Measurement Systems Analysis: Total Quality Management

STM Quality
Limited
Measurement Systems
Analysis
TOTAL QUALITY MANAGEMENT
M.S.A.
ABSL Power Solutions
STM Quality Limited 2007
STM Quality
Outline and Objectives Limited
Introduce Measurement Systems
Assess Measurement Systems Performance
Understand Measurement System Variation
STM Quality Limited

STM Quality
Requirements for M.S.A. Limited
TS16949 Clause 7.6.1. states:
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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STM Quality
Process Control Limited
A Typical Process
People
Methods Identifying
Material PROCESS Product Improvement
Equipment Opportunities
Environment
Input Process / System Output
Accurate Measurement
using Measurement System Analysis
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STM Quality
New Process Acceptance Limited
Observed Process Production Gauge

Variation Variation
Actual Process
Variation
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Assessing STM Quality
Measurement Systems Limited
Location variation
Bias
Stability
Width variation
Linearity
Repeatability, Reproducibility
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Determining and Assessing Bias Limited
Bias is the difference between Observed
the observed average of
Average Value
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 Limited
Time
Stability (or drift) is the total
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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Determining and Assessing Linearity Limited
Linearity is the difference in the bias values through the
expected operating range of the gauge.
Reference
Observed Reference
Value Observed
Average Value Value
Average Value
Smaller Larger
Bias Bias
50mm 200mm
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Determining Repeatability Limited
Repeatability is the variation in
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 Limited
Reproducibility is the variation in
the average of the measurements
made
by different appraisers
using the same measuring
instrument
when measuring the
identical characteristic
Reproducibility
on the same part
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Preparing For A STM Quality
Measurement System Study Limited
Variable Gauge Study (Average and Range Method)
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 STM Quality
Repeatability and Reproducibility Limited
There are three methods:
Range Method;
Average and Range Method;
Analysis of Variation Method (ANOVA).
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Range Method
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)
STM Quality Limited

Average and Range Method
Evaluates Repeatability and Reproducibility separately;

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) (99%- norm. distr.)
AV (appraiser variation) (99%- norm. distr.)
R&R (R&R) = EV + AV (99%- norm. distr.)
Part Variation PV (99%- norm. distr.)
Total VariationTV = (R&R) + PV (99%- norm. distr.)
STM Quality Limited

Analysis of Variation Method
Evaluates Repeatability and Reproducibility separately;

Evaluates Interaction between appraiser and part;
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) (99%- norm. distr.)
AV (appraiser variation) (99%- norm. distr.)
R&R (repeatability, reproducibility and interaction (I)
R&R (R&R) = EV + AV+I (99%- norm. distr.)
Part Variation PV (99%- norm. distr.)
Total Variation TV = (R&R) + PV (99%- norm. distr.)
STM Quality Limited

If repeatability is large compared to reproducibility, the reasons may be:
The instrument needs maintenance;
The gauge should be redesigned to be more rigid;
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.
STM Quality Limited

Measurement Systems Analysis: Total Quality Management

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STM Quality

TOTAL QUALITY MANAGEMENT

Introduce Measurement Systems

Assess Measurement Systems Performance

Understand Measurement System Variation

STM Quality Limited

TS16949 Clause 7.6.1. states:

Statistical studies shall be conducted to analyse the

STM Quality Limited

Input Process / System Output

STM Quality Limited

Observed Process Production Gauge

STM Quality Limited

STM Quality Limited

STM Quality Limited

STM Quality Limited

STM Quality Limited

STM Quality Limited

If reproducibility is large compared to repeatability then;

STM Quality Limited

There are three methods:

STM Quality Limited

Gives a quick approximation of measurement variability. It does not

(not sufficient for PPAP and QS-9000 clause 4.11.4)

STM Quality Limited

Evaluates Repeatability and Reproducibility separately;

STM Quality Limited

Evaluates Repeatability and Reproducibility separately;

STM Quality Limited

If reproducibility is large compared to repeatability, then possible causes

STM Quality Limited

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