Gage R&R Values

Gage R&R
Average & Range Method
Operator 1
Enter your data here->

Operator 2
Enter your data here->

Operator 3
Enter your data here->

Range Average
XDiff
UCL
LCL
Repeatability(EV)
Reproducibility(AV)
Gage Capability(R&R)
Spec Tolerance
Acceptability(%)

Part Number
1
2
3
4
5
6
Trial 1
161.9029
162.8849 157.4481 161.4723 163.9044
Trial2
161.6528
162.3719 157.6452 161.8202 163.1367
Trial3
161.1815
162.8556 157.4301 161.4192 163.5372
Trial4
161.6475
162.0956 157.1014 161.3480 163.6517
Trial 5
161.1152
162.8093 157.0261 161.0341 163.6724
Total
807.4998625 813.01721 786.6509 807.09378 817.9024
Average-Appraiser 1 161.4999725 162.60344 157.3302 161.41876 163.5805
Range1
0.787738479 0.7892746 0.619021 0.7860833 0.767646
Trial 1
161.3003
162.0552 157.3160 161.4939 163.4763
Trial2
161.6409
162.5852 157.4214 161.2322 163.2772
Trial3
161.5730
162.6567 157.6494 161.0481 163.3288
Trial4
161.6017
162.7871 157.4674 161.3633 163.7935
Trial 5
161.8177
162.5603 157.4561 161.2770 163.9772
Total
807.9336892 812.64439 787.3103 806.41456 817.8531
Average-Appraiser 2 161.5867378 162.52888 157.4621 161.28291 163.5706
Range2
0.517446303 0.7318805 0.333359
0.44582 0.699979
Trial 1
161.9907
162.6039 157.7899 161.1316 163.5870
Trial2
161.3322
162.2157 157.0020 161.1740 163.6769
Trial3
161.2918
162.7685 157.0717 161.1229 163.1688
Trial4
161.4487
162.4205 157.2639 161.2684 163.4256
Trial 5
161.5531
162.2439 157.5576 161.0933 163.8795
Total
807.6163975 812.2525 786.6851 805.79031 817.7378
Average-Appraiser 3 161.5232795 162.4505 157.337 161.15806 163.5476
Range3
0.698905244 0.5528191 0.787852 0.1751751 0.710754
0.6269
0.0833
1.3228
0.0000
0.2695
0.0000
0.2695
0.0100
26.95

% Using
% Using
AIAG - Automotive Industry Action Group Formula
TV
Tolerance
Equipment Variation (Repeatability)
0.2695
%EV
10.7%
16171%
Appraiser Variation (Reproducibility)
0.00000
%AV
0.0%
0%
R&R (Gage Capability)
0.2695

Constants
4 Trials 3 Trials
2 Trials # Trials
2.11
2.28
2.58
3.27
D4
0
0
0
0
D3
0.577
0.729
1.023
1.88
A2
0.4299 0.4857
0.5908 0.8862
K1
0.7071 0.5231
K2
2 Ops
3 Operators
5 Trials

5
2.11
0
0.577
0.4299
0.5231

%R&R
PV (Part Variation)
%PV
TV (Total Variation)

10.7%
2.4945
99.4%
2.5090

16171%
149669%

Conclusions / Recommendations
Gage system may be acceptable based on importance of application and cost
Gage may need maintenance, redesign, or better clamping
# Parts

#Trials
5

Calculate GageR&R using Anova

Anova Source
Appraiser

df

SS
2

MS
###

#Ops
5

With Interaction
Without Interaction
P
P
F
F
-4
Err:502
-34
Err:502
###

4
331.2742 82.818542 0.00035
8
### 234027.42 3E+006
60
4.1269
0.0688
68
###
###
74 335.7077465

Parts
Appraiser x Part
Gage w AP Interaction
Gage w/o AP Interaction
Total

Estimate of Variance

Repeatability
Appraiser
AppraiserxPart
R&R
Part

Std. Dev

0.06878
46805.4780240638
46805.4704003952
93611.01721
15596.30682

1.00000 0.00301 0.99998

0.00000

% Study
Variation

5.15* Stdev

0.262263832
216.3457372
216.3457196
305.9591757
124.8851745

EV
AV
INT
R&R
PV
TV

1.350659
1114.181
1114.18
1575.69
643.1586
1701.896

%
Contributio
n

0%
65%
65%
93%
38%

0%
43%
43%
86%
14%

Part by Appraiser Plot (Stacked)

