Enter data from Gage R & R Study into the grey cells below: Part Number: Characteristic: Gage

Description: Gage Number: Print Specification: Total Tolerance: Performed By: Date: Gage Type

Appraiser One
Trial One Trial Two Trial Three

Part 1

Part 2

Part 3

Part 4

Part 5

Part 6

Part 7

Part 8

Part 9

Part 10

Appraiser Two
Trial One Trial Two Trial Three

Part 1

Part 2

Part 3

Part 4

Part 5

Part 6

Part 7

Part 8

Part 9

Part 10

Appraiser Three
Trial One Trial Two Trial Three

Part 1

Part 2

Part 3

Part 4

Part 5

Part 6

Part 7

Part 8

Part 9

Part 10

GAGE REPEATABILITY AND REPRODUCIBILITY REPORT

Part No.: Characteristic: Specification: Tolerance Span: Average & Range Method Appraiser 1 Aprraiser's Name 0 0 0 0 1 0.00000 0.00000 0.00000 0.00000 #N/A 0.00000 0.00000 0.00000 0.00000 #N/A 0.00000 0.00000 0.00000 0.00000 #N/A Gage Name: Gage No.: Type of Gage: 0 0 0 Date: Performed by: Gage Study No.: 12/30/99 0

0
9 0.00000 0.00000 0.00000 0.00000 #N/A 0.00000 0.00000 0.00000 0.00000 #N/A 0.00000 0.00000 0.00000 0.00000 #N/A 10 Sum 0.00000 0.00000 0.00000 0.00000 #N/A 0.00000 0.00000 0.00000 0.00000 #N/A 0.00000 0.00000 0.00000 0.00000 #N/A

Trial 1 Trial2 Trial3 Total Avg-Appraiser 1 Range1 Trial 1 Trial2 Trial3 Total Avg-Appraiser 2 Range2 Trial 1 Trial2 Trial3 Total Avg-Appraiser 3 Range3 #DIV/0! 0.000000 #DIV/0! 0.0000

2 0.00000 0.00000 0.00000 0.00000 #N/A 0.00000 0.00000 0.00000 0.00000 #N/A 0.00000 0.00000 0.00000

3 0.00000 0.00000 0.00000 0.00000 #N/A 0.00000 0.00000 0.00000 0.00000 #N/A 0.00000 0.00000 0.00000

4 0.00000 0.00000 0.00000 0.00000 #N/A 0.00000 0.00000 0.00000 0.00000 #N/A 0.00000 0.00000 0.00000 0.00000 #N/A 0 #DIV/0! 0.00000 #DIV/0!

5 0.00000 0.00000 0.00000 0.00000 #N/A 0.00000 0.00000 0.00000 0.00000 #N/A 0.00000 0.00000 0.00000 0.00000 #N/A

6 0.00000 0.00000 0.00000 0.00000 #N/A 0.00000 0.00000 0.00000 0.00000 #N/A 0.00000 0.00000 0.00000 0.00000 #N/A

7 0.00000 0.00000 0.00000 0.00000 #N/A 0.00000 0.00000 0.00000 0.00000 #N/A 0.00000 0.00000 0.00000 0.00000 #N/A

8 0.00000 0.00000 0.00000 0.00000 #N/A 0.00000 0.00000 0.00000 0.00000 #N/A 0.00000 0.00000 0.00000 0.00000 #N/A

Xbar1 0 Rbar1

Appraiser 2 Aprraiser's Name

Xbar2 0 Rbar2

Appraiser 3 Aprraiser's Name

Xbar3 0 Rbar3

Range Average XDiff UCL LCL

0.00000 0.00000 #N/A #N/A Spec Tolerance Repeatability(EV) Reproducibility(AV) Gage Capability(R&R)

AIAG - Automotive Industry Action Group Formulas % Using Total Variation (TV) EV (Equipment Variation) #DIV/0! #DIV/0! %EV AV: (Appraiser Variation) %AV R&R (Gage Capability) %R&R PV (Part Variation) %PV TV (Total Variation) Observations 0 0.0% #DIV/0! #DIV/0! 0 #DIV/0! #DIV/0!

6 Sigma 5.15.Sigma % Using % Using Print Tolerance rint Tolerance P 0.0% 0.0%

0.0%

0.0%

0.0%

0.0%

0.0%

0.0%

#DIV/0! #DIV/0! NDC #DIV/0!

