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Gauge Repeatability and

United Composheets
(p) Ltd

This Gauge R and R Study is only Valid when number of samples per tr

Required Field

Specification

Part Number

Upper Tol.
21.50

AV0350/360

Unit of measure

Characteristic Outer Metal

Gauge Number

Lower Tol.
21.20

Tolerance
0.300

0.01

Rbar

Gauge Resolution

Machine Range 0-300mm


0.0147

Sample Analysis
Trials
Constant K1

Equipment Variation (E.V.)


E.V. = (Rbar) x (K1)
E.V. =
n = Number of samples

K1
0.00867

Appraiser Variation
A.V. = ((Xbar Diff * K2) - (E.V. / nr))

EV = equipment variation

Constant K2

0.5231

0.00387

0.0
Gauge Repeatability and Reproducibility
GRR = (E.V.) + (A.V.)
GRR =
0.00949
Rp =
Part Variation PV= Rp x K3
K3 =
PV =

0.5908

0.5908

r = Number of Trials

A.V. =

0.8862

0.0

0.236
0.3146

0.07411

Total Variation TV = GRR + PV


TV =
0.07471

Conditional 18.98%

Gauge R and R Acceptance Criteria


< 10% Tolerance Band
Gauge Acceptable
10% 30% Tolerance Band Gauge can be accepted based on importance of application, cos
>30% Tolerance Band
Considered not acceptable. Review opportunities to improve the

For information on the theory and the constants used in this excel sheet, see AIAG MSA Manual, Thrid Edition.

United Composheets
(p) Ltd

Gauge Repeatability and

Data

Appraiser
0
1
2
3
4
5
6
7
8
9
10

1
2
ASunil
Trial 1
Trial 2
21.420
21.440
21.450
21.440
21.350
21.350
21.410
21.420
21.280
21.270
21.480
21.470
21.340
21.360
21.250
21.250
21.320
21.340
21.350
21.380
213.650
213.720

3
Trial 3
21.430
21.440
21.370
21.420
21.280
21.480
21.350
21.260
21.320
21.360
213.710

4
Average
21.430
21.443
21.357
21.417
21.277
21.477
21.350
21.253
21.327
21.363
213.69
21.36933

Range
0.02000
0.01000
0.02000
0.01000
0.01000
0.01000
0.02000
0.01000
0.02000
0.03000
0.16
0.01600

5
BTrial 1
21.440
21.450
21.370
21.420
21.280
21.490
21.360
21.250
21.320
21.380
213.760

10

Samples measured

Ra bar
Xa bar

Ra bar

0.016

Rb bar
Rc bar

0.016
0.012
0.044
0.0147

Summation

Rbar
Samples Measures n=
Trials r =
Assessors

0.0160
21.3693

10
3
3

Comments:

Prtepared By:

Rb bar
Xb bar

Trials
2
3

D4 Constant
D4
3.27
2.58
2.580

UCLr =

UCLr represents the limit of the individuals R's.


Circles those that are beyond this limit. Identify the cause and co
Repeat these readings using the same appraiser and unit as orig
Or disregard the readings and recompute the averages and com

Gauge Repeatability and Reproducibility Study (GRR Study)

alid when number of samples per trial equals 10


Unit of measure mm

Date

Gauge Number HG-01

Compiled by Vargeshes

-300mm

14.04.06

Resolution
AL
Xbar Diff.

ALrel =

0.0080

Gauge
Resolution
AL rel =
Tolerance
AL rel =
AL rel

A.V. = appraiser variation

T
0.010
0.300
3.33%

10 % is acceptable
>10 20 % borderline acceptable
> 20 % not acceptable

R&R = Gauge Repeatability&Reproducibility

Tolerance Analysis
% E.V. = 100( E.V. / TV)
% E.V. =

Appraisers
17.33 Constant K2

11.60

% A.V. = 100 (A.V. / TV)


% A.V. =

0.7071

0.5231

Results based on Total Variation (TV)


Results based on percentage tolerance used where Cp

5.19

7.75

% R&R = 100 (GRR/ TV)


%R&R =

12.70

% PV = 100 (PV/TV)
%PV =
99.19
Number of distinct catagories
ndc
11.008

18.98

11

ndc ought to be 5

d on importance of application, cost of device, cost of repair. Here consider AV result and ndc.
eview opportunities to improve the measurement system.

Gauge Repeatability and Reproducibility Study (GRR Study)


Data collection sheet

Ajit
Trial 2
21.430
21.450
21.370
21.410
21.270
21.480
21.350
21.280
21.340
21.370
213.750

Trial 3
21.440
21.440
21.360
21.400
21.280
21.490
21.340
21.250
21.350
21.370
213.720

Average
21.437
21.447
21.367
21.410
21.277
21.487
21.350
21.260
21.337
21.373
213.74
21.37433

Range
0.01000
0.01000
0.01000
0.02000
0.01000
0.01000
0.02000
0.03000
0.03000
0.01000
0.16
0.01600

0.0160
21.3743

9
10
CMohan
Trial 1
Trial 2
21.420
21.420
21.440
21.450
21.380
21.390
21.420
21.430
21.280
21.290
21.500
21.510
21.350
21.360
21.250
21.240
21.340
21.320
21.370
21.380
213.750
213.790

Rc bar
Xc bar

Max Xbar

21.3773

Min Xbar
Xbar Diff.

