Gage R&R Study 2

Date: 12/31/2005 Operator 1: Hal

Gage Name: Thickness Operator 2: Beth
Gage Number: 101 Operator 3: Loa
Gage Type: Thickness
Product: Widget
Characteristic: Thickness
Upper Specification Limit: 2
Lower Specification Limit: -2
Performed By: Bill

Operator Trial/Part 1 2 3 4 5 6 7 8 9 10
Hal 1 0.29 -0.56 1.34 0.47 -0.8 0.02 0.59 -0.31 2.26 -1.36
Hal 2 0.41 -0.68 1.17 0.5 -0.92 -0.11 0.75 -0.2 1.99 -1.25
Hal 3 0.64 -0.58 1.27 0.64 -0.84 -0.21 0.66 -0.17 2.01 -1.31
Beth 1 0.08 -0.47 1.19 0.01 -0.56 -0.2 0.47 -0.63 1.8 -1.68
Beth 2 0.25 -1.22 0.94 1.03 -1.2 0.22 0.55 0.08 2.12 -1.62
Beth 3 0.07 -0.68 1.34 0.2 -1.28 0.06 0.83 -0.34 2.19 -1.5
Loa 1 0.04 -1.38 0.88 0.14 -1.46 -0.29 0.02 -0.46 1.77 -1.49
Loa 2 -0.11 -1.13 1.09 0.2 -1.07 -0.67 0.01 -0.56 1.45 -1.77
Loa 3 -0.15 -0.96 0.67 0.11 -1.45 -0.49 0.21 -0.49 1.87 -2.16
 Gage Repeatability and Reproducibility Report

Gage Name: Thickness Product: Widget Date: 12/31/05

Gage No. 101 Characteristic: Thickness Performed by: Bill
Gage Type: Thickness USL: 2
LSL: -2

Rbar= 0.341667 XbarDiff= 0.444667 Rp= 3.511111

K1= 0.5908 K2= 0.5231 K3= 0.3146
Measurement Unit Analysis % Total Variation (TV) % Tolerance
Repeatability - Equipment Variation (EV)
EV = Rbar * K1 % EV = 100(EV/TV) % EV = 100(EV/(USL-LSL)/6)
= 0.20186 = 17.61% = 30.28%
Reproducibility - Appraiser Variation (AV)
AV= Sqrt((XbarDiff * K2)2 - (EV2)/nr)) % AV = 100(AV/TV) % AV = 100(AV/(USL-LSL)/6)
= 0.22967 = 20.04% = 34.45%
Repeatability & Reproducibility (R & R)
R&R= sqrt(EV2 + AV2) % R&R = 100(R&R/TV) % R&R = 100(R&R/(USL-LSL)/6)
= 0.30577 = 26.68% = 45.87%
Part Variation (PV)
PV= Rp * K3 % PV = 100(PV/TV) % PV = 100(PV/(USL-LSL)/6)
= 1.1046 = 96.38% = 165.69%
Total Variation (TV)
TV= sqrt(R&R2 + PV2) ndc= 1.41(PV/R&R)
= 1.14614 = 5.093652

Conclusion

% R&R under 10% of Total Variation: Measurement system is acceptable

**** % R&R from 10% to 30% of Total Variation: Measurement system may be acceptable based the application

% R&R over 30% of Total Variation: Measurement system needs improvement

 Subgroup Averages Chart (Avg.=0, UCL=0.35, LCL=-0.35)

2.5

1.5

0.5
Average

0
Hal-1 Hal-2 Hal-3 Hal-4 Hal-5 Hal-6 Hal-7 Hal-8 Hal-9 Hal-10 Beth-1 Beth-2 Beth-3 Beth-4 Beth-5 Beth-6 Beth-7 Beth-8 Beth-9 Beth- Loa-1 Loa-2 Loa-3 Loa-4 Loa-5 Loa-6 Loa-7 Loa-8 Loa-9 Loa-10
10

-0.5

-1

-1.5

-2

-2.5

Operator-Part Number
 Stacked Averages Chart (Avg.=0, UCL=0.35, LCL=-0.35)

