4 Measure - Measurement System Analysis

Measure Phase
Measurement System Analysis

Welcome to Measure
Process Discovery
Six Sigma Statistics
Measurement System
Analysis
Basics of MSA
Variables MSA
Attribute MSA
Process Capability
Wrap Up & Action Items
OSSS LSS Green Belt v11.0 XL - Measure Phase 2 © OpenSourceSixSigma,LLC

Introduction to MSA
So far we have learned that the heart and soul of

Six Sigma is that it is a data-driven methodology.
– How do you know that the data you have used is
accurate and precise?
– How do know if a measurement is a repeatable and
reproducible?
How good are these?
Measurement System
Analysis
or
OSSS LSS Green Belt v11.0 XL - Measure Phase
MSA
3 © OpenSourceSixSigma,LLC
MSA is a mathematical procedure to quantify variation

introduced to a process or product by the act of measuring.
Item to be Reference
Measured Measurement
Operator Measurement Equipment
Process
Procedure
Environment
The item to be measured can be a physical part, document or a scenario for

customer service.
Operator can refer to a person or can be different instruments measuring the same
products.
Reference is a standard that is used to calibrate the equipment.
Procedure is the method used to perform the test.
Equipment is the device used to measure the product.
Environment isv11.0
OSSS LSS Green Belt theXLsurroundings
- Measure Phase where
4 the measures are performed.
© OpenSourceSixSigma,LLC
Measurement Purpose
In order to be worth collecting, measurements must

provide value - that is, they must provide us with
information and ultimately, knowledge
The question…
What do I need to know?

…must be answered before we begin to consider issues of
measurements, metrics, statistics, or data collection systems
Too often, organizations build complex data collection

and information management systems without truly
understanding how the data collected and metrics
calculated actually benefit the organization.

Purpose
The purpose of MSA is to assess the error due to

measurement systems.
The error can be partitioned into specific sources:
– Precision
• Repeatability - within an operator or piece of equipment
• Reproducibility - operator to operator or attribute gage
to attribute gage
– Accuracy
• Stability - accuracy over time
• Linearity- accuracy throughout the measurement range
• Resolution
• Bias – Off-set from true value
– Constant Bias
– Variable Bias – typically seen with electronic
equipment, amount of Bias changes with setting
levels

Accuracy and Precision
Accurate
Accuratebut butnot
notprecise
precise-- Precise
Precisebut
butnot
notaccurate
accurate--
On
Onaverage,
average,the theshots
shotsare
areinin The
Theaverage
averageisisnot
noton
onthe
the
the
thecenter
centerof ofthe
thetarget
targetbut
but center,
center,but
butthe
thevariability
variabilityisis
there
thereisisaalot
lotof
ofvariability
variability small
small

MSA Uses
MSA can be used to:
Compare internal inspection standards with the standards

of your customer.
Highlight areas where calibration training is required.
Provide a method to evaluate inspector training

effectiveness as well as serves as an excellent training tool.
Provide a great way to:

–Compare existing measurement equipment.
–Qualify new inspection equipment.

Why MSA?
Measurement System Analysis is important to:

• Study the % of variation in our process that is caused by
our measurement system.
• Compare measurements between operators.
• Compare measurements between two (or more)
measurement devices.
• Provide criteria to accept new measurement systems
(consider new equipment).
• Evaluate a suspect gage.
• Evaluate a gage before and after repair.
• Determine true process variation.
• Evaluate effectiveness of training program.

Appropriate Measures
Appropriate Measures are:

• Sufficient – available to be measured regularly
• Relevant –help to understand/isolate the problems
• Representative - of the process across shifts and

people
• Contextual – collected with other relevant information

that might explain process variability.

Poor Measures
Poor Measures can result from:

• Poor or non-existent operational definitions
• Difficult measures
• Poor sampling
• Lack of understanding of the definitions
• Inaccurate, insufficient or non-calibrated
measurement devices
Measurement Error compromises decisions that

affect:
– Customers
– Producers
– Suppliers

Examples of What to Measure
Examples of what and when to measure:

• Primary and secondary metrics
• Decision points in Process Maps
• Any and all gauges, measurement devices, instruments, etc
• “X’s” in the process
• Prior to Hypothesis Testing
• Prior to modeling
• Prior to planning designed experiments
• Before and after process changes
• To qualify operators
MSA is a Show Stopper!!!