166

164

162
Averagge
160

158

156

154
1

6
Part

Part by Appraiser Plot

166

164

162

164

162
Averagge
160

158

156

154
1

10

Appraiser 1

10

Range of Parts by Appraiser (Stacked)

0.9
0.8
0.7
0.6
0.5
Range
0.4
0.3
0.2
0.1
0
1

6
Parts

Range of Parts by Appraiser

0.9
0.8
0.7

Ap

Appraiser 2

Range of Parts by Appraiser

0.9
0.8
0.7
0.6
0.5
Range
0.4
0.3
0.2
0.1
0
1

Appraiser 1

10

Appraiser 2

10

Ap

0.8
0.7
0.6
0.5
Range
0.4
0.3
0.2
0.1
0
1

10

Appraiser 2

Appraiser 1
Instructions

10

Ap

1. Select 10 DIFFERENT parts and at least two "appraisers" and one gage
(If you don't use enough parts, part variation will be small and magnify the appraiser/equipment variation)
2. RANDOMLY, have appraisers measure each part at least twice
3. Then enter the results of each measurement in Cells C3:L7, C11:L15, C19:L23
4. The template will automatically calculate all of the values based on your data
5. Evaluate your measurement system based on %R&R and make adjustments as required.

Gage Repeatability and Reproducibility

Measurement is one common cause of variation. Gage R&R helps improve measurement systems
If repeatability (EV - Can the same person using the same gauge measure the same thing consistently)
is larger than reproducibility, reasons include:
1. Gage instrument needs maintenance
2. Gage needs to be redesigned
3. Clamping or location needs to be improved
4. Excessive within-part variation
If reproducibility (AV-can two appraisers measure the same thing and get the same result)
is larger than repeatability, reasons include:
1. Operator needs to be better trained in how to use and read gage
2. Calibrations on gage are not clear
3. Fixture required to help operator use gage more consistently
Gage System Acceptability
%R&R<10%
%R&R<30%
%R&R>30%

Gage System Okay (Most variation caused by parts, not people or equipment)
May be acceptable based on importance of application and cost of gage or repair
Gage system needs improvement (people and equipment cause over 1/3 of variation

Verified using AIAG Measurement Systems Analysis 3rd Edition

Gage R&R Values

Gage R&R Percentages

10

Sum

807.613
806.627
806.424
805.844 Xbar1
805.657 161.286566

Reference
12.500 <-Insert Reference Value Here
Bias

Rbar1
0.74995262
805.642
806.157
806.256
807.013 Xbar2
807.088 161.28624

148.787

Reference
12.500
Bias

Rbar2
0.54569694
807.103
805.401
805.424
805.827 Xbar3
806.327 161.203284

148.786

Reference

Rbar3
0.58510126

UCL represents the limit of the individual R's

Circle those beyond the limit.
Identify and correct causes
LCL = 0 D3=0 for up to 7 trials

12.500

Bias
148.703

cked)

AverageAppraiser 1

10

10

10

Appraiser 3

Stacked)

ser

Rang
e1

10

ser

10

Appraiser 3

10

10

Appraiser 3

n caused by parts, not people or equipment)

ortance of application and cost of gage or repair
(people and equipment cause over 1/3 of variation)

10

Range Method

Range Method
Part
Appraiser 1
Appraiser 2
Range

2
12
11
1

GR&R

2.521008

Insert Process
Standard
Deviation
%GR&R

5.121849
49%

Insert Your Data Here

3
4
22
12
10
23
13
12
1
1
2

Page 13

Average

11
21
10

13.4
16 d2
3
1.19

Bias

Reference
Value
Value
Bias
5.8
6.0
5.7
5.9
5.9
6.0
6.1
6.0
6.1
6.4
6.3
6.0
6.1
6.2
5.6
6.0

-0.2
-0.3
-0.1
-0.1
0.0
0.1
0.0
0.1
0.4
0.3
0.0
0.1
0.2
-0.4
0.0

tAverage/
Stdev(r)
Statistic/
n
Mean
Stdev
Stdev(b) critical
15
6.006667 0.21202 0.2251409 0.114683
Bias
0.0067
0.0581311
2.2064
95% Confidence
Lower
Upper
-0.118656 0.131989
Bias Acceptable
Reference: AIAG MSA Version 3 pgs 85-88