2.5

1.5

0.5 Xbar
UCL
Average

0 LCL
Hal
-0.5 Beth
Loa

-1

-1.5

-2

-2.5
1 2 3 4 5 6 7 8 9 10

Part Number
 Stacked Range Chart (Avg.=0.34, UCL=0.88, LCL=None)

1.2

0.8

Rbar
UCLr
Average

0.6
Hal
Beth
Loa

0.4

0.2

0
1 2 3 4 5 6 7 8 9 10

Part Number
 Range Chart (Avg.=0.34, UCL=0.88, LCL=None)

1.2

0.8

0.6
Average

0.4

0.2

0
Hal-1 Hal-2 Hal-3 Hal-4 Hal-5 Hal-6 Hal-7 Hal-8 Hal-9 Hal-10 Beth-1 Beth-2 Beth-3 Beth-4 Beth-5 Beth-6 Beth-7 Beth-8 Beth-9 Beth- Loa-1 Loa-2 Loa-3 Loa-4 Loa-5 Loa-6 Loa-7 Loa-8 Loa-9 Loa-10
10

Operator-Part Number
 Range Chart for Hal (Avg.=0.184, UCL=0.474, LCL=None)

0.5

0.45

0.4

0.35

0.3
Range

0.25

0.2

0.15

0.1

0.05

0
Hal-1 Hal-2 Hal-3 Hal-4 Hal-5 Hal-6 Hal-7 Hal-8 Hal-9 Hal-10

Part/Sample
 Range Chart for Beth (Avg.=0.513, UCL=1.32, LCL=None)

1.4

1.2

0.8
Range

0.6

0.4

0.2

0
Beth-1 Beth-2 Beth-3 Beth-4 Beth-5 Beth-6 Beth-7 Beth-8 Beth-9 Beth-10

Part/Sample
 Range Chart for Loa (Avg.=0.328, UCL=0.844, LCL=None)

0.9

0.8

0.7

0.6

0.5
Range

0.4

0.3

0.2

0.1

0
Loa-1 Loa-2 Loa-3 Loa-4 Loa-5 Loa-6 Loa-7 Loa-8 Loa-9 Loa-10

Part/Sample
 Bias Chart (Avg=0.001, UCL=0.111, LCL=-0.109)

0.3

0.2

0.1
Average

0
Hal Beth Loa

-0.1

-0.2

-0.3

Operator
 Consistency Chart (Avg=0.34, UCL=0.509, LCL=0.171)

0.6

0.5

0.4
Average Range

0.3

0.2

0.1

0
Hal Beth Loa

Operator
XYPlots

XY Plot for Hal

3
2
1
Value

0
-1
-2
-3
-2 -1.5 -1 -0.5 0 0.5 1 1.5 2 2.5
Part Average

XY Plot for Beth

3
2
1
Value

0
-1
-2
-3
-2 -1.5 -1 -0.5 0 0.5 1 1.5 2 2.5
Part Average

XY Plot for Loa

3
2
1
Value

0
-1
-2
-3
-2 -1.5 -1 -0.5 0 0.5 1 1.5 2 2.5
Part Average
 Frequency Frequency Frequency

0
1
2
3
4
5
6
0
1
2
3
4
5
6
7

0
1
2
3
4

0.5
1.5
2.5
3.5
4.5
-0.58 -0.58
-0.58
-0.53 -0.53
-0.53
-0.48 -0.48
Normalized Histograms

-0.48
-0.43 -0.43
-0.43
-0.38 -0.38
-0.38
-0.33 -0.33
-0.33
-0.28 -0.28
-0.28
-0.23 -0.23
-0.23
-0.18 -0.18
-0.18
-0.13 -0.13
-0.13
-0.08 -0.08 -0.08
-0.03 -0.03 -0.03
0.02 0.02 0.02
0.07 0.07 0.07
0.12 0.12 0.12
0.17 0.17 0.17
Hal: Normalized Histogram

Loa: Normalized Histogram

Beth: Normalized Histogram

0.22 0.22 0.22

0.27 0.27 0.27
0.32 0.32 0.32

Normalized Value = Observed Value - Part Average

Normalized Value = Observed Value - Part Average
Normalized Value = Observed Value - Part Average

