307 4.1455 4.2278
3.5753 3.9302 3.8819 4.2245 4.3089 3.4455 3.8448 3.9060 4.1532 4.2184
3.6175 3.8992 3.7932 4.1831 4.2525 3.3678 3.7882 3.8979 4.1984 4.2471
Range Check 0.06 0.04 0.09 0.06 0.06 0.08 0.06 0.03 0.05 0.03 0.055
Kathrin 3.5883 3.9185 3.8504 4.1615 4.2268 3.4056 3.8026 3.8656 4.1473 4.2207
3.6287 3.9065 3.8489 4.2083 4.2344 3.3945 3.8037 3.8491 4.0980 4.2187
3.6309 3.9451 3.8509 4.2350 4.2779 3.3960 3.8001 3.8750 4.1237 4.2131
Range Check 0.04 0.04 0.00 0.07 0.05 0.01 0.00 0.03 0.05 0.01 0.031
Jean Luc 3.5773 3.8809 3.8529 4.1768 4.2647 3.4328 3.8105 3.8514 4.1407 4.2235
3.5827 3.8717 3.7805 4.1613 4.2388 3.3797 3.7996 3.8857 4.1519 4.2113
3.6287 3.8735 3.7968 4.1745 4.1989 3.3998 3.7866 3.8522 4.1252 4.2245
Range Check 0.05 0.01 0.07 0.02 0.07 0.05 0.02 0.03 0.03 0.01 0.037
Red Range Number indicates "Out of Range" --> Measurement needs to be replicated or removed and re-averaged and recomputed.
0.041

%Total Variation %Contribution

[Std.Dev] [Variance] 0.105
EV 3.26% 0.11%
Op 1.70% 0.03%
Op*Part 0.00% 0.00%
R&R 3.68% 3.68% 0.14% 0.14%
Parts 100.00% 100.00%
Gage system O.K
Number of
distinct categories 38 ###

prepared by ilucka@ford.com Seite 9

 www.efaw.de

BACK to
ead Before
Use

prepared by ilucka@ford.com Seite 10

This should be 50% out
of Control.
Look for similar shapes Xbar Chart By OPERATOR (TV)
across operators.
Inside Control limits:
4.40of the gage
Blind spot
(Measurement
SAMPLE MEAN

Variation)
4.20

4.00

3.80 Values
UCL
Mean
3.60 LCL

3.40

3.20
Scale Y-axis to your
need
3.00

in rin c
am h Lu
n j at a n
e K
B Je
Operator
This should be in Control.
R Chart helps to identify
unusual measurements R Chart by Operator (TV)
Resolution/Repeatability
and Stability Issues.
0.12

0.10
Sample Range

0.08

Ind. R
Mean R
0.06
UCL R
LCL R

0.04

0.02

Scale Y-axis to your

need
0.00

in in c
am t hr Lu
enj Ka ean
B J
Operator
Ideally:
the lines will follow the
same pattern OP * Part Interaction
otherwise it indicates OP *
Part Interaction
4.40
the part averages will vary
enough that differences
between parts are clear
4.20

4.00
Average

3.80
Benjamin
Kathrin
Jean Luc
3.60

3.40

3.20

3.00
1 2 3 4 5 6 7 8 9 10
Part
 www.efaw.de

GAGE REPEATABILITY AND REPRODUCIBILITY DATA SHEET (%GRR --> % Tolerance)

Part Number Gage Name Operator A Spock

Part Name Requested Pp Operator B Zulo

please fill the light Gage Use Process Control

Product Control
Specification Operator C Kirk
yellow cells !
3 5 No Yes
Trials Parts Operators Date Performed
Parts do represent entire Process Variation ? No
3 10 3
Part No. 1 2 3 4 5 6 7 8 9 10 BACK to
Read Before
Spock 3.6396 3.9355 3.8446 4.1651 4.2812 3.4333 3.8044 3.9307 4.1455 4.2278
Use
3.5753 3.9302 3.8819 4.2245 4.3089 3.4455 3.8448 3.9060 4.1532 4.2184
3.6175 3.8992 3.7932 4.1831 4.2525 3.3678 3.7882 3.8979 4.1984 4.2471
Range Check 0.06 0.04 0.09 0.06 0.06 0.08 0.06 0.03 0.05 0.03 0.055
Zulo 3.5883 3.9185 3.8504 4.1615 4.2268 3.4056 3.8026 3.8656 4.1473 4.2207
3.6287 3.9065 3.8489 4.2083 4.2344 3.3945 3.8037 3.8491 4.0980 4.2187
3.6309 3.9451 3.8509 4.2350 4.2779 3.3960 3.8001 3.8750 4.1237 4.2131
Range Check 0.04 0.04 0.00 0.07 0.05 0.01 0.00 0.03 0.05 0.01 0.031
Kirk 3.5773 3.8809 3.8529 4.1768 4.2647 3.4328 3.8105 3.8514 4.1407 4.2235
3.5827 3.8717 3.7805 4.1613 4.2388 3.3797 3.7996 3.8857 4.1519 4.2113
3.6287 3.8735 3.7968 4.1745 4.1989 3.3998 3.7866 3.8522 4.1252 4.2245
Range Check 0.05 0.01 0.07 0.02 0.07 0.05 0.02 0.03 0.03 0.01 0.037
Red Range Number indicates "Out of Range" --> Measurement needs to be replicated or removed and re-averaged and recomputed.
0.041

