Define

Control

Measure
6s

Improve

Analyze

MSA
Gage Repeatability and
Reproducibility
PROPRIETARY

Gage Repeatability and

Reproducibility
Repeatability

How well one person, can repeat the same

measurement
Sometimes called test-retest error
If repeatability is poor, look at the gage itself or the
method

Reproducibility

How well different people can get the same answer as

each other
If reproducibility is poor, look at training, standards,
and definitions

AUTOLIV-ANA/TR/9-13-05/MSA Gage R&R - 2

PROPRIETARY

Sources of Variation
Observed Variation

Part-to-Part Variation

Measurement System
Variation

Repeatability
(Variation due to
gage)

The variation that is observed in a

process is a combination of the
actual variation in the process and
the variation in the measurement
system

AUTOLIV-ANA/TR/9-13-05/MSA Gage R&R - 3

Reproducibility
(Variation due to
operators)

Operator

PROPRIETARY

Operator by part

Gage R&R
Used on measurement
systems with variable
data

Meters
Scales
Calipers
Rulers
Managers ratings
Etc.

Answers two very

important questions:

Can the measurement

system can see small
changes in the process?

Can the measurement

system tell good parts
from bad?

AUTOLIV-ANA/TR/9-13-05/MSA Gage R&R - 4

PROPRIETARY

Percent Study Variation

The Gage R&R percent of
Study Variation is:

The ratio of the

measurement system
standard deviation to the
observed standard deviation
Quantifies how much of the
variation is due to the
measurement system
Indicates whether the
measurement system Is
adequate to see changes in
the process

AUTOLIV-ANA/TR/9-13-05/MSA Gage R&R - 5

6 s ms
GRR %SV
6 s observed

PROPRIETARY

Observed

Measurement
System

Gage R&R Rule of Thumb

GRR %SV

s ms

s observed
Over .30,
Danger
.10 to .30,
Caution

Below .10,
OK
AUTOLIV-ANA/TR/9-13-05/MSA Gage R&R - 6

PROPRIETARY

The Gray Areas

Area I

Parts are measured bad

LSL

Area II

USL

Parts are sometimes

measured good and
sometimes bad
Due to random variation in

the measuring system

II

III

II

Target

Area III

Parts are measured

This is usually what the

customer cares about!!!!

good

AUTOLIV-ANA/TR/9-13-05/MSA Gage R&R - 7

PROPRIETARY

Precision to Tolerance
The Gage R&R percent of
Tolerance is:

The ratio of the six times the

measurement system
standard deviation to the
tolerance range
Quantifies the amount of
measurement system
variation compared to the
tolerance
Indicates whether the
measurement system Is
adequate to see the
difference between good and
bad parts

AUTOLIV-ANA/TR/9-13-05/MSA Gage R&R - 8

6 s ms
GRR %Tol
Tol Range

PROPRIETARY

Tolerance
Range

Measurement
System

Gage R&R Rule of Thumb

6 s ms
GRR %Tol
Tol Range
Over .30,
Danger
.10 to .30,
Caution

Below .10,
OK
AUTOLIV-ANA/TR/9-13-05/MSA Gage R&R - 9

PROPRIETARY

GR&R Setup
Sample Parts

Running the Test

Need to represent the long term

variation
Need to have enough to capture the
process variation
Usually 10-15

Randomize

Randomizing the order of the parts as

Operators

Need to be operators that will actually

be measuring the process

Usually 3-5

Un-bias

Hide part identification from operators

Randomize
Run measurement system as current

Replicates

Need to have enough the capture the

variation due to repeatability

Usually 2-3

situation

Take notes

Notice any unusual occurrences or

changes

*Recommend a total of 90 runs (i.e.

10 parts, 3 operators, 3 replicates)

AUTOLIV-ANA/TR/9-13-05/MSA Gage R&R - 10

they are tested is necessary to prevent

any unforeseen factors from influencing
the results
Randomizing also reduces the chance of
operators remembering what their last
measurement was

Keep track of the order in which the

PROPRIETARY

data were measured

Gage R&R Set-up in Minitab

Select

Stat > Quality Tools > Gage Study >

Create Gage R&R Study Worksheet

AUTOLIV-ANA/TR/9-13-05/MSA Gage R&R - 11

PROPRIETARY

Gage R&R Set-up in Minitab

Create a Standard Gage R&R (10-2-3)

Ten parts
Two operators
Three replicates
Sixty measurements in all

AUTOLIV-ANA/TR/9-13-05/MSA Gage R&R - 12

PROPRIETARY

Ensure randomization

Gage R&R Set-up in Minitab

Gather the Data
Enter the name of the
measurement in a empty
column to the right
Select the first part in the Part
column and have the operator in
the same row measure it
Record his/her measurement in
the Measurement column
Continue through all the rows in
the order they appear!!!

