The New MSA 3rd Edition

Mike Down General Motors Corporation Dave Benham DaimlerChrysler Corporation Peter Cvetkovski Ford Motor Company Greg Gruska Third Generation, Inc.
Major Changes to the Manual Systematic Understanding of the Measurement Process:

The introduction acquaints the reader with this concept. For years suppliers and those in the automotive industry have relied on GRR as a method of accepting and approving measurement devices with mixed results. In many cases the GRR was sufficient to quantify the impact of the equipment and the operator on the measurement results. But in some cases this proved to be a faulty assumption. Other variables like operator training, instructions, temperature, etc. had a greater impact on the results. Time was wasted reacting to these results, in many cases causing downtime and unnecessary process adjustment. The new manual opens the door to evaluating more than just two variables, to an appreciation of all the variables that impact the results. Measurement Development and Source Selection

Two new sections have been added to the manual: 1) measurement strategy and planning, 2) measurement source development. The measurement strategy and planning section investigates possible design criteria that arise during the process of selecting and developing a measurement system. A generic check sheet is provided as a thought starter in this investigation. This section stresses that decisions made early on in the process can have a great influence on the quality of the resultant measurement system. In writing the section on source selection and development the workgroup determined that measurement systems are not always purchased through conventional channels and they sometimes miss a proper APQP (Advanced Product Quality Planning) evaluation. This section was added for the same reason as the strategy development area. Decisions concerning suppliers of measurement systems have a major impact on the quality of the final measurement. Change and Expansion on the Subject of Bias and Linearity

Another area the workgroup agreed to strengthen was the bias and linearity section in the manual. The original manual introduced the subject of bias and linearity, but did not provide the reader with clear direction on what to do with the results. The new manual includes calculations which allow the reader to evaluate bias and linearity depending on the risk. This will be dependent on the criticality of the measurement and how the measurement will be used. Examples are included to help the reader become comfortable with the calculation and the results. New Methods for Analysis of Attribute Measurement Systems

Another area of the manual that was significantly changed was the section on attribute measurement systems analysis. The previously published short method was not always conducted in a manner that was statistically valid and therefore was often mis-applied. The risk analysis method is now introduced which includes both hypothesis test analysis and signal detection theory. Resources are noted for both of these methods and a system example is given. The analytic method is also introduced as an attribute measurement system is tracked and evaluated over time.

Complex Measurement Systems (Non-Replicable)

The workgroup recognized, because of feedback over the last 10 years, the need to include discussion around non-conventional measurement methods. For example, questions have been raised concerning how measurement variation can be quantified for a destructive or non-replicable test. The term non-replicable is introduced to describe measurement situations where the measurement cannot be repeated due to physical change to the part. Even though some examples of the analysis were included in the original appendix, it was difficult for the reader to find and understand. This has been improved through bringing the information forward and creating a chapter, adding more information and directing the reader to accessible books and periodicals. A table is included in the chapter to direct the reader to the information based on the measurement system being evaluated. Comparison of MSA and Measurement Uncertainty

A section was added to review the principle behind analyzing measurement uncertainty. This has been commonly used in Europe in relation to ISO and has begun to be recognized in the U.S. The workgroup felt that the each method has a different goal and focus. Measurement uncertainty is focused at reducing all the factors that impact measurement to a set of confidence intervals to show that a measurement could lie somewhere between those values. MSA on the other hand is concerned with understanding the impact of the variables on the measurement result and trying to reduce its variation so that correct decisions can be made regarding part qualification the control of manufacturing processes. Addressing the 5.15 Multiplying Factor

Over the years there have been many debates around the origin and use of the 5.15 multiplying factor used in the calculation and evaluation of GRR. Because of changes in the calculation of GRR, the 5.15 is eventually factored out. Therefore including it or eliminating it had no net impact on the results, therefore it has been removed from the major calculations in the manual.

Number of Distinct Categories (ndc)

The number of distinct categories (ndc) metric has been added to the manual to aid the reader in evaluating the discrimination ability of a measurement system. The Web page at AIAG Finally, to keep the MSA a living document, an area on the AIAG web site is available to give feedback on the manual, ask questions, find white papers published on measurement, and to view the table of contents and glossary from the manual. The workgroup feels this will assist in keeping the MSA principles current and assist in improving the manual in the future.