WELCOME

TO

MSA TRAINING PROGRAM

OBJECTIVE
To provide

Basic concept of measurement system Detail application methodology of all statistical studies for variable and attribute data Methods to meet QS9000 & ISO/TS16949 requirements

Introduction
Uses of measurement data are Decision to adjust a manufacturing process Determine the significant relationship between two or more variables using statistical studies The result of analytical studies is depends upon the Quality of data produced by measurement system

Why MSA required?

Defect prevention Prediction Statistics Data Inspection
MSA is mandatory prior to SPC
SPC

PURPOSE OF MSA

Quantify Variation present in the Measurement system Compare the Consistency of inspectors Provide methods for Validation of Measurement System

Measurement Systems
Process to assign a number or decision to a characteristic Process

Appraiser Checking Method Instrument Environment

E.g, OD checking, Concentricity checking

Terminologies

Standard Effective resolution Location variation Width variation Uncertainty

Statistical properties of MS
Ideal Measurement system is the one Which produces always only the correct measurements Always agree with the standard Statistical data produced over time

Statistical properties of MS
Properties of GOOD Measurement Systems : Adequate discrimination & Sensitivity System is always under statistical control Variability of the measurement system is small compared to Manufacturing process variation and Tolerance

Criteria for MS design selection

Team members Purpose of use Frequency of use Part specification Sensitivity required Contact? Non contact/ Auto? Manual?

Statistical properties of MS
Classification Measurement system errors are: Bias Linearity Stability Repeatability Reproducibility

Statistical properties of MS
Determination of these errors will help us to: Criteria to accept new MS Compare one against another To evaluate a suspect gage To evaluate the effectiveness of repair

QS9000 / ISO-TS16949 Requirements

Define a process for implementation of MS Identify all types of measurement systems Cover all systems covered in Control Plan Perform Appropriate statistical study Use MSA ( or Customer approved) Manual Obtain Customer approval for use of methods other than MSA manual

QS9000 / ISO-TS16949 Requirements

Types of MS is based on L.C Range Construction Parameter Manufacturer

QS9000 / ISO-TS16949 Requirements

Vernier L.C 0.02 mm Range 0 200mm ConstructionOrdinary Parameter- O.D Vernier L.C 0.02 mm Range 0 200mm ConstructionOrdinary Parameter- Width

Is it Same or different type of MS ?

QS9000 / ISO-TS16949 Requirements

Bore Dial Gage L.C 0.001 mm Range 18-35 mm ConstructionOrdinary Parameter- Bore Air gage L.C 0.001 mm Range --Construction- Dial Parameter- Bore

Discrimination

Ability to detect the small changes in process Traditional rule

1/10th of Tolerance 1/3rd Considering the cost/ criticality 1/10th of Process variation Resolution 1/10th of Process variation

MSA/ SPC requirement

ACCURACY & PRECISION

ACCURACY

PRECISION

Closeness to reference or master value Required where two or more MS measuring a same characteristic Same parameters are checked at Suppliers end or at Customer end

Ability of MS to repeat the same reading Required where MS is repeatedly used to assess and adjust the process In process inspection as per control plan

ACCURACY & PRECISION

ACCURACY Captured by

PRECISION Captured by

BIAS LINEARITY STABILITY

REPEATABILITY REPRODUCIBILITY

BIAS WHAT IT IS ?
Ref. Value

BIAS= X bar - Ref.Value

bar

BIAS - STEPS
1. Capture reference value Use masters calibrated traceable to standards

Measure by better instrument than the instrument being measured

By Layout inspection

2. Measure the part/ master by Min. 10 times

BIAS - STEPS
3. Calculate BIAS for individual reading & draw histogram 4. Calculate , bias, t limits APPENDIX C t distribution table

ACCEPTANCE CRITERIA Zero must lie between t Limits of Bias distribution or Bias should be within acceptable gage error as defined in Calibration Proc.