Components of Variation
Whenever you measure anything, the variation that you

observe can be segmented into the following components…
Observed Variation
Unit-to-unit (true) Measurement System

Variation Error
Precision Accuracy
Repeatability Reproducibility Stability Bias Linearity
All measurement systems have error. If you don’t know how much of
the variation you observe is contributed by your measurement system,
you cannot make confident decisions.
If you were one speeding ticket away from losing your license,
how fast would you be willing to drive in a school zone?

Precision
A precise metric is one that returns the same value of

a given attribute every time an estimate is made.
Precise data are independent of who estimates them

or when the estimate is made.
Precision can be partitioned into two components:

– Repeatability
– Reproducibility
Repeatability and Reproducibility = Gage R+R

Repeatability
Repeatability is the variation in measurements obtained with

one measurement instrument used several times by one
appraiser while measuring the identical characteristic on the
same part.
Repeatability
For example:
– Manufacturing: One person measures the purity of multiple
samples of the same vial and gets different purity measures.
– Transactional: One person evaluates a contract multiple times
(over a period of time) and makes different determinations of
errors.

Reproducibility
Reproducibility is the variation in the average of the

measurements made by different appraisers using the
same measuring instrument when measuring the
identical characteristic on the same part.
Reproducibility
Y Operator A
Operator B
For example:
– Manufacturing: Different people perform purity test on
samples from the same vial and get different results.
– Transactional: Different people evaluate the same contract
and make different determinations.

Time Estimate Exercise
Exercise objective: Demonstrate how well you

can estimate a 10 second time interval.
1. Pair up with an associate.

2. One person will say start and stop to indicate how
long they think the 10 seconds last. Do this 6 times.
3. The other person will have a watch with a second
hand to actually measure the duration of the
estimate. Record the value where your partner can’t
see it.
4. Switch tasks with partner and do it 6 times also.
5. Record all estimates, what do you notice?

Accuracy
An accurate measurement is the difference between the observed

average of the measurement and a reference value.
– When a metric or measurement system consistently over or under
estimates the value of an attribute, it is said to be “inaccurate”
Accuracy can be assessed in several ways:
– Measurement of a known standard
– Comparison with another known measurement method
– Prediction of a theoretical value
What happens if we don’t have standards, comparisons or theories?
True
Average
Accuracy
Warning, do not assume your
metrology reference is gospel.
Measurement

Accuracy Against a Known Standard
In transactional processes, the measurement system can

consist of a database query.
– For example, you may be interested in measuring
product returns where you will want to analyze the
details of the returns over some time period.
– The query will provide you all the transaction details.
However, before you invest a lot of time analyzing the

data, you must ensure the data has integrity.
– The analysis should include a comparison with known
reference points.
– For the example of product returns, the transaction
details should add up to the same number that
appears on financial reports, such as the income
statement.

Accuracy vs. Precision
ACCURATE PRECISE BOTH
+ =
Accuracy relates to how close

the average of the shots are
to the Master or bull's-eye.
Precision relates to the

spread of the shots or
NEITHER
Variance.

Bias
Bias is defined as the deviation of the measured value

from the actual value.
Calibration procedures can minimize and control bias

within acceptable limits. Ideally, Bias can never be
eliminated due to material wear and tear!
Bias Bias

Stability
Stability of a gauge is defined as error (measured in terms of

Standard Deviation) as a function of time. Environmental
conditions such as cleanliness, noise, vibration, lighting,
chemical, wear and tear or other factors usually influence
gauge instability. Ideally, gauges can be maintained to give a
high degree of Stability but can never be eliminated unlike
Reproducibility. Gage Stability studies would be the first
exercise past calibration procedures.
Control Charts are commonly used to track the Stability of a
measurement system over time.
Drift
Stability is Bias
characterized as a function
of time!