21.3693
0.0080

11
Trial 3
21.430
21.450
21.390
21.420
21.270
21.500
21.360
21.250
21.330
21.380
213.780

0.0120
21.3773

0.0378

e individuals R's.
this limit. Identify the cause and correct.
he same appraiser and unit as originally used.
recompute the averages and complete the Gauge R and R manually and attach the results to this form.

Approved By

Page

1 of 2

on Total Variation (TV)


on percentage tolerance used where Cp=1

Page

2 of 2

12
Average
21.423
21.447
21.387
21.423
21.280
21.503
21.357
21.247
21.330
21.377
213.77
21.37733

Range
0.01000
0.01000
0.01000
0.01000
0.02000
0.01000
0.01000
0.01000
0.02000
0.01000
0.12
0.01200

Xp
Rp

21.374
0.236

21.430
21.446
21.370
21.417
21.278
21.489
21.352
21.253
21.331
21.371

0.02
0.01
0.04
0.03
0.02
0.04
0.02
0.04
0.03
0.03

2
3
4
5
6
7
8
9
10

K3 Faktor

0.31460

0.7071
0.5231
0.4467
0.403
0.3742
0.3534
0.3375
0.3249
0.3146

0
0
0
0
0
0
0
0
0.3146

Sona

GAUGE BIAS STUDY

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15

OBSERVATION
0.0180
0.0180
0.0180
0.0200
0.0180
0.0180
0.0180
0.0190
0.0180
0.0180
0.0180
0.0180
0.0190
0.0180
0.0180

HISTOGRAM
12
10
FREQUENCY

TRIALS (n)

8
6
4
2
0
MEASURED VALUE

0.2740

MAX (X) =

AVG (X) =

0.0183

D = MAX (X) - MIN (X) =

0.0020

REF. VALUE =

0.0180

b =r /n = 0.000145328

t = b/b =

BIAS (b) = AVG (X) - REF. VALUE =


v=

10.8 TM =

L = b - TM =

0.0003

0.02

MIN (X) =

0.02 r = D/ d2 =

SUM (X)

0.05

DATE : 6-11-2003
AIR PLUG GAUGE
AP 167
SH.KRISHAN

Gauge Name
Gauge No.
Appraiser

PART NO.:
A020-2111
PART NAME:
RBS OMNI
SPECIFICATION: DIA 50.0+0.03

M = d2 b /d2* =

d2* =

0.0001

0.0003

-0.000036

U = b +TM =

0.000569

d2 = 3.55333, FOR n = 15 (SUBGROUP SIZE) & NO OF SUBGROUPS (g) = 1


= 0.05 FOR 95 % CONFIDENCE LEVEL
v = 10.8 FOR n = 15 & g = 1
BIAS IS ACCEPTABLE IF L0 U

0.0006

3.5533

1.8349

d2 =

T = t(v, 1 - a/2) =

3.47
2.131

REMARKS:-

CHECKED BY :-

APPROVED BY :-

#VALUE!
#VALUE!

0.0180
0.0180
0.0180
0.0200
0.0180
0.0180
0.0180
0.0190
0.0180
0.0180
0.0180
0.0180
0.0190
0.0180

