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MSA-R&R Training Program

DATE- 27/7/2013
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M.S.A. (R &R) TRAINING

What is MSA ?

MSA primarily deals with analyzing the effect of the measurement system on the measured value
Emphasis is on the effect due to equipment and personnel We test the system to determine numerical values of its statistical properties and compare them to accepted standards Quality of the data is of great importance ( Bias & variance)
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CAUSES OF VARIATION Common vs Assignable Causes

COMMON CAUSE
ASSIGNABLE CAUSE
-Consists of many individual - -Consists of just one or few causes individual causes -Cannot be economically -Easy to detect and generally eliminated economical to eliminate -Process follows a predictab -No specific pattern le pattern -

MSA

Define the Measurement System

Dis crimination

Metrological Calibration, Traceability & Uncertainty

Bias,Linearity, Stability

Conducting GRR

MEASUREMENT SYSTEM DATA

Data collected for controlling a process contains variations from two different and independent sources: - Manufacturing Process Variation ( MPV) - Measurement System Variation (MSV ) - Total Variation (TV)= MPV+MSV

MEASUREMENT SYSTEM DATA

Measurement System Variation must be smaller than the manufacturing process variation MSV < MPV +
MSV MPV

TOTAL VARIATION ( TV )

DISCRIMINATION
The ability of the system to detect and indicate even small changes of the measured characteristic, also known as resolution Measurement system is unacceptable for analysis if it cannot detect process variation Measurement system is unacceptable for controlling process if it cannot detect special cause variation

MEASUREMENT SYSTEM ERRORS

FIVE CATEGORIES:

BIAS LINEARITY STABILITY REPEABILITY REPRODUCIBILITY

LOCATION ERRORS

WIDTH ERRORS

MEASUREMENT SYSTEM ERRORS

Repeatability : Variation in measurements obtained with one Measurement instrument when used several times by one assessor While measuring identical characteristics on the same part graph on R- Chart Reproducibility : Variation in average of measurements made by different assessors using same measuring instrument when measuring identical characteristic on same part graph on X - Chart

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MEASUREMENT SYSTEM ERRORS

Average and Range Method:

The method allows the measurement systems variation to be Decomposed into Repeatability and Reproducibility but not Their Interaction. GRR = EV2 + AV2 ( Graphical & numerical Method )

ndc = 1.41 ( PV / GRR ) ndc > 5 Note : The sum of the percent consumed by each factor will not be equal 100 %

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MEASUREMENT SYSTEM ERRORS

Repeatability > Reproducibility

- Instrument needs maintenance - Improve clamping or location of gaging

- Excessive within part variation Reproducibility > Repeatability - Appraisers need better gage use training - need better operational definition - need fixture to provide consistency in gage use

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CASE STUDY : A V.C of L.C 0.02 mm is used for the measurement Of O.D having a tolerance of +/- 1.5 mm. The VC is used for The Process capability studies and the results of R&R Study carried out indicated the following results:

1) EV = 0.20188 2) AV = 0.22963 3) PV= 1.10456 Calculate the GRR,ndc and TV.Also suggest the usage of VC based on R&R results.

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MEASUREMENT SYSTEM DATA Uncertainty of Measurement

Used internationally to describe the quality of a measurement value. The width of the statistical band in which the true value would lie is termed as Uncertainty in measurement. The first measurement system uncertainty is generated by the process of calibration
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MEASUREMENT SYSTEM DATA

Uncertainty of Measurement The reference material itself The calibration process The environment and personnel performing calibration actually contribute to the measurement uncertainty

Thus the need for accredited labs

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HIERARCHY OF TRACEABILITY
International Meter (m) SI unit of Length IBWM Quantum Monochromatic Wavelength of Hg-198 & Cd- 114 Lamps National Lab 8 0.1 to 5 parts in 10

Reference

Grade 00 & 0 Slip Gauge

NPL Interferometer 0.04 to 0.1 m

Comparator 0.1 to 0.2 m

Inspection

Grade 1 & 2 Slip Gauge

Working

VC,Mic,HG, Plug

Length Standards 1 m to 0.1 m

BIS-BS-IS

Product

1mm up to 1 m

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Measurement System Evaluation

Bias
Bias is the difference between the observed average of the measurements and the reference value.
The reference value, also known as the accepted reference value or master value, is a value that serves as an agreed-upon reference for the measured values.
MSE/970311/RK17
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Bias
Reference Value Observed Average

repeatability & Reproducibility

Procedure
1. Three (or two) operators are involved: A, B, and C.

2. Ten parts are used. They are numbered in a way which wil interfere with the measurement.

3. Ensure the measuring equipment is calibrated before the s commences.

4. Operator A measures the 10 parts. The results are record an observer.

5. Step 4 is repeated by operator B and C. The measuremen performed in the same order. 6. The cycle of measuring the 10 parts is repeated twice (i.e. repeats per part per operator).
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repeatability & Reproducibility

Calculation
1. repeatability (Equipment Variation, EV):

2. Reproducibility (Appraiser Variation, AV):

q = number of parts n = number of repeats

3. repeatability & Reproducibility (r&R):

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MSE/970311/RK32

repeatability & Reproducibility

Factors K1 and K2

K1

2 4.566

Repeats 3 3.042

4 2.501

5 2.214

K2

2 3.652

Operators 3 2.703

4 2.302

5 2.077

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MSE/970311/RK33

repeatability & Reproducibility

Based upon the Tolerance
repeatability = (EV / Tolerance) x 100%

Reproducibility

= (AV / Tolerance) x 100%

r&R

= (r&R / Tolerance) x 100%

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MSE/970311/RK34

repeatability & Reproducibility

Acceptance Criteria
%r&R < 20% Measurement System is acceptable Measurement System is may be acceptable : 20% < %r&R < 30% - improve for critical applications - decrease sorting limits for critical parameters Measurement System needs improvement - process control: %r&R > 30% measurement masks process variation no realistic Cp/Cpk - inspection: decrease sorting limits
The basis of the calculation of %r&R, i.e. Tolerance or Process Capability must be stated.
MSE/970311/RK36

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