0.37 0.37 0.37

0.42 0.42 0.42
0.47 0.47 0.47
0.52 0.52 0.52
0.57 0.57 0.57
0.62 0.62 0.62
0.67 0.67 0.67
Error Charts

Error Charts
0.8
0.6
0.4
0.2 Hal
0 Beth
Error

-0.2 Loa
-0.4 Zero Line
-0.6
-0.8
111111111222222222333333333444444444555555555
Part

Error Charts
0.8
0.6
0.4
0.2 Hal
0 Beth
Error

-0.2 Loa
-0.4 Zero Line
-0.6
-0.8
6 6 6 7 7 7 8 8 8 9 9 9 10 10 10
Part
Whisker Plots

Whiskers
3
2
Appr. Hal Value

1
Average
0
Maximum
-1 Minimum
-2
-3
1 2 3 4 5 6 7 8 9 10
Part

Whiskers
3
2
Appr. Beth Value

1
Average
0
Maximum
-1 Minimum
-2
-3
1 2 3 4 5 6 7 8 9 10
Part

Whiskers
3
2
Appr. Loa Value

1
Average
0
Maximum
-1 Minimum
-2
-3
1 2 3 4 5 6 7 8 9 10
Part
Scatter Plots

Scatter Plots
3
2
1
Hal
Value

0
Beth
-1 Loa
-2
-3
111111111222222222333333333444444444555555555
Part

Scatter Plots
3
2
1
Hal
0
Value

Beth
-1 Loa
-2
-3
6 6 6 6 6 7 7 7 7 8 8 8 8 8 9 9 9 9 10 10 10 10 10

Part
 Run Chart by Part

2.5

1.5

0.5

0
Value

-0.5

-1

-1.5

-2

-2.5
0 1 2 3 4 5 6 7 8 9 10 11

Part Number
Part Appraiser Appraiser B
1 0.85 0.8
2 0.75 0.7
3 1 0.95
4 0.45 0.55
5 0.5 0.6
Range Method for Gage R&R

Average Range (Rbar) = 0.07

Upper Control Limit = 0.22869
Lower Control Limits = None
In Control? Yes
GRR = Rbar/d2* = 0.058772
Process Standard Deviation = 0.0777
%GRR = 100(GRR/Process Standard Deviation = 75.6%
Conclusion: The measurement system needs improvement.

Range Chart
0.25

0.2

0.15
Range

0.1

0.05

0
1 2 3 4
Part Number
4 5
Bias Example Reference Value = 6

Trial Value
1 5.8
2 5.7
3 5.9
4 5.9
5 6.0
6 6.1
7 6.0
8 6.1
9 6.4
10 6.3
11 6.0
12 6.1
13 6.2
14 5.6
15 6.0
 Alpha=0.05
Standard
Reference Deviation t value (2
n Mean Value (s) t statistic df tailed) Bias
Measured Value 15 6.006667 6 0.21202 0.121781 14 2.144787 0.006667

There is no evidence that the average is significantly different than reference value. You may assume the bias is zero

Bias - Independent Sample Method

4.5
4
3.5
3
Frequency

2.5
2
1.5
1
0.5
0
5.6 5.7 5.8 5.9 6.0 6.1 6.2 6.3 6.4
Measured Value
 Confidence Interval

Lower Upper
5.889254 6.124079

may assume the bias is zero.

6.4
Sample Results
1 100.1
2 101.9
3 101
4 100.2
5 100.6
6 101.5
7 100.6
8 100.2
9 101.1
10 101.6
11 100.8
12 101.4
13 101.5
14 100.8
15 102
16 100.9
17 100.5
18 101.3
19 101.6
20 101.3
 Alpha=0.05
Standard
Reference Deviation t value (2
n Mean Value (s) t statistic df tailed) Bias
Measured Value 15 101.045 100.3 0.566127 5.885146 19 2.093024 0.745

There is evidence that the average is significantly different than the reference value. The bias is not zero.