-0.0320
-0.0065
0.019
0.0445
0.07
0.0700

0.0180
0.0180
0.1020
0.0200

-0.0320
-0.0065
0.019
0.0445
0.07
0.0700

0
0
14
1
0
0

Sona

GAUGE LINEARITY STUDY


Gauge Name
Gauge No.
Appraiser

PART NO.:
A020-2111
PART NAME:
RBS OMNI
SPECIFICATION: DIA 50.0+0.03

PARTS
3

0.018

0.026

0.021

0.025

0.018

0.018

0.026

0.021

0.025

0.018

0.018

0.025

0.021

0.025

0.017

0.018

0.026

0.022

0.025

0.018

0.020

0.026

0.021

0.025

0.018

0.018

0.026

0.021

0.024

0.018

0.018

0.024

0.021

0.025

0.017

0.018

0.026

0.021

0.025

0.018

0.019

0.026

0.021

0.025

0.018

0.018

0.026

0.021

0.025

0.018

0.018

0.026

0.022

0.025

0.018

0.018

0.026

0.021

0.025

0.018

GAUGE LINEARITY ANALYSIS


12

0.1080

0.0260

-0.00030

0.0000

0.0210

0.00020

0.0000

0.0250

-0.00010

0.0180

-0.00020

Y
-0.0001

0.022

2
0

0.00068

0.0044

2E-005

0.33846 0.35846 0.59872

1E-004 -0.00003 -0.00013 7.059E-005

0.00044

-0.0006

4E-007

0.00629 0.02629 0.16215

3E-005 -0.00002 -5E-005 7.927E-006

0.0000

0.00063

0.0034

1E-005

0.2021

8E-005 -0.00003 -0.0001

0.0000

0.00032

-0.0036

1E-005

0.22657 0.24657 0.49656

Y2

D2

0.00

0.000

0.000

5.142E-005

L=B-Q

8E-005 -0.00001 -1E-004 6.886E-005

a = [ XY - ( X * Y/gm)]/ [ X2 - {(X)2/gm}] =
=

s = Sqrt [( Y2 - b Y - a XY )/ (gm - 2)] =


T = t( v, 1 - /2) =

Conclusion:

0.47127

0.0001

b = Y - aX
= 0.05

0.2221

U=B+Q

8E-005 -0.00001 -1E-004 6.886E-005

B = b + ax

0.22657 0.24657 0.49656

Q = sT* (j)

1E-005

(j)

-0.0036

H = D2/ D2

0.00032

XY X2
0.0000

j=(1\gm) + H

0.0000

D2

0.00030

d = X - X bar

0.0180

10

X2

XY

1
2
3
4
5

Bias (Y)

S.no

Ref. Value (X)

0.00030 -0.00030 0.00020 -0.00010 -0.00020

No. (g)

Ref. value
No. (m)
1
2
3
4
5
6
7
8
9
10
Avg (X )
Bias

DATE :6-11-2003
AIR PLUG GAUGE
AP 167
SH.KRISHAN

-0.0018936162

2.0902E-005
7.4155E-005
2.228

v = gm - 2

48

ltl = lal / [s/ sqrt[ (D2)]=

7E-01

Conclusion:

For acceptable linearity ltl should be less than T.

CHECKED BY:-

APPROVED BY:-

D2

0.0000572

Calculation of a
X Y/gm
X2 - { ( X)2/gm} =
( X * Y/gm)
[ XY - ( X * Y/gm)]
a=

calculation of s
a XY
b Y
( Y2 - b Y - a XY )

-2.09021106124E-009
0.0000
0.00000026394766

-0.000000216
0.0000
0.00023328
0.002
-0.0018936162
Y2
9E-08
9E-08
4E-08
1E-08
4E-08

( Y2 - b Y - a XY )/ (gm - 2)
Sqrt [( Y2 - b Y - a XY )/ (gm - 2)]

5.498909609654E-009
7.415463309635E-005

calculation of ltl
0.0018936162
0.0075630682
0.0027637078
0.6851723684

GAUGE BIAS STUDY

MICROTURNERS V

TRIALS (n)

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15

OBSERVATION
10.5050
10.5050
10.5050
10.5050
10.5060
10.5060
10.5070
10.5070
10.5070
10.5060
10.5050
10.5060
10.5050
10.5060
10.5060

SUM (X)

157.5870

AVG (X) =

10.5058

REF. VALUE =

10.5070

v=

14
12
12

12

10

10

66
44

0 1

10.507

MIN (X) =

b =r /n =
-0.0012

0.0001453278
M = d2 b /d2* =

10.505 r = D/ d2 =

0.0020

d2* =

t = b/b =

0.000142

0.000302

-0.001502

U = b +TM =

-0.0008976

REMARKS:-

APPROVED BY :-

0.0006

3.5533

-8.2572

d2 = 3.55333, FOR n = 15 (SUBGROUP SIZE) & NO OF SUBGROUPS (g) = 1


= 0.05 FOR 95 % CONFIDENCE LEVEL
v = 10.8 FOR n = 15 & g = 1
BIAS IS ACCEPTABLE IF L0 U

CHECKED BY :-

MEASURED VALUE
VALU
MEASURED

D = MAX (X) - MIN (X) =

10.8 TM =

L = b - TM =

HISTOGRAM
HISTOGRAM

MAX (X) =

BIAS (b) = AVG (X) - REF. VALUE =


0.05

DATE : 20.11.08
MICROMETER
M-005
IKRAR

Gauge Name
Gauge No.
Appraiser

SG-001
SLIP GAUGE
DIM 10.507

FREQUENCY
FREQUENCY

PART NO.:
PART NAME:
SPECIFICATION:

d2 =

T = t(v, 1 - a/2) =

3.47
2.131

#VALUE!
#VALUE!

10.5050
10.5050
10.5050
10.5050
10.5060
10.5060
10.5070
10.5070
10.5070
10.5060
10.5050
10.5060
10.5050
10.5060

10.4550
10.4805
10.506
10.5315
10.557
10.5570

10.5060
10.5050
0.1020
10.5070

10.4550
10.4805
10.506
10.5315
10.557
10.5570

0
0
12
3
0
0

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