%Tolerance %Tolerance
(Study Variation/ (Study Variation/
Tolerance)
Tolerance) 0.105
EV 7.30% 100.00% 84.17%
Op 3.80% 80.00%
x-bar chart
60.00%
Op*Part 0.00% 40.00% R-Chart
Interaction
R&R 8.23%
20.00%
0.00%
7.30% 3.80% 8.23%
chart
Parts 84.17% EV Op Op*Part R&R Parts

Gage system O.K

prepared by ilucka@ford.com Seite 14

 www.efaw.de

BACK to
Read Before
Use

prepared by ilucka@ford.com Seite 15

This should be 50% out
of Control.
Look for similar shapes Xbar Chart By OPERATOR (TV)
across operators.
Inside Control limits:
4.40of the gage
Blind spot
(Measurement
Variation)
SAMPLE MEAN

4.20

4.00

Values
UCL
3.80
Mean
LCL

3.60

3.40

Scale Y-axis to your

need
3.20

c k lo irk
u
S po Z K
Operator
This should be in Control.
R Chart helps to identify
unusual measurements R Chart by Operator (TV)
Resolution/Repeatability
and Stability Issues.
0.12

0.10
Sample Range

0.08

Ind. R
Mean R
0.06
UCL R
LCL R

0.04

0.02

Scale Y-axis to your

need
0.00

ck lo rk
o Zu Ki
Sp Operator
Ideally:
the lines will follow the
same pattern OP * Part Interaction
otherwise it indicates OP *
4.40
Part Interaction

the part averages will vary

enough that differences
between parts are clear
4.20

4.00
Average

Spock
3.80 Zulo
Kirk

3.60

3.40

3.20
1 2 3 4 5 6 7 8 9 10
Part
 3.61 3.92 3.84 4.19

UCL 3.97 3.97 3.97 3.97

Mean 3.92 3.92 3.92 3.92
LCL 3.88 3.88 3.88 3.88

0.06 0.04 0.09 0.06

Anzahl n A UCL R 0.11 0.11 0.11 0.11

3 1.023 Mean R 0.04 0.04 0.04 0.04
2.58 LCL R 0.00 0.00 0.00 0.00
UCL= Mean + *A
LCL= Mean - *A

%Tolerance
(Study Variation/
Tolerance)
EV 7.30%
Op 3.80%
Op*Part x
R&R 8.23%
Parts 84.17%
 4.28 3.42 3.81 3.91 4.17 4.23 3.62 3.92 3.85 4.20 4.25 3.40 3.80 3.86 4.12 4.22 3.60
Spock Zulo

3.97 3.97 3.97 3.97 3.97 3.97 3.97 3.97 3.97 3.97 3.97 3.97 3.97 3.97 3.97 3.97 3.97
3.92 3.92 3.92 3.92 3.92 3.92 3.92 3.92 3.92 3.92 3.92 3.92 3.92 3.92 3.92 3.92 3.92
3.88 3.88 3.88 3.88 3.88 3.88 3.88 3.88 3.88 3.88 3.88 3.88 3.88 3.88 3.88 3.88 3.88

0.06 0.08 0.06 0.03 0.05 0.03 0.04 0.04 0.00 0.07 0.05 0.01 0.00 0.03 0.05 0.01 0.05
Spock Zulo
0.11 0.11 0.11 0.11 0.11 0.11 0.11 0.11 0.11 0.11 0.11 0.11 0.11 0.11 0.11 0.11 0.11
0.04 0.04 0.04 0.04 0.04 0.04 0.04 0.04 0.04 0.04 0.04 0.04 0.04 0.04 0.04 0.04 0.04
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
3.88 3.81 4.17 4.23 3.40 3.80 3.86 4.14 4.22
Kirk

3.97 3.97 3.97 3.97 3.97 3.97 3.97 3.97 3.97

3.92 3.92 3.92 3.92 3.92 3.92 3.92 3.92 3.92
3.88 3.88 3.88 3.88 3.88 3.88 3.88 3.88 3.88

0.01 0.07 0.02 0.07 0.05 0.02 0.03 0.03 0.01

Kirk
0.11 0.11 0.11 0.11 0.11 0.11 0.11 0.11 0.11
0.04 0.04 0.04 0.04 0.04 0.04 0.04 0.04 0.04
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00