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Home > Knowledge Center > Toolbox > Measurement System Analysis (MSA)
Characterization
A measurement system can be characterized, or described, in five ways:
Requirements
Following are general requirements of all capable measurement systems: Statistical stability over time.
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Variability small compared to the process variability. Variability small compared to the specification limits (tolerance). The resolution, or discrimination of the measurement device must be small relative to the smaller of either the specification tolerance or the process spread (variation). As a rule of thumb, the measurement system should have resolution of at least 1/10th the smaller of either the specification tolerance or the process spread. If the resolution is not fine enough, process variability will not be recognized by the measurement system, thus blunting its effectiveness.
Stability Assessment
1. Select a part from the middle of the process spread and determine its reference value relative to a traceable standard. If a traceable standard is not available, measure the part ten times in a controlled environment and average the values to determine the Reference Value. This part/sample will be designated as the Master Sample . 2. Over at least twenty periods (days/weeks), measure the master sample 3 to 5 times. Keep the number of repeats fixed. Take readings throughout the period to capture the natural environmental variation. 3. Plot the data on an x & R chart - consult the Statistical Process Control section of the Toolbox and calculate control limits. 4. Evaluate the control chart for statistical control. Again, consult the Statistical Process Control section of the Toolbox for assistance with this assessment.
Bias Assessment
1. Referring to the & R chart, subtract the Reference Value from to yield the Bias: Bias = x - Reference Value Process Variation = 6 Standard Deviations (Sigma) 2. Calculate the Bias percentage: Bias Percentage = Bias / Process Variation
3. Analyze the results. If there is a relatively high value, examine the following potential root causes: Appraisers not following the measurement procedure An error in measuring the Reference Value Instability in the measurement. If the SPC chart shows a trend, the measurement device could be wearing or calibration could be drifting.
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The analysis of measurement error is output in the green-shaded boxes on page 2 of the spreadsheet, which is shown below:
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Variation from the measurement device, or Repeatability, equals 25.98% of the total part variation, and 28% of the specification tolerance. Variation from the appraisers, or Reproducibility, is equal to 6.02% of the total part variation, and 7% of the specification tolerance. Total variation from Repeatability and Reproducibility combined (they are not directly additive) is 26.67% of the total variation, and 29% of the specification tolerance. The rule of thumb for acceptance of a measurement system is a total Gage R&R of 30% or less of the lessor of Total Variation or the Specification Tolerance. In this case, the measurement system is capable, and can be used as a basis of decision making. If the measurement system has error in excess of 30%, the first step to improve results is to analyze the breakdown of the error source. If the largest contributor to error is Repeatability, then the equipment must be improved. Likewise, if Reproducibility is the largest source of error, appraiser training and adherence to procedures can yield improvement. You can download a functional version of the Gage R&R spreadsheet. MoreSteam Hint: If the measurement system is not capable (error above 30%), error can be normalized by taking multiple measurements and averaging the results. This can be time consuming and expensive, but it can be used to provide reliable measurement data while the measurement system process is being improved.
Further Analysis
There are other methods that can be used to evaluate measurement systems. Most statistical software packages, including Minitab, support ANOVA methods. You can download free trial versions of several software packages through the Toolbox. For additional information on Measurement System Analysis, consult the following: An excellent statistics handbook is available free online from a partnership of SEMATECH and NIST (National Institute of Standards and Technology - U.S. Commerce Department) at http://www.itl.nist.gov/div898/handbook/mpc/section4/mpc4.htm You can purchase an excellent guide to Measurement System Analysis (MSA) for a nominal charge from the Automotive Industry Action Group under the publications/quality section of their Web site, or by calling (248) 358-3570. The AIAG also offers publications on other topics: QS-9000 Advanced Product Quality Planning (APQP) Failure Mode and Effects Analysis (FMEA) Statistical Process Control (SPC) Juran's Quality Handbook (Juran's Quality Handbook, 5th Ed) by Joseph M. Juran (Editor), A. Blanton Godfrey (Editor), A. Blanford Godfrey ISBN: 007034003X
Summary
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Measurement Systems Analysis is a key step to any process improvement effort. By understanding existing measurement systems a team can LOGIN better understand the data provided by those systems and make better business decisions.
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