Linearity
Linearity is defined as the difference in Bias values throughout

the measurement range in which the gauge is intended to be used.
This tells you how accurate your measurements are through the
expected range of the measurements. It answers the question,
"Does my gage have the same accuracy for all sizes of objects
being measured?"
Linearity = |Slope| * Process Variation Low Nominal High
+e
B i a s (y)
% Linearity = |Slope| * 100
0.00
*
-e
*
*
Reference Value (x)
y = a + b.x
y: Bias, x: Ref. Value
a: Slope, b: Intercept

Types of MSA’s
MSA’s fall into two categories:

– Attribute
– Variable
Attribute Variable
– Pass/Fail – Continuous scale
– Go/No Go – Discrete scale
– Document Preparation – Critical dimensions
– Surface imperfections – Pull strength
– Customer Service – Warp
Response
Transactional projects typically have Attribute based

measurement systems.
Manufacturing projects generally use Variable studies more
often, but do use Attribute studies to a lesser degree.

Variable MSA’s
SigmaXL® calculates a column of variance components (VarComp) which are

used to calculate % Gage R&R using the ANOVA Method.
Measured True
Value Value
Estimates for a Gage R&R study are obtained by calculating the variance
components for each term and for error. Repeatability, Operator and
Operator*Part components are summed to obtain a total Variability due to
the measuring system.
We use variance components to assess the Variation contributed by each
source of measurement error relative to the total Variation.

Cheat Sheet
Contribution of Variation to the

total Variation of the study. Use % Study Var when you are interested in
comparing the measurement system
Variation to the total Variation.
% Study Var is calculated by dividing each
% Contribution, based on variance value in Study Var by Total Variation and
components, is calculated by dividing Multiplying by 100.
each value in VarComp by the Total
Variation then multiplying the result by Study Var is calculated as 5.15 times the
Standard Deviation for each source.
100. (5.15 is used because when data are
normally distributed, 99% of the data fall
within 5.15 Standard Deviations.)

Cheat Sheet
SigmaXL® Report:
When the process tolerance is entered in

the system, SigmaXL® ® calculates %
Tolerance which compares measurements

system Variation to customer
specification. This allows us to determine
the proportion of the process tolerance
that is used by the Variation in the
measurement system.
0.186980
Distinct Categories  1.41
0.031861517
 5.8685 1.41
8 (Rounded Down )

Number of Distinct Categories
The number of distinct categories tells you how many

separate groups of parts the system is able to distinguish.

Unacceptable for
estimating process
parameters and indices
Only indicates whether
the process is
producing conforming
1 Data Category
or nonconforming parts

Generally unacceptable
for estimating process
parameters and indices
Only provides coarse
2 - 4 Categories
estimates

Recommended
5 or more Categories

AIAG Standards for Gage Acceptance
Here are the Automotive Industry Action Group’s

definitions for Gage acceptance.
% Tolerance
or % Contribution System is…
% Study Variance
10% or less 1% or less Ideal
10% - 20% 1% - 4% Acceptable
20% - 30% 5% - 9% Marginal
30% or greater 10% or greater Poor