BIAS VARIOUS CASES

Ref. Value Ref. Value

bar

BIAS VARIOUS CASES

Ref. Value Ref. Value

bar

CAUSE OF LARGE GAGE BIAS

Error in Master
Instrument Worn

Made to wrong dimension

Measuring wrong characteristic Improper use by operator Improper calibration

APPLICABILITY OF GAGE BIAS

Not a Problem like R&R
Required where Accuracy to be captured

Being Carried out as part of Calibration

Applicable for Gages designed by the Organization

LINEARITY
Difference in Bias over the Operating range of the Gage
ve

Bias

+ve Bias

X bar

X bar

Linearity Steps
1. Collect 5 parts / masters over the operating range of the gage through process variation

2. Capture reference value for the 5 parts

3. Measure at least 12 times in a random manner to cover all 5 parts 4. Measure at least 12 times in a random manner to cover all 5 parts

Linearity Steps
5. Calculate Average, BIAS and enter the data in a Spread sheet 6. Draw Best fit line for the average, Lower limit and Higher limit of Bias

Linearity Acceptance criteria

ZERO LINE MUST BE CONTAINED WITHIN THE TWO LIMIT LINES OR WITHIN ACC.CRITERIA OF CAL ERROR + VE Upper t limits

0
- VE

Lower t limits

Is this MS acceptable ?

LINEARITY - CASES

Causes for Gage Linearity

Error in Master Instrument -Worn -Made to wrong dimension -Measuring wrong characteristic -Improper use by operator -Improper calibration

Applicability of Gage Linearity

To Capture Accuracy over the operating range to assure its suitability of gage for the entire process variation Required for Special gages designed by the Organization

Can be performed as part of Calibration

Stability study What?

Variation of Bias w.r.t time when measured over a Same Master

T1

T2

T3

Stability How?
No.of Samples/ Masters Subgroup Size 1 or 3 at Minimum, Mid and Higher Specification limits 1 or 3 times over a period in the Morning, Noon and Evening

Frequency

Charts

Daily,Weekly, Monthly based on the stability assessment of instrument One chart for each sample, XMR , or X bar& R or X bar & S

Stability Acceptance criteria

No out of Control conditions in Control charts with careful interpretation No drift

No trend
Zero must lie within two limits of bias variation

Stability Applicability
To compare two or more measurement systems measuring a same characteristic e.g Bore dial gage & Air gage

To establish or evaluate the Calibration Frequency

Constitution of total variation

Total variation

Manufacturing process variation

Part to part variation Within part variation

Measurement system variation

Appraiser variation Equipment variation Appraiser part interaction

Methods to capture variation

Elements of Variation TV PV WIV AV EV App & part interaction Range Method
X bar & R Method

ANOVA Method

Repeatability & Reproducibility

Repeatability One Appraiser One Equipment Same part Several trials

Reproducibility
Same equipment Same Parts

Several trials
Different Appraiser

This Variation is represented by Equipment

This Variation is represented by Appraiser

Range method
No.of Samples 5 nos. gives 80 % chance of detecting a wrong MS. 10 nos gives 90% chance No.of Appraisers Min. 2 Formula Sigma = R bar / d2*

Range method - Exercise

Appraiser A 1. 15.03 2. 15.04 3. 15.02 4. 15.05 5. 15.02
Appraiser B Range 0.02 0.00 0.01 0.00

15.05 15.04 15.03 15.05 15.02

0.00

Tol = 0.05, TV(SPC)= 0.120

Range method - Exercise

Average R = 0.006 Std.deviation = 0.006 / 1.128 = 0.0053

where n=2 d2 is1.128, n=3 d2 is 1.693 R&R ( 1 sigma) = 0.0053

% R&RTV % R&RTOL = (0.0053)/ (0.120/6) * 100 = 26.5 = (0.0053)/ ( 0.050/6) * 100= 66.5

Interpretation = MS IS NOT ACCEPTABLE

Range method - Exercise

COMPARE AGAINST TOLERANCE WHEN TV IS MORE THAN TOLERANCE WHERE SPC IS NOT IMPLEMENTED COMPARE AGAINST TOTAL VARIATION WHEN TV IS LESS THAN TOLERANCE WHERE SPC IS IMPLEMENTED

Range method Acceptance criteria

% R&R < 10 % OF TOL OR TV

% R&R 10 30 % OF TOL OR TV ACCEPTABLE SUBJECT TO ANALYSIS AND JUSTIFICATION W.R.T COST OF REPAIR AND CRITICALITY

Range method Applicability

Being the short study it is suitable for studying MS where it is time consuming to measure one measurement e.g Concentricity, R/O Being the Short study this can be used for Periodic verification of R&R to detect any changes rather than average range method

Average & Range Method

No.of Samples 10 nos. Randomly selected representing actual process variation

No.of Appraisers 3 From personnel actually performing on a day to day operation No.of trials Min 2 . Preferably 3

Average & Range Methodsteps for conducting study

1. Identify the parts from 1 10 2. Mark the Place where to check to eliminate Within part variation 3. Communicate the purpose of the study to all appraisers 4. Conduct the study in a Random manner covering all parts for required no.of trials through all appraisers 5. Monitor all appraisers are following the same method

