Gage R&R Values

Gage R&R Part Number

Average & Range Method 1 2 3 4 5 6 7 8
Operator 1 Trial 1 161.6508 162.5668 157.5987 161.9037 163.8076
Enter your data here-> Trial2 161.1549 162.7113 157.7611 161.2863 163.3995
Trial3 161.4190 162.6538 157.3049 161.6204 163.6912
Trial4 161.6343 162.9597 157.9433 161.3526 163.2313
Trial 5 161.8266 162.6752 157.6376 161.1265 163.5233
Total 807.6855773 813.56674 788.2456 807.28949 817.6528
Average-Appraiser 1 161.5371155 162.71335 157.6491 161.4579 163.5306
Range1 0.671711272 0.3928687 0.638466 0.7772257 0.576324
Operator 2 Trial 1 161.5776 162.3079 157.5036 161.0750 163.4142
Enter your data here-> Trial2 161.0847 162.2246 157.6049 161.1317 163.9237
Trial3 161.8291 162.4535 157.5959 161.0731 163.2890
Trial4 161.8593 162.1868 157.6109 161.3349 163.1641
Trial 5 161.3434 162.9470 157.4774 161.0620 163.4634
Total 807.6940996 812.11976 787.7928 805.67683 817.2545
Average-Appraiser 2 161.5388199 162.42395 157.5586 161.13537 163.4509
Range2 0.774523104 0.7601658 0.133503 0.2729047 0.759576
Operator 3 Trial 1 161.6686 162.2504 157.0860 161.2617 163.9176
Enter your data here-> Trial2 161.0201 162.8325 157.3845 161.2074 163.2548
Trial3 161.9606 162.4131 157.9525 161.4278 163.1081
Trial4 161.0749 162.5266 157.7435 161.6626 163.5313
Trial 5 161.8338 162.7873 157.6500 161.0930 163.2464
Total 807.5580841 812.80977 787.8165 806.65251 817.0582
Average-Appraiser 3 161.5116168 162.56195 157.5633 161.3305 163.4116
Range3 0.940547298 0.5820781 0.866417 0.5695674 0.809469

Range Average 0.6350 Constants

XDiff 0.1561 5 Trials 4 Trials 3 Trials 2 Trials # Trials 5
UCL 1.3399 2.11 2.28 2.58 3.27 D4 2.11
LCL 0.0000 0 0 0 0 D3 0
Repeatability(EV) 0.2730 0.577 0.729 1.023 1.88 A2 0.577
Reproducibility(AV) 0.0607 0.4299 0.4857 0.5908 0.8862 K1 0.4299
Gage Capability(R&R) 0.2797 0.7071 0.5231 K2 0.5231
Spec Tolerance 0.0100 2 Ops 3 Operators
Acceptability(%) 27.97

% Using % Using
AIAG - Automotive Industry Action Group Formula TV Tolerance
Equipment Variation (Repeatability) 0.2730
%EV 11.5% 16380%
Appraiser Variation (Reproducibility) 0.06071
%AV 2.5% 3643%
R&R (Gage Capability) 0.2797
%R&R 11.7% 16780%
PV (Part Variation) 2.3672
%PV 99.3% 142034%
TV (Total Variation) 2.3837

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

# Parts #Trials #Ops

5 5 3

Calculate GageR&R using Anova With Interaction Without Interaction

Anova Source df SS MS F P F P
Appraiser 2 ### ### -4 Err:502 -34 Err:502
Parts 4 301.5334 75.383346 0.00032 1.00000 0.00274 0.99998
Appraiser x Part 8 ### 234133.26 3E+006 0.00000
Gage w AP Interaction 60 4.4457 0.0741
Gage w/o AP Interaction 68 ### ###
Total 74 306.5174863