SigmaXL® Graphic Output Cheat Sheet
Components of Variation
The
TheSigmaXL
SigmaXL®report
®
reportbreaks
breaksdown
downthe
thevariation
variationin inthe
themeasurement
measurementsystem
systeminto
into
specific sources. The bar chart shown was created using Excel’s Clustered Column
specific sources. The bar chart shown was created using Excel’s Clustered Column Bar Bar
Chart
Charttotographically
graphicallydisplay
displaythe
theComponents Variation. Each
ComponentsofofVariation. Eachcluster
clusterof
ofbars
barsrepresents
represents
aasource
sourceof ofvariation.
variation.
In
Inaagood
goodmeasurement
measurementsystem,
system,the
thelargest
largestcomponent
componentof ofVariation
VariationisisPart-to-Part
Part-to-Part
variation.
variation. If instead you have large amounts of variation attributed to GageR&R,
If instead you have large amounts of variation attributed to Gage R&R,
then corrective action is needed.
then corrective action is needed.
SigmaXL
SigmaXL®provides
®
providesan
anRRChart
Chartand
andXbar
XbarChart
Chartby
byOperator.
Operator. The
TheRRchart
chartconsists
consistsofofthe
thefollowing:
following:
- The plotted points are the difference between the largest and smallest measurements on each
- The plotted points are the difference between the largest and smallest measurements on each
part for each operator. If the measurements are the same then the range = 0.
part for each operator. If the measurements are the same then the range = 0.
- The Center Line, is the grand average for the process.
- The Center Line, is the grand average for the process.
- -The
TheControl
ControlLimits
Limitsrepresent
representthe
theamount
amountofofvariation
variationexpected
expectedfor
forthe
thesubgroup
subgroupranges.
ranges. These
These
limits are calculated using the variation within subgroups.
limits are calculated using the variation within subgroups.
If any of the points on the graph go above the upper Control Limit (UCL), then that operator is
If any of the points on the graph go above the upper Control Limit (UCL), then that operator is
having problems consistently measuring parts. The Upper Control Limit value takes into account
having problems consistently measuring parts. The Upper Control Limit value takes into account
the number of measurements by an operator on a part and the variability between parts. If the
the number of measurements by an operator on a part and the variability between parts. If the
operators are measuring consistently, then these ranges should be small relative to the data and
operators are measuring consistently, then these ranges should be small relative to the data and
the points should stay in control.
the points should stay in control.
SigmaXL
SigmaXL®provides
®
providesan
anRRChart
Chartand
andXbar
XbarChart
Chartby
byOperator.
Operator. The
TheXbar
XbarChart
Chartcompares
comparesthe
thepart-to-part
part-to-part
variation to repeatability. The Xbar chart consists of the following:
variation to repeatability. The Xbar chart consists of the following:
- The plotted points are the average measurement on each part for each operator.
- The plotted points are the average measurement on each part for each operator.
- The Center Line is the overall average for all part measurements by all operators.
- The Center Line is the overall average for all part measurements by all operators.
- The Control Limits (UCL and LCL) are based on the variability between parts and the number of
- The Control Limits (UCL and LCL) are based on the variability between parts and the number of
measurements in each average.
measurements in each average.
Because the parts chosen for a Gage R&R study should represent the entire range of possible parts, this
Because the parts chosen for a Gage R&R study should represent the entire range of possible parts, this
graph should ideally show lack-of-control. Lack-of-control exists when many points are above the Upper
graph should ideally show lack-of-control. Lack-of-control exists when many points are above the Upper
Control Limit and/or below the Lower Control Limit.
Control Limit and/or below the Lower Control Limit.
In this case there are several points out of control which indicates the measurement system is adequate.
In this case there are several points out of control which indicates the measurement system is adequate.

SigmaXL®’s Gage R&R Multi-Vari Output
The Multi-Vari Charts show each Part as a separate graph. Each Operator’s response readings are denoted as a vertical
The Multi-Vari Charts show each Part as a separate graph. Each Operator’s response readings are denoted as a vertical
line
linewith
withthe
thetop
toptick
tickcorresponding
correspondingtotothe
theMaximum
Maximumvalue,
value,bottom
bottomtick
tickisisthe
theMinimum,
Minimum,and
andthe
themiddle
middletick
tickisisthe
theMean.
Mean.The
The
horizontal
horizontalline
lineacross
acrosseach
eachgraph
graphisisthe
theoverall
overallaverage
averagefor
foreach
eachpart.
part.
Ideally
Ideallythe
the connected
connectedmeans
meansred
redline
lineshould
shouldbe
behorizontal
horizontal(i.e.,
(i.e.,small
smallreproducibility)
reproducibility)and
andthe
thevertical
verticallines
linesshould
shouldbe
beshort
short
(small repeatability).
(small repeatability).

Pattern Means…
Lines are virtually Operators are Using
Usingthe
theSigmaXL
SigmaXL®two-way
two-wayANOVA
ANOVA tool
®
identical measuring the parts the tool
same
creates
creates an interaction chart that showsthe
an interaction chart that shows the
average measurements taken by
average measurements taken by each each
One line is consistently That operator is operator
higher or lower than the measuring parts operatoron
oneach
eachpart
partininthe
thestudy,
study,
others consistently higher or
arranged
arranged by part. Each line connectsthe
by part. Each line connects the
lower than the others averages for a single operator.
averages for a single operator.
Lines are not parallel or The operators ability to
they cross measure a part depends
Ideally,
Ideally,the
thelines
lineswill
willfollow
followthe
thesame
same
on which part is being pattern
pattern and the part averages willvary
and the part averages will vary
measured (an enough
enough that differences between partsare
that differences between parts are
interaction between clear.
clear.
OSSS LSS Green Belt v11.0 XL - operator and part) 34
Measure Phase © OpenSourceSixSigma,LLC
The “By Part” Multi-Vari Chart allows us to analyze all of the measurements taken in the study
arranged by part. The measurements are represented by dots; the means by the middle bar.
The red line connects the average measurements for each part.
Ideally,
 Multiple measurements for each individual part have little variation (the dots for one
part will be close together)
• Averages will vary enough that differences between parts are clear

