Core Tools: Measurement Systems Analysis (MSA)

Core tools
"Core tools" refers the essential or fundamental tools that support implementation
and improvement of a quality management system
These tools were developed originally in the automotive industry and be a part of
the requirements from the ISO/TS 16949 technical specification focused mainly to
assure the reliability of the suppliers that industry.
Core tools are conformed by PPAP, APQP, AMEF, SPC and MSA. These are
processes development by Chrysler, Ford and General Motors to design, prevent,
measure, control, analyze, develop and approve the products and quality services
to satisfy the needs and expectative of the customer.
In this summary only going to talk about the MSA
Measurement Systems Analysis (MSA)
The measurement systems analysis divides in two sides: one of these cover the
methodology of a measurements and calibrations laboratories and the other side is
responsible of the statistics tools to assure the quality in the measurements results.
MSA unify criteria about how could be accepted or releases a measurement
system.
This tool focuses in the study and the control of the variability of the measure
systems and its relation with the production process. Between the most common
terms of MSA there is called GR&R that is basically a statistic tool which quantify
the variability of the measurement system its sources and its relation with the
variability of the production process.
Process Precision Measurements
Gage R&R
Gage R&R statistically isolates different types of variation in the measurement

process. These types of variation include:
 Repeatability = equipment variation = within variation

 Reproducibility = appraiser variation = between variation
 Residual or pure error
 Variation due to interaction effects. For example, out of several inspectors,
one might have a tendency to read one gage differently than others.
Gage R&R- Gage Repeatability and Reproducibility can be applied to any kind of
measurement (attribute or variables, indeterminate or determinate). The two most
common methods used and supported by statistical software are the ANOVA
method (Analysis Of Variance) and the average and range method.
Repeatability refers to the variation in measurements obtained with one
measurement instrument when used several times by one assessor while
measuring the identical characteristics on the same part.
Reproducibility refers to the variation in the average of measurements made by

different assessors using the same measuring instrument while measuring the
identical characteristics on the same part.
R&R is the combination of repeatability and reproducibility variation, and is

considered as the total measurement variation excluding within part variation and
variation in central location.
MSA Applications
 Establish criteria for suitability and acceptability of new measuring

equipment
 Compare one measuring device against another
 Evaluate suspect equipment
 Compare the performance of an equipment before and after its repair
 Calculate measurement system variation
 Establish acceptability of manufacturing process
 Manage & improve the measurement process.
Process Accuracy Measurements
Stability
Stability (or drift) is total variation in measurements obtained with a measurement

system on same master or parts when measuring a single characteristic over an
extended time period (a time period is days, not hours). Stability is the key to
predictability. Stable processes are those that are free from special cause
variation. In terms of measuring equipment, stability is determined by using a
control chart. As measurements are taken, points within the limits indicate that the
process has not changed and the prediction is made that it is not likely to change in
the future. Statistical process control (SPC), scatter plots, or other forms of
statistical analysis are used to measure process stability.
Linearity
Linearity is the difference in the accuracy values through the expected operating
range of the equipment. Selecting the parts throughout the operating range of the
instrument can determine the linearity. The accuracy of these parts is determined
by the difference between the master measurement and the observed average
measurement.
Bias
Difference between observed average of measurements and reference value. The

reference value, also known as accepted reference value or master value, is a
value that serves as an agreed upon reference for measured values. A reference
value can be determined by averaging several measurements with a higher level of
measuring equipment.
EXAMPLE
Gage R&R
Variable Gage R&R
In a Variable Gage R&R there are generally two to three operators’ appraisers with
5-10 process outputs measured by each appraiser. Each process output is
measured 2-3 times by each operator. Depending on the cost and time involved
you can add more appraisers and measurements and replications.
When performing the replicated appraisals it is critical that the measurements are
randomized so that no patterns or predictability can be entered in by the appraiser.
This bias will mislead the team and create a useless Gage R&R.
For example, an appraiser may remember the 7th part that was measured was
borderline and made a decision to give it one measurement. The appraiser may
have spent a lot of time on that part in the initial assessment and if the 2nd round
of measurements are not randomized, that person will remember the measurement
(appraisal) they concluded during the first round.
So...the message is to move the parts around each repetitive set of

measurements. However, the parts must be identified so the person entering the
data into the statistical software enters the reading under the correct part.
Four Criteria in Variable Gage R&R
The following four areas will be assessed. A statistical software program will
generate these values once the data is entered. The GB/BB will be responsible for
finding these values and determining whether each passes and if the entire
measurement system is adequate to determine process capability. Process
capability can not be determined with reliability if the measurements (the data) are
suspect.
1) % Study Variation is based on standard deviation

2) % Tolerance is based on USL and LSL
3) % Contribution is based on variance
4) The number of distinct categories based on process variation
Ideally, all four categories should be in the GREEN zone. Examining the visual aids
below shows commonly used judgement criteria for each category.
Variable Gage R&R Criteria
2) % Tolerance
Shown below is an example of a % TOLERANCE calculation. In this case we are

using 3 appraisers measuring 6 different parts.
This study shows the measurement error as a percent of tolerance in short period
of time. It includes both repeatability and reproducibility, can not be separated.
5.15 Study Variation = 99% (constant)
The TOP TABLE at the top is a part of the d2 distribution. This value is a constant
that is found by looking at the column with 3 appraisers and going across with the
row with 6 parts. In this example the d2 value is 1.73.
The LOWER TABLE shows that actual measurements that each of the appraisers
cam up with using their variable gage. The range of the three measurements for
each part is shown on the right. Then the average range is shown (=0.69) and this
is carried on to the Gage Error formula.
Calculating % Tolerance in Variable Gage R&R study
To convert this gage error of 2.05 to a percentage of tolerance multiply by 100 and
divide by the process tolerance for the analysis.
The process tolerance is the difference in the specification limits. For example, if
the USL is 27 and the LSL is 2, then the tolerance is 25.
With the tolerance being 25, then:
Percent Tolerance Example Second Part
Referring back to the RED/YELLOW/GREEN criteria display for % TOLERANCE, it

shown that 8.2% is a passing value and this part of the Variable Gage R&R is
acceptable.
Greendelia Sáenz Amador IMI-07

Core Tools: Measurement Systems Analysis (MSA)

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Core tools

Process Precision Measurements

Gage R&R statistically isolates different types of variation in the measurement

 Repeatability = equipment variation = within variation

Reproducibility refers to the variation in the average of measurements made by

R&R is the combination of repeatability and reproducibility variation, and is

 Establish criteria for suitability and acceptability of new measuring

Process Accuracy Measurements

Stability (or drift) is total variation in measurements obtained with a measurement

Difference between observed average of measurements and reference value. The

Variable Gage R&R

So...the message is to move the parts around each repetitive set of

Four Criteria in Variable Gage R&R

1) % Study Variation is based on standard deviation

3) % Contribution is based on variance

4) The number of distinct categories based on process variation

Variable Gage R&R Criteria

Shown below is an example of a % TOLERANCE calculation. In this case we are

Calculating % Tolerance in Variable Gage R&R study

With the tolerance being 25, then:

Percent Tolerance Example Second Part

Referring back to the RED/YELLOW/GREEN criteria display for % TOLERANCE, it

Greendelia Sáenz Amador IMI-07

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