AUTOLIV-ANA/TR/9-13-05/MSA Gage R&R - 13

PROPRIETARY

Gage R&R Requirements

The sample parts should represent the normal population

Taken randomly from different lots, operators, machines, etc.

Parts with too much variation

Using extremes
This will over estimate the process variation and make the gage
R&R artificially low

Parts with too little variation

Using consecutive parts

This will under estimate the process variation and make the gage
R&R artificially high

Measure the parts in the environment where they are

usually measured

No special operators
No special conditions

AUTOLIV-ANA/TR/9-13-05/MSA Gage R&R - 14

PROPRIETARY

Using Minitab for Gage R&R

Select

Stat > Quality Tools > Gage Study >

Gage R&R Study (Crossed)

AUTOLIV-ANA/TR/9-13-05/MSA Gage R&R - 15

PROPRIETARY

Using Minitab for Gage R&R

Select the proper columns for Part numbers and

Operators
Select the measurement data you wish to evaluate
Input the tolerance (USL and LSL or Range)

AUTOLIV-ANA/TR/9-13-05/MSA Gage R&R - 16

PROPRIETARY

Minitab Gage R&R Results

Gage R&R

Measurement
System is adequate
but not good

%Contribution
(of VarComp)
7.76
3.39
4.37
4.37
92.24
100.00

Source
Total Gage R&R
Repeatability
Reproducibility
Operator
Part-To-Part
Total Variation

VarComp
0.09143
0.03997
0.05146
0.05146
1.08645
1.17788

Source
Total Gage R&R
Repeatability
Reproducibility
Operator
Part-To-Part
Total Variation

StdDev (SD)
0.30237
0.19993
0.22684
0.22684
1.04233
1.08530

Study Var
(6 * SD)
1.81423
1.19960
1.36103
1.36103
6.25396
6.51180

Combined Gage R&R

%Study Var
(%SV)
27.86
18.42
20.90
20.90
96.04
100.00

Repeatability
Component

Reproducibility
Component

Number of Distinct Categories = 4

The number of distinct categories the process can be divided

into by the measurement system (This ought to be greater
than or equal to 5 for an adequate measurement system)
AUTOLIV-ANA/TR/9-13-05/MSA Gage R&R - 17

PROPRIETARY

Minitab Gage R&R Results

Gage R&R

Source
Total Gage R&R
Repeatability
Reproducibility
Operator
Part-To-Part
Total Variation

VarComp
0.04687
0.03997
0.00690
0.00690
1.08645
1.13332

Measurement System is
not adequate to see
good and bad parts

%Contribution
(of VarComp)
4.14
3.53
0.61
0.61
95.86
100.00

The gage should be

evaluated
Combined
%Tolerance

Process tolerance = 4

Source
Total Gage R&R
Repeatability
Reproducibility
Operator
Part-To-Part
Total Variation

StdDev (SD)
0.21650
0.19993
0.08306
0.08306
1.04233
1.06457

Study Var
(6 * SD)
1.29901
1.19960
0.49839
0.49839
6.25396
6.38745

%Study Var
(%SV)
20.34
18.78
7.80
7.80
97.91
100.00

Number of Distinct Categories = 6

AUTOLIV-ANA/TR/9-13-05/MSA Gage R&R - 18

PROPRIETARY

%Tolerance
(SV/Toler)
32.48
29.99
12.46
12.46
156.35
159.69

Repeatability
Component

Reproducibility
Component

Minitab Graphics

AUTOLIV-ANA/TR/9-13-05/MSA Gage R&R - 19

PROPRIETARY

Minitab Graphics

AUTOLIV-ANA/TR/9-13-05/MSA Gage R&R - 20

PROPRIETARY

Additional Method to use Minitab for

Gage R&R
Select

Assistant > Measurement System Analysis (MSA)

Gage R&R Study (Crossed)3

The assistant also has the option to create the Gage R&R

AUTOLIV-ANA/TR/9-13-05/MSA Gage R&R - 21

PROPRIETARY

Additional Method to use Minitab for

Gage R&R

Select the proper columns for Part numbers and Operators

Select the measurement data you wish to evaluate
Input historical data if available
Input the tolerance (USL and LSL or Range)

AUTOLIV-ANA/TR/9-13-05/MSA Gage R&R - 22

PROPRIETARY

Minitab Graphics

AUTOLIV-ANA/TR/9-13-05/MSA Gage R&R - 23

PROPRIETARY