The
The“By
“ByOperator”
Operator”Multi-Vari
Multi-VariChart
Chartisiscreated
createdby bymodifying
modifyingthe
theX’s
X’sfrom
fromparts
partsto
tooperator.
operator.
This helps us determine whether the variability in measurements are consistent
This helps us determine whether the variability in measurements are consistent acrossacross
operators.
operators.
The
Theby
byoperator
operatorgraph
graphshows
showsall
allthe
thestudy
studymeasurements
measurementsarranged
arrangedby
byoperator.
operator. Dots
Dots
represent the measurements; the middle bars represent the means. The red line connects
represent the measurements; the middle bars represent the means. The red line connects
the
theaverage
averagemeasurements
measurementsfor
foreach
eachoperator.
operator.
If the red line is … Then…
Parallel to the x-axis The operators are measuring the parts similarly
Not parallel to the x-axis The operators are measuring the parts differently
You
Youcan
canalso
alsoassess
assesswhether
whetherthe theoverall
overallVariability
Variabilityininpart
partmeasurement
measurementisisthe
thesame
sameusing
using
this graph. Is the spread in the measurements similar? Or is one operator
this graph. Is the spread in the measurements similar? Or is one operator more Variable more Variable
than
than the
the
OSSS others?
LSS
others?
Green Belt v11.0 XL - Measure Phase 36 © OpenSourceSixSigma,LLC
Practical Conclusions
For this example, the measuring system contributes little to the overall
Variation, as confirmed by both the Gage R&R table and graphs.
The Variation due to the measurement system, as a percent of study
(Total) Variation is causing 16.80% of the Variation seen in the process.
By AIAG Standards this gage should be used. By all standards, the
data being produced by this gage is acceptable, and valid for analysis.
% Tolerance
or % Contribution System is…
% Study Variance
10% or less 1% or less Ideal
10% - 20% 1% - 4% Acceptable
20% - 30% 5% - 9% Marginal
30% or greater 10% or greater Poor

Repeatability and Reproducibility Problems
Repeatability Problems:
• Calibrate or replace gage.
• If only occurring with one operator, re-train.
Reproducibility Problems:
• Measurement machines
– Similar machines
• Ensure all have been calibrated and that the standard
measurement method is being utilized.
– Dissimilar machines
• One machine is superior.
• Operators
– Training and skill level of the operators must be assessed.
– Operators should be observed to ensure that standard procedures
are followed.
• Operator/machine by part interactions
– Understand why the operator/machine had problems measuring
some parts and not others.
• Re-measure the problem parts
• Problem could be a result of gage linearity
• Problem could be fixture problem
• Problem could be poor gage design

Design Types
Crossed Design
• A Crossed Design is used only in non-destructive testing and assumes that
all the parts can be measured multiple times by either operators or
multiple machines.
– Gives the ability to separate part-to-part Variation from measurement
system Variation.
– Assesses Repeatability and Reproducibility.
– Assesses the interaction between the operator and the part.
Nested Design
• A Nested Design is used for destructive testing (we will learn about this in
MBB training) and also situations where it is not possible to have all
operators or machines measure all the parts multiple times.
– Destructive testing assumes that all the parts within a single batch are
identical enough to claim they are the same.
– Nested designs are used to test measurement systems where it is not
possible (or desirable) to send operators with parts to different
locations.
– Do not include all possible combinations of factors.
– Uses slightly different mathematical model than the Crossed Design.

Gage R & R Study
Gage R&R Study

– Is a set of trials conducted to assess the Repeatability and
Reproducibility of the measurement system.
– Multiple people measure the same characteristic of the same set
of multiple units multiple times (a crossed study)
– Example: 10 units are measured by 3 people. These units are
then randomized and a second measure on each unit is taken.
A Blind Study is extremely desirable.