Average & Range Methodsteps for conducting study

6. Record the observations in a manner which is not seen by the appraisers FORMAT7. If any abnormal readings are observed ask the appraiser to repeat the reading 8. Maintain the samples till the completion of analysis

9. Draw R chart and X bar chart and interpret

10. Calculate EV,AV,PV & TV and it Percentage against TOL or TV and ndc

X bar & R chart Method Acceptance criteria

% R&R < 10 % OF TOL OR TV

% R&R 10 30 % OF TOL OR TV ACCEPTABLE SUBJECT TO ANALYSIS AND JUSTIFICATION W.R.T COST OF REPAIR AND CRITICALITY No. of distinct data categories
ndc > 5 where SPC is used ndc >2 where no SPC is used

R chart interpretation

CONDITION One or more than one point of one appraiser out of UCL R One or more than one point of all appraisers out of UCL R In one part all appraisers points are out of UCL R

INTERPRETATION His method is different from others Measurement System is sensitive to appraisers skill Part is deformed or Damaged

X chart interpretation
CONDITION More than 50 % of readings are out of control limits INTERPRETATION Measurement system is adequate enough to capture process variation

Causes for R&R

When repeatability is large compared to
reproducibility Instrument needs maintenance

Redesign gage for more rigidity

Improve clamping or location of gauging Excessive within part variation

( Conduct R & R with within part variation )

Causes for R&R

When reproducibility is large compared to
repeatability Appraisers need better gage use training

Need better operational definition

Incremental divisions on instrument are not readable

Need fixture to provide consistency in gage use.

X bar & R method Applicability

To capture Precision, Mandatory before SPC study
Measurement Systems which are used repeatedly on line to control the process based on the measurement data Where individual readings are affected by the precision of the instrument Applicable for all MS used in In process where the MS can be repeated

ATTRIBUTE MEASUREMENT
COMPARES EACH PART TO A SPECIFIC SET OF LIMITS AND ACCEPTS THE PART IF THE LIMITS ARE SATISFIED

IS DESIGNED TO ACCEPT/REJECT A SET OF MASTER PARTS

CANNOT INDICATE HOW GOOD OR HOW BAD A PART IS,ONLY WHETHER THE PART IS ACCEPTED OR REJECTED (PASS/FAIL) VISUAL STANDARDS MAY RESULT IN 5 TO 7 DISTINCT DATA CATEGORIES. MSA MANUAL DOES NOT PRESCRIBE ANY METHOD OF EVALUATION OF THE SAME

GPC METHOD IS MOST APPROPRIATE ANALYSIS

RISK ANALYSIS METHOD IS CUMBERSOME, BUT IT IS PREFERRED BY SOME CUSTOMERS (Eg, FORD)

Gage performance curve method

LSL USL HIGH RISK AREA

II

III

II

GPC KEY INSTRUCTIONS

Select the gage to be studied Calibrate the gage to know the actual size of the gage Understand the distribution and location of the process Decide the on which side of specifications samples to be taken and the measurement method Select samples (8) and repeat minimum 20 times on a random manner and count no.of accepts ( a )

GPC KEY INSTRUCTIONS

Select Minimum 8 samples out of that One sample on lower than specification, no.of accepts a = 0 One sample on higher specification, no of accepts a = 20 Six parts on the gray area where, a is more than or equal to 1 and less than or equal to 19 Select sample repeat the study till we meet the above criteria

GPC KEY INSTRUCTIONS

Calculate Probabilities of acceptance using formulae Plot Probabilities of acceptance as % in normal probability paper Calculate Bias & Repeatability Conclude the decision on the acceptability of gage

RISK ASSESSMENT Key steps

Take 50 parts representing entire process variation having bad, marginally bad, good & marginally good parts Mark as 1 to 50 Select 3 appraisers Conduct study in a random manner and record the decisions, 1 as OK and 0 as Not ok

RISK ASSESSMENT Key steps

Get the reference value for all the 50 parts using layout inspection/ variable instrument and decide its status as 0 or 1 Compare each trial of each inspector with the another inspector for their decision Complete the cross tabulation table Calculate Kappa for

A Vs B, A vs. C , B Vs C A vs. Ref, B Vs Ref., C vs. Ref.

Risk analysis Acceptance criteria

Decision
Acceptable for the appraiser Marginally acceptable for the appraiser

Effectiveness
More than 90 % More than 80%

Unacceptable for the appraiser Need improvement

Less than 80 %

MSA TRAINING

ANY QUESTIONS ?

Thank You