Bias - Independent Sample Method

2.5
2
1.5
Frequency

1
0.5

0
1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0
00. 00. 00. 00. 00. 00. 00. 00. 00. 01. 01. 01. 01. 01. 01. 01. 01. 01. 01. 02.
1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
Measured Value

X Chart
104
103 1
102
Sample Result

101 1
100
99 1
98
97
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
Sample Number

Moving Range Chart

2.5
1
2
Moving Range

1.5

1
1
0.5

0
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
Sample Number
 1.5

Moving Ran
1
1
0.5

0
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
Sample Number
 Confidence Interval

Lower Upper
100.78 101.31

bias is not zero.

9 0
01. 02.
1 1

8 19 20

8 19 20
8 19 20
Part 1 2 3 4 5
Ref Value 2 4 6 8 10
1 2.7 5.1 5.8 7.6 9.1
2 2.5 3.9 5.7 7.7 9.3
3 2.4 4.2 5.9 7.8 9.5
4 2.5 5 5.9 7.7 9.3
5 2.7 3.8 6 7.8 9.4
6 2.3 3.9 6.1 7.8 9.5
7 2.5 3.9 6 7.8 9.5
8 2.5 3.9 6.1 7.7 9.5
9 2.4 3.9 6.4 7.8 9.6
10 2.4 4 6.3 7.5 9.2
11 2.6 4.1 6 7.6 9.3
12 2.4 3.8 6.1 7.7 9.4
 Linearity
y = -0.132x + 0.737, R Sqr = 71.4%

1.5

Bias
0.5
Regression
Upper 95% CI
Bias

Lower 95% CI
Bias Average
0
Bias=0

-0.5

-1
2 3 4 5 6 7 8 9 10

Reference Values
Attribute Gage R&R Study
Date: 1231/05 Operator 1: Hal
Gage Name: Att Gage Operator 2: Beth
Gage Number: 102 Operator 3: Loa
Gage Type: Att Gage
Product: Widget
Characteristic: Attribute
Pass Value 1
Fail Value 0
Performed By: Bill

Reference 1 1 0 0 0
Operator Trial/Part 1 2 3 4 5
Hal 1 1 1 0 0 0
Hal 2 1 1 0 0 0
Hal 3 1 1 0 0 0
Beth 1 1 1 0 0 0
Beth 2 1 1 0 0 0
Beth 3 1 1 0 0 0
Loa 1 1 1 0 0 0
Loa 2 1 1 0 0 0
Loa 3 1 1 0 0 0
 1 1 1 0 1 1 0 1
6 7 8 9 10 11 12 13
1 1 1 0 1 1 0 1
1 1 1 0 1 1 0 1
0 1 1 0 1 1 0 1
1 1 1 0 1 1 0 1
1 1 1 0 1 1 0 1
0 1 1 0 1 1 0 1
1 1 1 0 1 1 0 1
0 0 1 0 1 1 1 1
0 1 1 0 1 1 0 1
 1 1 1 1 1 1 1 1
14 15 16 17 18 19 20 21
1 1 1 1 1 1 1 1
1 1 1 1 1 1 1 1
0 1 1 1 1 1 1 0
1 1 1 1 1 1 1 1
1 1 1 1 1 1 1 0
1 1 1 1 1 1 1 1
1 1 1 1 1 1 1 0
0 1 1 1 1 1 1 1
0 1 1 1 1 1 1 0
 0 1 1 0 0 1 1 1
22 23 24 25 26 27 28 29
0 1 1 0 0 1 1 1
0 1 1 0 1 1 1 1
1 1 1 0 0 1 1 1
0 1 1 0 0 1 1 1
1 1 1 0 0 1 1 1
0 1 1 0 0 1 1 1
1 1 1 0 0 1 1 1
1 1 1 0 0 1 1 1
0 1 1 0 1 1 1 1
 0 1 1 1 0 1 1 0
30 31 32 33 34 35 36 37
0 1 1 1 0 1 1 0
0 1 1 1 0 1 1 0
0 1 1 1 1 1 0 0
0 1 1 1 0 1 1 0
0 1 1 1 0 1 1 0
1 1 1 1 1 1 1 0
0 1 1 1 0 1 1 0
0 1 1 1 1 1 0 0
0 1 1 1 1 1 1 0
 1 0 1 1 0 1 1 0
38 39 40 41 42 43 44 45
1 0 1 1 0 1 1 0
1 0 1 1 0 0 1 0
1 0 1 1 0 1 1 0
1 0 1 1 0 1 1 0
1 0 1 1 0 1 1 0
1 0 1 1 0 1 1 0
1 0 1 1 0 1 1 0
1 0 1 1 0 1 1 0
1 0 1 1 0 0 1 0
 1 1 0 1 0
46 47 48 49 50
1 1 0 1 0
1 1 0 1 0
1 1 0 1 0
1 1 0 1 0
1 1 0 1 0
1 1 0 1 0
1 1 0 1 0
1 1 0 1 0
1 1 0 1 0
Attribute Gage R&R Effectiveness