– Best scenario: operator does not know the measurement is a part
of a test
– At minimum: operators should not know which of the test parts
they are currently measuring.
NO, not that kind of R&R!

Variable Gage R & R Steps
Step 1: Call a team meeting and introduce the concepts of the Gage R&R
Step 2: Select parts for the study across the range of interest
– If the intent is to evaluate the measurement system throughout the
process range, select parts throughout the range
– If only a small improvement is being made to the process, the range of
interest is now the improvement range
Step 3: Identify the inspectors or equipment you plan to use for the analysis
– In the case of inspectors, explain the purpose of the analysis and that the
inspection system is being evaluated not the people
Step 4: Calibrate the gage or gages for the study
– Remember Linearity, Stability and Bias
Step 5: Have the first inspector measure all the samples once in random order
Step 6: Have the second inspector measure all the samples in random order
– Continue this process until all the operators have measured all the parts
one time
– This completes the first replicate
Step 7: Repeat steps 5 and 6 for the required number of replicates
– Ensure there is always a delay between the first and second inspection
Step 8: Enter the data into SigmaXL® and analyze your results
Step 9: Draw conclusions and make changes if necessary

Gage R & R Study
Part Allocation From Any Population
10 x 3 x 2 Crossed Design is shown

A minimum of two measurements/part/operator is required
Three is better!
Trial 1
Operator 1
Trial 2
P
a
Trial 1
r 1 2 3 4 5 6 7 8 9 10 Operator 2
t Trial 2
s
Trial 1
Operator 3
Trial 2
Data Collection Sheet
Create a data collection sheet for:

– 10 parts
– 3 operators
– 2 trials

The Data Collection Sheet

Gage R & R
Open the worksheet “Gage AIAG2 - SigmaXL

Format”.
Variables:
– Part
– Operator
– Response

Gage R & R
Use 1.0 for the

tolerance.

Graphical Output
Looking at the “Components of Variation” chart, the Part to Part Variation needs
to be larger than Gage Variation.
If in the “Components of Variation” chart the “Gage R&R” bars are larger than
the “Part-to-Part” bars, then all your measurement Variation is in the measuring
tool i.e.… “maybe the gage needs to be replaced”.
Part to Part
Variation
needs to be
larger than
Gage Variation

Graphical Output
The same concept applies to the “Response by Operator”

chart. If there is extreme Variation within operators, then the
training of the operators is suspect.
Operator
Error

Session Window
I can see clearly now!

Session Window
If the Variation due to Gage R & R is high, consider:

• Procedures revision?
• Gage update? • 20 % < % Tol GRR < 30%  Gage Unacceptable
• Operator issue? • 10 % < % Tol GRR < 20 %  Gage Acceptable
• Tolerance validation?
• 1 % < % Tol GRR < 10 %  Gage Preferable

Signal Averaging
Signal Averaging can be used to reduce Repeatability

error when a better gage is not available.
– Uses average of repeat measurements.
– Uses Central Limit theorem to estimate how many
repeat measures are necessary.
Signal Averaging is a
method to reduce
Repeatability error in a
poor gage when a better
gage is not available or
when a better gage is not
possible.

Signal Averaging Example
Suppose SV/Tolerance is 35%.
SV/Tolerance must be 15% or less to use gage.
Suppose the Standard Deviation for one part measured by one

person many times is 9.5.
Determine what the new reduced Standard Deviation should

be.

Signal Averaging Example
Determine sample size:
Using
Using the
the average
average ofof 66
repeated
repeated measures
measures
will
will reduce
reduce the
the
Repeatability
Repeatability
component
component of of
measurement
measurement error error to
to
the
the desired
desired 15%
15% level.
level.
This method should be considered temporary!

Paper Cutting Exercise
Exercise objective: Perform and Analyze a

variable MSA Study.
1. Cut a piece of paper into 12 different lengths that

are all fairly close to one another but not too
uniform. Label the back of the piece of paper to
designate its “part number”
2. Perform a variable gage R&R study as outlined in this
module. Use the following guidelines:
– Number of parts: 12
– Number of inspectors: 3
– Number of trials: 5
3. Create a SigmaXL® data sheet and enter the data
into the sheet as each inspector performs a
measurement. If possible, assign one person to data
collection.
4. Analyze the results and discuss with your mentor.