%
% Study Contributio
Estimate of Variance Std. Dev 5.15* Stdev Variation n
Repeatability 0.07409 0.272202933 EV 1.401845 0% 0%
Appraiser 46826.642147533 216.3946445 AV 1114.432 65% 43%
AppraiserxPart 46826.638097405 216.3946351 INT 1114.432 65% 43%
R&R 93653.35434 306.0283554 R&R 1576.046 93% 86%
Part 15603.85875 124.9154064 PV 643.3143 38% 14%
TV 1702.285

Part by Appraiser Plot (Stacked)

166

164

162

Ave ragge
160

158

156

154
1 2 3 4 5 6 7 8 9
Part

Part by Appraiser Plot

166
 Part by Appraiser Plot

166

164

162

Ave ragge
160

158

156

154
Appraiser 1 Ap
1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5
Appraiser 2

Range of Parts by Appraiser (Stacked)

0.9

0.8

0.7

0.6
Range
0.5

0.4

0.3

0.2

0.1

0
1 2 3 4 5 6 7 8
Parts
 0.9

0.8

0.7

0.6
Range
0.5

0.4

0.3

0.2

0.1

0
1 2 3 4 5 6 7 8
Parts

Range of Parts by Appraiser

0.9

0.8

0.7

0.6
Range
0.5

0.4

0.3

0.2

0.1

0
1 2 3 4
Appraiser
5 6
1 7 8 9 10 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5
Ap6
Appraiser 2
 0.7

0.6
Range
0.5

0.4

0.3

0.2

0.1

0
1 2 3 4
Appraiser
5 6
1 7 8 9 10 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5
Ap6
Appraiser 2

Instructions 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% Gage System Okay (Most variation caused by parts, not people or equipment)
%R&R<30% May be acceptable based on importance of application and cost of gage or repair
%R&R>30% 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

9 10 Sum
807.528
806.313
806.689
807.121 Xbar1 Reference
806.789 161.377608 12.500 <-Insert Reference Value Here
Bias
Rbar1 148.878
0.61131912
805.878
805.970
806.241
806.156 Xbar2 Reference
806.293 161.221519 12.500
Bias
Rbar2 148.722
0.54013462
806.184
805.699
806.862
806.539 Xbar3 Reference
806.610 161.275801 12.500
Bias
Rbar3 148.776
0.75361587

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
cked)

Average-
Appraiser 1

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

Stacked)

Rang
e1

7 8 9 10
 Rang
e1

7 8 9 10

ser

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

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)
 Range Method

Range Method Insert Your Data Here

Part 1 2 3 4 5 Average
Appraiser 1 12 22 12 10 11 13.4
Appraiser 2 11 23 13 12 21 16 d2
Range 1 1 1 2 10 3 1.19

GR&R 2.521008
Insert Process
Standard
Deviation 5.121849
%GR&R 49%

Page 13
 Bias

t-
Reference Average/ Stdev(r) Statistic/
Value Value Bias n Mean Stdev Stdev(b) critical
5.8 6.0 -0.2 15 6.006667 0.21202 0.2251409 0.114683
5.7 -0.3 Bias 0.0067 0.0581311 2.2064
5.9 -0.1
5.9 -0.1 95% Confidence
6.0 0.0 Lower Upper
6.1 0.1 -0.118656 0.131989
6.0 0.0 Bias Acceptable
6.1 0.1
6.4 0.4 Reference: AIAG MSA Version 3 pgs 85-88
6.3 0.3
6.0 0.0
6.1 0.1
6.2 0.2
5.6 -0.4
6.0 0.0

