Measurement Systems Analysis: Total Quality Management

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Measurement Systems Analysis
TOTAL QUALITY MANAGEMENT
M.S.A.
Power Solutions ABSL STM Quality Limited 2007
Outline and Objectives

Introduce Measurement Systems
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Assess Measurement Systems Performance
Understand Measurement System Variation
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Requirements for M.S.A.

TS16949 Clause 7.6.1. states:
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Statistical studies shall be conducted to analyse the
variation present in the results of each type of measuring and test equipment system. This requirement shall apply to measurement systems referenced in the control plan. The analytical methods and acceptance criteria used shall conform to those in customer reference manuals on measurement systems analysis. Other analytical methods and acceptance criteria may be used if approved by the customer.
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Process Control
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A Typical Process
People Methods Material Equipment Environment
Input
PROCESS
Product
Identifying Improvement Opportunities
Process / System
Output
Accurate Measurement using Measurement System Analysis

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New Process Acceptance

Observed Process
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Production Gauge
Variation
Variation
Actual Process
Variation
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Assessing Measurement Systems
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Location variation
Bias Stability
Width variation
Linearity Repeatability, Reproducibility

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Determining and Assessing Bias

Bias is the difference between
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Observed Average Value
the observed average of measurement and the reference value. Bias 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 Reference measured values. A reference Value value can be determined by averaging several measurements with a higher level of measuring equipment.
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Determining and Assessing Stability

Stability (or drift) is the total
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Time
variation in the measurements obtained with a measurement system on the same master or part when measuring a single characteristic over an extended time period
Reference Value
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STM Quality Limited Determining and Assessing Linearity

Linearity is the difference in the bias values through the
expected operating range of the gauge.
Reference Value
Reference Value
Smaller Bias
Larger Bias
50mm
200mm
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Determining Repeatability
Repeatability is the variation in
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measurements obtained By one appraiser with one measurement instrument when used several times while measuring the identical characteristic on the same part
Repeatability
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Determining Reproducibility
Reproducibility is the variation in
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the average of the measurements made by different appraisers using the same measuring instrument when measuring the identical characteristic on the same part
Reproducibility
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Preparing For A Measurement System Study

Variable Gauge Study (Average and Range Method)
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The average and range method of gauge study breaks the gauge error into repeatability and reproducibility. Optimum conditions: 3 operators; 3 trials; 10 parts. Study of the results can provide information concerning the causes of the measurement error.
If reproducibility is large compared to repeatability then; The operator is not properly trained in how to use and read the gauge; Graduations on the gauge are not clear.
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Determining and Assessing Repeatability and Reproducibility
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There are three methods:

Range Method; Average and Range Method; Analysis of Variation Method (ANOVA).
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Range Method
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Gives a quick approximation of measurement variability. It does not
decompose the variability into repeatability and reproducability. Conducted with 2 appraisers and 5 parts; Each appraiser measures each part once; Evaluate the range at each part; Estimate the variation between the measurement results over the average Range (R/d2); Gauge R&R = 99%-area under the normal distribution curve (2*2,576*variation). (not sufficient for PPAP and QS-9000 clause 4.11.4)
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Average and Range Method
Evaluates Repeatability and Reproducibility separately; Conducted typically with three appraisers and 10 parts;
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Each appraiser measures each part three time in a random order;

Evaluation graphical or numerical; EV (equipment variation) AV (appraiser variation)
R&R (R&R) = EV + AV
Part Variation PV Total VariationTV = (R&R) + PV
(99%- norm. distr.) (99%- norm. distr.) (99%- norm. distr.) (99%- norm. distr.) (99%- norm. distr.)
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Analysis of Variation Method
Evaluates Repeatability and Reproducibility separately; Evaluates Interaction between appraiser and part;
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Conducted typically with three appraisers and 10 parts;

Each appraiser measures each part three time in a random order; Evaluation graphical or numerical; EV (equipment variation)
AV (appraiser variation)
R&R (repeatability, reproducibility and interaction (I) R&R (R&R) = EV + AV+I Part Variation PV
(99%- norm. distr.) (99%- norm. distr.) (99%- norm. distr.) (99%- norm. distr.) (99%- norm. distr.)
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Total Variation TV = (R&R) + PV

The instrument needs maintenance; The gauge should be redesigned to be more rigid;
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If repeatability is large compared to reproducibility, the reasons may be:
The clamping or location for gauging needs to be improved; There is excessive part variation. If reproducibility is large compared to repeatability, then possible causes
could be: The appraiser needs to be better trained in how to use and read the gauge instrument; Calibrations on the gauge dial are not clear; A fixture of some sort may be needed to help the appraiser use the gauge more consistently.
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