Part by Appraiser Plot (Stacked)

1.00000

0.90000

0.80000

0.70000

0.60000 Averagge

0.50000

0.40000

0.30000

0.20000

0.10000

0.00000 1 2
Avg-Appraiser 1

3
Avg-Appraiser 2

4
Avg-Appraiser 3 UCL

5
XCL

6 Part LCL

10

Part by Appraiser Plot

12

10

Averagge

0
UCL XCL LCL

Appraiser 2

Range of Parts by Appraiser (Stacked)

Range of Parts by Appraiser (Stacked)

12.00000

10.00000

8.00000

Range

6.00000

4.00000

2.00000

0.00000 1 2 3
Range1

4
Range2 Range3 UCL

5
Rave Parts

10

Range of Parts by Appraiser

12

10

Range

0
UCL Rave

Appraiser 2

Gage Repeatability and Reproducibility Report

Part Number Characteristics: Specifications: Tolerance Span: From data sheet: 0 0 0 0 Double R Bar: #DIV/0! Gage Name: Gage No.: Gage Type: 0 0 0 Date: Performed by: 12/30/1899 0

X Bar Dif:

0.000000

Rp:

0.000000

Measurement Unit Analysis

Repeatability - Equipment Variation (EV)

% Total Variation (Tol)

% EV = 100 [EV/(TOL/5.15)]

EV = R Double Bar * K1
EV = #DIV/0! Trials 2 3 K1 0.89 0.59 % EV = #DIV/0!

Reproducibility - Appraiser Variation (AV) % AV = 100[AV/(TOL/5.15]

AV = Sqrt ((XbarDiff * K2) - (EV )/(nr))

2 2

% AV = AV = #DIV/0! n = parts r = trials Repeatability & Reproducibility (GRR) Apraisers K2 2 0.71 3 0.52

#DIV/0!

% GRR = 100[GRR/(TOL/5.15)]

GRR = Sqrt (EV2+AV2)

% GRR = GRR = Part Variation (PV) #DIV/0! Parts 2 3 4 5 6 7 8 9 10 K3 0.7071 0.5231 0.4467 0.4030 0.3742 0.3534 0.3375 0.3249 0.3146 % PV = 100[PV/(TOL/5.15)] % PV = #DIV/0! #DIV/0!

PV = Rp x K3
PV = Total Variation (TV) 0.000000

ndc = 1.41 (PV/GRR) ndc = #DIV/0!

TV = Sqrt (GRR2+PV2)
TV = #DIV/0!

Gage Repeatability and Reproducibility Report

Part Number Characteristics: Specifications: Tolerance Span: From data sheet: 0 0 0 0 Double R Bar: #DIV/0! Gage Name: Gage No.: Gage Type: 0 0 0 Date: Performed by: 12/30/1899 0

X Bar Dif:

0.000000

Rp:

0.000000

Measurement Unit Analysis

Repeatability - Equipment Variation (EV)

% Total Variation (Tol)

% EV = 100 [EV/(TOL/6)]

EV = R Double Bar * K1
EV = #DIV/0! Trials 2 3 K1 0.89 0.59 % EV = #DIV/0!

Reproducibility - Appraiser Variation (AV) % AV = 100[AV/(TOL/6]

AV = Sqrt ((XbarDiff * K2) - (EV )/(nr))

2 2

% AV = AV = #DIV/0! n = parts r = trials Repeatability & Reproducibility (GRR) Apraisers K2 2 0.71 3 0.52

#DIV/0!

% GRR = 100[GRR/(TOL/6)]

GRR = Sqrt (EV2+AV2)

% GRR = GRR = Part Variation (PV) #DIV/0! Parts 2 3 4 5 6 7 8 9 10 K3 0.7071 0.5231 0.4467 0.4030 0.3742 0.3534 0.3375 0.3249 0.3146 % PV = 100[PV/(TOL/6)] % PV = #DIV/0! #DIV/0!

PV = Rp x K3
PV = Total Variation (TV) 0.000000

ndc = 1.41 (PV/GRR) ndc = #DIV/0!

TV = Sqrt (GRR2+PV2)
TV = #DIV/0!

Gage Repeatability and Reproducibility Report

Part Number Characteristics: Specifications: Tolerance Span: From data sheet: 0 0 0 0 Double R Bar: #DIV/0! Gage Name: Gage No.: Gage Type: 0 0 0 Date: Performed by: 12/30/1899 0

X Bar Dif:

0.000000

Rp:

0.000000

Measurement Unit Analysis

Repeatability - Equipment Variation (EV)

% Total Variation (TV)

% EV = 100 [EV/TV]

EV = R Double Bar * K1
EV = #DIV/0! Trials 2 3 K1 0.89 0.59 % EV = #DIV/0!

Reproducibility - Appraiser Variation (AV) % AV = 100[AV/TV]

AV = Sqrt ((XbarDiff * K2) - (EV )/(nr))

2 2

% AV = AV = #DIV/0! n = parts r = trials Repeatability & Reproducibility (GRR) Apraisers K2 2 0.71 3 0.52

#DIV/0!

% GRR = 100[GRR/TV]

GRR = Sqrt (EV2+AV2)

% GRR = GRR = Part Variation (PV) #DIV/0! Parts 2 3 4 5 6 7 8 9 10 K3 0.7071 0.5231 0.4467 0.4030 0.3742 0.3534 0.3375 0.3249 0.3146 % PV = 100[PV/TV] % PV = #DIV/0! #DIV/0!