Page 14

Bias

d2*/d2
df
3.55333
3.47193

g
10.8 d2*
df
d2
t crit 95%

2
1.41421
1
1.12838
4.303

3
1.91155
2
1.69257
3.182

ersion 3 pgs 85-88

Page 15

4
2.23887
2.9
2.05875
2.776

5
2.48124
3.8
2.3593
2.571

6
2.67253
4.7
2.53441
2.447

Bias

7
2.82981
5.5
2.70436
2.365

8
2.96288
6.3
2.8472
2.306

9
3.07794
7
2.97003
2.262

10
3.17905
7.7
3.07751
2.228

11
3.26909
8.3
3.17287
2.201

Page 16

12
3.35016
9
3.25846
2.179

13
3.42378
9.6
3.33598
2.16

14
3.49116
10.2
3.40676
2.145

Bias

15
3.55333
10.8
3.47193
2.131

16
3.61071
11.3
3.53198
2.12

17
3.66422
11.9
3.58788
2.11

18
3.71424
12.4
3.64006
2.101

19
3.76118
12.9
3.68896
2.093

Page 17

20
3.80537
13.4
3.735
2.086

Linearity

Trials

1
2
3
4
5
6
7
8
9
10
11
12
Average
Reference
Values
Bias
Range
bias=
slope*ref+b
Slope=
b=
Goodness of fit
Insert Process
Variation
Linearity
%Linearity

Part
3

2.7

<- Insert Your Data Here

Linearity evaluates a g
to measure accurately
Imagine measuring a b
1. at the grip
2. in the middle
3. and at the widest pa

2.70
2.00
0.70
0.00

<- Insert Known Reference Values

0.00

0.00

0.00

0.00

Err:502
Err:502
Err:502

Err:502
Err:502
Linearity Plot

0.80
0.70
0.60
0.50
Bias
0.40
0.30
0.20
0.10
0.00
1.50

2.00

2.50

3.00

Re ference Value

Page 18

3.50

4.00

Linearity

our Data Here

Linearity evaluates a gauge's ability

to measure accurately across a wide range
Imagine measuring a baseball bat:
1. at the grip
2. in the middle
3. and at the widest part

nown Reference Values Here

Page 19

Appraiser A
Part #

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40

Appraiser B

Appraiser C

Trial 1

Trial 2

Trial 3

Trial 1

Trial 2

Trial 3

Trial 1

Trial 2

1
0
1

1
0
1

1
0
0

1
0
1

1
0
1

1
0
0

1
0
1

1
0
0

Reference Results
Ref Value Code
0.476901
+
0.576459
0.544951
X
-

Trial 3 Reference

1
0
0

1
0
1
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0

LSL
USL
0.45
0.55
1. Enter Spec Limits Above
2. Have 3 appraisers accept/reject 10+ p
3. Enter pass/fail in columns B-J
4. Enter Reference value in column L
5. Evaluate effectiveness columns AJ-AV

41
42
43
44
45
46
47
48
49
50

0
0
0
0
0
0
0
0
0
0
0 = Fail
1 = Pass

+ = within spec limits

- = outside spec limits
x = gray area around spec limits

%R&R Gray zone

25%
0.02500
er Spec Limits Above
e 3 appraisers accept/reject 10+ parts
er pass/fail in columns B-J
er Reference value in column L
uate effectiveness columns AJ-AV

A-B
1 2
1 1
0 0
1 1

3
1
0
0

B-C
1 2
1 1
0 0
1 -1

3
1
0
0

C-A
A-REF
1 2 3 1 2 3
1
1 1 1 1 1
0
0 0 0 0 0
1 -2 0 1 1 -2

B-REF
1 2 3
1 1 1
0 0 0
1 1 -2

C-REF
1 2 3
1 1 1
0 0 0
1 -2 -2

Crosstabulation
B
Total
A
0
1
0
4
0
4
1
0
5
5
Total
4
5
9

B
0
1
Total

C
0
1
Total

C
0
4
0
4

1
1
4
5

A
0
4
1
5

1
0
4
4

Crosstabulation
REF
Total
A
0
1
0
3
0
3
1
1
5
5
Total
4
5
9

Total
B
5
4
9

0
1
Total

Total
C
4
5
9

0
1
Total

REF
0
3
1
4

1
0
5
5

Total

REF
0
3
2
5

1
0
4
4

3
6
9
Total
3
6
9

around spec limits

Miss
Effectiveness
Rate
A 89%
11%
B 89%
11%
C 78%
22%
System
85%
15%
85%
Effectiveness
Acceptable
>= 90%
Marginal
>=80%
Unacceptable
<80%