Attribute MSA
A methodology used to assess Attribute Measurement

Systems.
Attribute
Attribute Gage
Gage Error
Error
Repeatability
Repeatability Reproducibility
Reproducibility Calibration
Calibration
– They are used in situations where a continuous

measure cannot be obtained.
– It requires a minimum of 5x as many samples as a
continuous study.
– Disagreements should be used to clarify operational
definitions for the categories.
• Attribute data are usually the result of human judgment
(which category does this item belong in).
• When categorizing items (good/bad; type of call; reason for
leaving) you need a high degree of agreement on which
way an item should55be categorized.
OSSS LSS Green Belt v11.0 XL - Measure Phase © OpenSourceSixSigma,LLC
Attribute MSA Purpose
The purpose of an Attribute MSA is:

– To determine if all inspectors use the same criteria to determine “pass” from
“fail”.
– To assess your inspection standards against your customer’s requirements.
– To determine how well inspectors are conforming to themselves.
– To identify how inspectors are conforming to a “known master,” which
includes:
• How often operators ship defective product.
• How often operators dispose of acceptable product.
– Discover areas where:
• Training is required.
• Procedures must be developed.
• Standards are not available.
An Attribute MSA is similar in many ways to the continuous MSA, including

the purposes. Do you have any visual inspections in your processes? In
your experience how effective have they been?

Visual Inspection Test
Take 60 Seconds and count the number of times “F” appears in this
paragraph?
The Necessity of Training Farm Hands for First

Class Farms in the Fatherly Handling of Farm Live
Stock is Foremost in the Eyes of Farm Owners.
Since the Forefathers of the Farm Owners Trained
the Farm Hands for First Class Farms in the
Fatherly Handling of Farm Live Stock, the Farm
Owners Feel they should carry on with the Family
Tradition of Training Farm Hands of First Class
Farmers in the Fatherly Handling of Farm Live
Stock Because they Believe it is the Basis of Good
Fundamental Farm Management.

How can we Improve Visual Inspection?
Visual Inspection can be improved by:

• Operator Training & Certification
• Develop Visual Aids/Boundary Samples
• Establish Standards
• Establish Set-Up Procedures
• Establish Evaluation Procedures
– Evaluation of the same location on each part.
– Each evaluation performed under the same
lighting.
– Ensure all evaluations are made with the same
standard.
Look closely now!

Attribute Agreement Analysis
Attribute MSA (Binary)

Attribute MSA is also known as Attribute Agreement Analysis. The
response must be binary (e.g. Pass/Fail, Good/Bad, G/NG, Yes/No).
1. Open the worksheet Attribute MSA

– AIAG. This is an example from the
AIAG MSA Reference Manual, 3rd
Edition, page 127. Note that the
worksheet data must be in stacked
column format
2. Click SigmaXL > Measurement

Systems Analysis > Attribute MSA
(Binary). Ensure that the entire data
table is selected. Click Next.
3. Select Part, Appraiser, Assessed

Result and Reference as shown.
Check Report Information and enter
AIAG Example, Page 127.
4. Click OK. The results are shown on

the next slide.

Attribute MSA (Binary)

M&M Exercise
Exercise objective: Perform and Analyze an Attribute

MSA Study.
• You will need the following to complete the study:

– A bag of M&Ms containing 50 or more “pieces”
– The attribute value for each piece.
– Three or more inspectors.
Number Part Attribu • Judge each M&M as pass or fail.

te
1 M&M Pass – The customer has indicated that they want a bright and
shiny M&M and that they like M’s.
2 M&M Fail
3 M&M Pass • Pick 50 M&Ms out of a package.
• Enter results into SigmaXL®'s Attribute MSA Template

and draw conclusions.
• The instructor will represent the customer for the

Attribute score.
Summary
At this point, you should be able to:
• Understand Precision & Accuracy
• Understand Bias, Linearity and Stability
• Understand Repeatability & Reproducibility
• Understand the impact of poor gage capability on product quality
• Identify the various components of Variation
• Perform the step by step methodology in Variable and Attribute