PV = Rp x K3
PV = Total Variation (TV) 0.000000

ndc = 1.41 (PV/GRR) ndc = #DIV/0!

TV = Sqrt (GRR2+PV2)
TV = #DIV/0!

Gage R&R Study

Instructions 1. Select 10 DIFFERENT parts and three "appraisers" and one gage (If you don't use enough parts, part variation will be small and magnify the appraiser/equipment variation) Rule: if you're measuring to 0.0001 range of parts should be 10 times the resolution (e.g., 0.4995 to 0.5005) The parts should represent the full print toerance for the characteristic being evaluated for best results. 2. RANDOMLY, have appraisers measure each part a total of three times. 3. Then enter the results of each measurement in the "Data Entry Form" tab. 4. The template will automatically calculate all of the values based on your data 5. Evaluate your measurement system based on %R&R and make adjustments as required.

Gage Repeatability and Reproducibility Measurement is one common cause of variation. Gage R&R helps improve measurement systems If Repeatability (EV - Can the same person using the same gauge measure the same thing consistently) is greater than 30% and larger than Reproducibility (AP), reasons include: 1. Gage instrument needs maintenance 2. Gage needs to be redesigned 3. Clamping or location needs to be improved 4. Excessive within-part variation The Cell for the %EV in the Gage R&R Study will be green if the %EV is less than 30% and less than the %AV. The Cell for the %EV in the Gage R&R Study will be yellow if the %EV is more than the %AV. The Cell for the %EV in the Gage R&R Study will be red if the %EV more than 30%.

If Reproducibility (AV-can three appraisers measure the same thing and get the same result) is greater than 30% and larger than Repeatability (EV), reasons include: 1. Operator needs to be better trained in how to use and read gage 2. Calibrations on gage are not clear 3. Fixture required to help operator use gage more consistently The Cell for the %AV in the Gage R&R Study will be green if the %AV is less than 30% and less than the %EV. The Cell for the %AV in the Gage R&R Study will be yellow if the %AV is more than the %EV. The Cell for the %AV in the Gage R&R Study will be red if the %AV more than 30%. Gage System Acceptability %R&R<10% 10%<%R&R<30% %R&R>30% Gage System Okay (Most variation caused by parts, not people or equipment) May be acceptable based on importance of application and cost of gage or repair Gage system needs improvement (people and equipment cause over 1/3 of variation)

If the %R&R <10% the cell for the %R&R will be green. If the %R&R <30% but greater than 10% the cell for the %R&R will be yellow. If the %R&R >30% the cell for the %R&R will be red. NDC is a determination of the Number of Distinct Categories that can be reliably distinguished by the measurement system The NDC should be greater than 5 for the Gage R&R Study to be considered valid, however a value between 2 and 5 The NDC with a value between 2 and 5 can be determined to be acceptable The NDCwith a value less than 2 means the Gage R&R Study is not valid.

Results

The "Gage R&R Report Tol 5.15 Sigma" is based on the tolerance of the characteristic measured divided by 5.15 Sigma The "Gage R&R Report Tol 6 Sigma" is based on the tolerance of the characteristic measured divided by 6 Sigma The "Gage R&R Report TV" is based on the total variation of the parts checked for the study. Verified using AIAG Measurement Systems Analysis 3rd Edition References: http://www.aiag.org/publications http://www.qimacros.com/200303Six.html

Calculations not verified Calculate GageR&R using Anova Anova Source Appraiser Parts Appraiser x Part Gage w AP Interaction Gage w/o AP Interaction Total With Interaction P F 0 1.00000 0.0000 0 1.00000 0 0 1.00000 0 0.00000000 ###

df 2 9 18 60 78 89
Estimate of Variance

SS

MS

0.0000 0.0000 0.0000 0.0000 0.0000 0 Without Interaction

Std. Dev

Without Interaction Repeatability Appraiser AppraiserxPart R&R Part

Total Variation % Contribution

0.0000000 0 0 0.00000 0.00000

0 0 0 0 0

EV AV INT R&R PV TV

0.0% 0.0% 0.0% 0.0% 0.0% 0

0% 0% 0% 0% 0%

Without Interaction P F 0 1.00000 0 1.00000

With Interaction
Total Variation Using Tolerance Estimate of Variance Std. Dev Total Variation Using Total Variation % Contribution Tolerance

0.0% 0.0% 0.0% 0.0% 0.0% 0

0.00000 0 0 0.00000 0.00000

0 0 0 0 0

EV AV INT R&R PV TV

0.0% 0.0% 0.0% 0.0% 0.0% 0.00000

0% 0% 0% 0% 0%

0.0% 0.0% 0.0% 0.0% 0.0%