Page 14
 Bias

d2*/d2 df g 2 3 4 5 6 7
3.55333 10.8 d2* 1.41421 1.91155 2.23887 2.48124 2.67253 2.82981
3.47193 df 1 2 2.9 3.8 4.7 5.5
d2 1.12838 1.69257 2.05875 2.3593 2.53441 2.70436
t crit 95% 4.303 3.182 2.776 2.571 2.447 2.365

ersion 3 pgs 85-88

Page 15
 Bias

8 9 10 11 12 13 14 15 16
2.96288 3.07794 3.17905 3.26909 3.35016 3.42378 3.49116 3.55333 3.61071
6.3 7 7.7 8.3 9 9.6 10.2 10.8 11.3
2.8472 2.97003 3.07751 3.17287 3.25846 3.33598 3.40676 3.47193 3.53198
2.306 2.262 2.228 2.201 2.179 2.16 2.145 2.131 2.12

Page 16
 Bias

17 18 19 20
3.66422 3.71424 3.76118 3.80537
11.9 12.4 12.9 13.4
3.58788 3.64006 3.68896 3.735
2.11 2.101 2.093 2.086

Page 17
 Linearity

Part
Trials 1 2 3 4 5
1 2.7 <- Insert Your Data Here
2
3 Linearity evaluates a gaug
4 to measure accurately acr
5 Imagine measuring a base
6 1. at the grip
7 2. in the middle
8 3. and at the widest part
9
10
11
12
Average 2.70
Reference
Values 2.00 <- Insert Known Reference Values He
Bias 0.70
Range 0.00 0.00 0.00 0.00 0.00
bias=
slope*ref+b
Slope= Err:502
b= Err:502
Goodness of fit Err:502
Insert Process
Variation
Linearity Err:502
%Linearity 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 3.50 4.00
Reference Value

Page 18
 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 Appraiser B Appraiser C Reference Results
Part # Trial 1 Trial 2 Trial 3 Trial 1 Trial 2 Trial 3 Trial 1 Trial 2 Trial 3 Reference Ref Value Code LSL USL
1 1 1 1 1 1 1 1 1 1 1 0.476901 + 0.45 0.55
2 0 0 0 0 0 0 0 0 0 0 0.576459 - 1. Enter Spec Limits Above
3 1 1 0 1 1 0 1 0 0 1 0.544951 X 2. Have 3 appraisers accept/reject 10+ p
4 0 - 3. Enter pass/fail in columns B-J
5 0 - 4. Enter Reference value in column L
6 0 - 5. Evaluate effectiveness columns AJ-AV
7 0 -
8 0 -
9 0 -
10 0 -
11 0 -
12 0 -
13 0 -
14 0 -
15 0 -
16 0 -
17 0 -
18 0 -
19 0 -
20 0 -
21 0 -
22 0 -
23 0 -
24 0 -
25 0 -
26 0 -
27 0 -
28 0 -
29 0 -
30 0 -
31 0 -
32 0 -
33 0 -
34 0 -
35 0 -
36 0 -
37 0 -
38 0 -
39 0 -
40 0 -
41 0 -
42 0 -
43 0 -
44 0 -
45 0 -
46 0 -
47 0 -
48 0 -
49 0 -
50 0 -
0 = Fail + = within spec limits
1 = Pass - = outside spec limits
x = gray area around spec limits
 A-B B-C C-A A-REF B-REF C-REF
%R&R Gray zone 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3
25% 0.02500 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
er Spec Limits Above 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
e 3 appraisers accept/reject 10+ parts 1 1 0 1 -1 0 1 -2 0 1 1 -2 1 1 -2 1 -2 -2 Crosstabulation Crosstabulation
er pass/fail in columns B-J B Total REF Total
er Reference value in column L A 0 1 A 0 1
uate effectiveness columns AJ-AV 0 4 0 4 0 3 0 3
1 0 5 5 1 1 5 5
Total 4 5 9 Total 4 5 9

C Total REF Total

B 0 1 B 0 1
0 4 1 5 0 3 0 3
1 0 4 4 1 1 5 6
Total 4 5 9 Total 4 5 9

A Total REF Total

C 0 1 C 0 1
0 4 0 4 0 3 0 3
1 1 4 5 1 2 4 6
Total 5 4 9 Total 5 4 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%