MSA’s

The Certified Lean Six Sigma Green Belt
Assessment
The Certified Lean Six Sigma Green Belt (CLSSGB)
tests are useful for assessing Green Belt’s knowledge
of Lean Six Sigma. The CLSSGB can be used in
preparation for the ASQ or IASSC Certified Six Sigma
Green Belt (CSSGB) exam or for any number of other
certifications, including private company
certifications.
The Lean Six Sigma Green Belt Course

Manual
Open Source Six Sigma Course Manuals are
professionally designed and formatted manuals used
by Belt’s during training and for reference guides
afterwards. The OSSS manuals complement the OSSS
Training Materials and consist of slide content,
instructional notes data sets
and templates.
Get the latest products at…
www.OpenSourceSixSigma.com

4 Measure - Measurement System Analysis

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Measure Phase

Measurement System Analysis

Six Sigma Statistics

Wrap Up & Action Items

OSSS LSS Green Belt v11.0 XL - Measure Phase 2 © OpenSourceSixSigma,LLC

So far we have learned that the heart and soul of

How good are these?

MSA is a mathematical procedure to quantify variation

The item to be measured can be a physical part, document or a scenario for

In order to be worth collecting, measurements must

What do I need to know?

Too often, organizations build complex data collection

OSSS LSS Green Belt v11.0 XL - Measure Phase 5 © OpenSourceSixSigma,LLC

The purpose of MSA is to assess the error due to

OSSS LSS Green Belt v11.0 XL - Measure Phase 6 © OpenSourceSixSigma,LLC

OSSS LSS Green Belt v11.0 XL - Measure Phase 7 © OpenSourceSixSigma,LLC

MSA can be used to:

Compare internal inspection standards with the standards

Highlight areas where calibration training is required.

Provide a method to evaluate inspector training

Provide a great way to:

OSSS LSS Green Belt v11.0 XL - Measure Phase 8 © OpenSourceSixSigma,LLC

Measurement System Analysis is important to:

OSSS LSS Green Belt v11.0 XL - Measure Phase 9 © OpenSourceSixSigma,LLC

Appropriate Measures are:

• Relevant –help to understand/isolate the problems

• Representative - of the process across shifts and

• Contextual – collected with other relevant information

OSSS LSS Green Belt v11.0 XL - Measure Phase 10 © OpenSourceSixSigma,LLC

Poor Measures can result from:

Measurement Error compromises decisions that

OSSS LSS Green Belt v11.0 XL - Measure Phase 11 © OpenSourceSixSigma,LLC

Examples of what and when to measure:

MSA is a Show Stopper!!!

Whenever you measure anything, the variation that you

Unit-to-unit (true) Measurement System

Repeatability Reproducibility Stability Bias Linearity

OSSS LSS Green Belt v11.0 XL - Measure Phase 13 © OpenSourceSixSigma,LLC

A precise metric is one that returns the same value of

Precise data are independent of who estimates them

Precision can be partitioned into two components:

Repeatability and Reproducibility = Gage R+R

OSSS LSS Green Belt v11.0 XL - Measure Phase 14 © OpenSourceSixSigma,LLC

Repeatability is the variation in measurements obtained with

OSSS LSS Green Belt v11.0 XL - Measure Phase 15 © OpenSourceSixSigma,LLC

Reproducibility is the variation in the average of the

OSSS LSS Green Belt v11.0 XL - Measure Phase 16 © OpenSourceSixSigma,LLC

Exercise objective: Demonstrate how well you

1. Pair up with an associate.

OSSS LSS Green Belt v11.0 XL - Measure Phase 17 © OpenSourceSixSigma,LLC

An accurate measurement is the difference between the observed

OSSS LSS Green Belt v11.0 XL - Measure Phase 18 © OpenSourceSixSigma,LLC

In transactional processes, the measurement system can

However, before you invest a lot of time analyzing the

OSSS LSS Green Belt v11.0 XL - Measure Phase 19 © OpenSourceSixSigma,LLC

ACCURATE PRECISE BOTH

Accuracy relates to how close

Precision relates to the

OSSS LSS Green Belt v11.0 XL - Measure Phase 20 © OpenSourceSixSigma,LLC

Bias is defined as the deviation of the measured value

Calibration procedures can minimize and control bias

OSSS LSS Green Belt v11.0 XL - Measure Phase 21 © OpenSourceSixSigma,LLC

Stability of a gauge is defined as error (measured in terms of