Gage Name: Att Gage Product: Widget Date: 1231/05

Gage No. 102 Characteristic: Attribute Performed by: Bill
Gage Type: Att Gage

% Appraiser1 % Score vs Attribute2

Source Hal Beth Loa Hal Beth Loa
Total Inspected 50 50 50 50 50 50
# Matched 42 45 40 42 45 40
False Negative (Appraiser biased toward rejection) 0 0 0
False Positive (Apprasier biased toward acceptance) 0 0 0
Mixed (Appraiser accepts and rejects the same part) 8 5 10
95% UCI 92.8% 96.7% 90.0% 92.8% 96.7% 90.0%
Calculated Score 84.0% 90.0% 80.0% 84.0% 90.0% 80.0%
95% LCI 70.9% 78.2% 66.3% 70.9% 78.2% 66.3%

System % Effectiveness Score3 System % Effectiveness Score vs Reference4

Total Inspected 50 50
# in Agreement 39 39
95% UCI 88.5% 88.5%
Calculated Score 78.0% 78.0%
95% LCI 64.0% 64.0%

Notes:
(1) Appraiser agrees with him/herself on all trials
(2) Appraiser agrees on all trails with the known reference
(3) All appraisers agreed within and between themselves
(4) All appraisers agreed with and between themselves and agreed with the reference
(5) UCI and LCLI are the upper and lower confidence interval bounds respectively
Kappa Measures for the Appraisers

Kappa Hal Beth Loa

Hal - 0.86 0.78
Beth 0.86 - 0.79
Loa 0.78 0.79 -

There is good to excellent agreement since all kappa values are greater than 0.75

Kappa Values For Each Appraiser to Reference

Hal Beth Loa

Kappa 0.88 0.92 0.77

There is good to excellent agreement since all kappa values are greater than 0.75
 Hal * Beth Crosstabulation
Beth
Fail Pass Total Kappa
Hal Fail Count 44 6 50 0.86
Expected Count 15.7 34.3 50.0
Pass Count 3 97 100
Expected Count 31.3 68.7 100
Total Count 47 103 150
Expected Count 47.0 103.0

Hal * Loa Crosstabulation

Loa
Fail Pass Total Kappa
Hal Fail Count 43 7 50 0.78
Expected Count 17.0 33.0 50.0
Pass Count 8 92 100
Expected Count 34.0 66.0 100
Total Count 51 99 150
Expected Count 51.0 99.0

Beth * Loa Crosstabulation

Loa
Fail Pass Total Kappa
Beth Fail Count 42 5 47 0.79
Expected Count 16.0 31.0 47.0
Pass Count 9 94 103
Expected Count 35.0 68.0 103
Total Count 51 99 150
Expected Count 51.0 99.0

Hal * REF Crosstabulation

REF
Fail Pass Total Kappa
Hal Fail Count 45 5 50 0.88
Expected Count 16.0 34.0 50.0
Pass Count 3 97 100
Expected Count 32.0 68.0 100
Total Count 48 102 150
Expected Count 48.0 102.0
 Beth * REF Crosstabulation
REF
Fail Pass Total Kappa
Beth Fail Count 45 2 47 0.92
Expected Count 15.0 32.0 47.0
Pass Count 3 100 103
Expected Count 33.0 70.0 103
Total Count 48 102 150
Expected Count 48.0 102.0

Loa * REF Crosstabulation

REF
Fail Pass Total Kappa
Loa Fail Count 42 9 51 0.77
Expected Count 16.3 34.7 51.0
Pass Count 6 93 99
Expected Count 31.7 67.3 99
Total Count 48 102 150
Expected Count 48.0 102.0