PLANNING A GAGE

R&R STUDY

D. M. Schneider
 GAGE R&R STUDY

A Gage R&R study is a part of Measurement

System Analysis. The purpose of a gage R&R
study is to identify and quantify the sources of
variability that can affect the measurement
process.

D. M. Schneider
 PLANNING A GAGE R&R STUDY

In order to assure that the results of a gage R&R

study are worthwhile, careful and extensive
planning is needed.

Failure to give consideration to the many

variables that may influence a gage may cause
the results of the study to be compromised or
misleading.

D. M. Schneider
 BASIC CONSIDERATIONS

• Acceptance Criteria
• Written, Defined Test Method
• Number of Operators
• Homogeneity of Sample
• Sample Preparation
• Calibration
• Test Environment

D. M. Schneider
 ADDITIONAL CONSIDERATIONS

• Length of Study
• Number of Gages
• Number of Materials
• Number of Replications

D. M. Schneider
 ACCEPTANCE CRITERIA

• Amount of accuracy and precision

desired.

• Amount of product specification

consumed by the total measuring
error.

• Total error includes precision,

repeatability and reproducibility.

D. M. Schneider
 WRITTEN, DEFINED TEST METHOD

• Insure that there is a well written test

procedure.

• Interpretation of steps and activities

must be clear to all.

• The test method must prescribe

within the method all setups, settings,
activities, calibrations, etc. (i.e., times,
temperatures, pressures, reagent purities,
etc.).

D. M. Schneider
 NUMBER OF OPERATORS
• No two operators do a task exactly the
same.
• People differ in dexterity, reaction time,
color sensitivity, interpolation in scale
reading, etc.
• The study should involve more than two
operators especially for measuring systems
that are complex.
• Select operators who are trained and
normally use the gage.
• Generally, no more than 5 operators.
D. M. Schneider
 HOMOGENEITY OF MATERIAL

• Minimizing the problem of sample

variation, i.e.,
• bulk samples should be blended
• liquids should be thoroughly stirred
• a specific spot marked on the part

• Individual samples should be homogeneous

– the study is to determine the variability
of the gage and not the actual process.

D. M. Schneider
 SAMPLE PREPARATION
• For some measuring systems, sample
preparation is important to understanding
gage error.

• For the situation where sample preparation

is not to be included in the study then one
individual must prepare all samples.

• For the situation where sample preparation

is to be included in the study then all
individuals must prepare enough samples
for the other individuals in the study to
measure.
D. M. Schneider
 CALIBRATION
• One of the variables associated with test
equipment is its state of calibration or lack
of calibration.
• The test procedure must specify the
frequency of calibration and a routine
calibration should not occur during the study.
• If non routine calibrations are to occur
during the study then questions like who
will do it, when will it done, etc. must be
answered.
• Verify that the gage is currently calibrated.
D. M. Schneider
 TEST ENVIRONMENT

• The properties of many materials are

sensitive to ambient conditions.
• The performance of many measuring
systems are sensitive to ambient conditions.
• Since ambient conditions cannot be
controlled perfectly, acceptable tolerance
ranges for ambient conditions must be
defined.
• The gage R&R study should be conducted
under the same conditions where the gage is
normally used (or will normally be used).
D. M. Schneider
 LENGTH OF STUDY

• Operator differences, calibration and

ambient conditions may change with time.

• Actual day to day variations should be

included in the study in order to estimate
the effect on the test equipment.

• The number days will depend on the

stability of all the variables that can affect
the test equipment.

D. M. Schneider
 NUMBER OF GAGES

• Even two pieces of test equipment made

by the same manufacturer are not identical.

• For measuring systems such as

micrometers, include 2-3 in the study.

• When more than one measuring system

is included in the study, make sure that
each operator measures each sample/part
using each measuring system.

D. M. Schneider
 NUMBER OF SAMPLES

• Does the measuring system have the same

accuracy and precision in the entire range of
operation (usability)?

• If the measuring system is to be used in a

wide range (i.e., narrow width to wide width)
then the samples/parts used in the study must
span this range of use.

• 5-10 samples/parts spanning the range of

use is considered acceptable.

D. M. Schneider
 NUMBER OF REPLICATION

• What is the inherent variation of the

actual gage?

• In a very short time frame, how close in

agreement are repeated measures from
this gage?
• In its purest sense, replications help
estimate the pure precision of the gage
(i.e., minimal opportunity for special
causes to affect the gage).
• 2-3 replications is usually sufficient.
D. M. Schneider
 TYPES OF STUDIES:
VERY SHORT TERM - BASIC STUDY -
ONE OPERATOR
RESULT Mat A Mat B Mat C
1 X X X
2 X X X
3 X X X
4 X X X
5 X X X

Note: Each x is a replication

D. M. Schneider
 TYPES OF STUDIES
SHORT TERM - BASIC STUDY
Mat A Day 1 Day 2 Day 3
Oper 1 x,x,x x,x,x x,x,x
Oper 2 x,x,x x,x,x x,x,x
Oper 3 x,x,x x,x,x x,x,x
Oper 4 x,x,x x,x,x x,x,x
Mat B Day 1 Day 2 Day 3
Oper 1 x,x,x x,x,x x,x,x
Oper 2 x,x,x x,x,x x,x,x
Oper 3 x,x,x x,x,x x,x,x
Oper 4 x,x,x x,x,x x,x,x
Mat C Day 1 Day 2 Day 3
Oper 1 x,x,x x,x,x x,x,x
Oper 2 x,x,x x,x,x x,x,x
Oper 3 x,x,x x,x,x x,x,x
Oper 4 x,x,x x,x,x x,x,x
Note: Each x is a replication
D. M. Schneider
 TYPES OF STUDIES:
LONG TERM - BASIC STUDY
Mat A Day 1 Day 2 ... Day N
Oper 1 x,x,x x,x,x ... x,x,x
Oper 2 x,x,x x,x,x ... x,x,x
Oper 3 x,x,x x,x,x ... x,x,x
Oper 4 x,x,x x,x,x ... x,x,x
Mat B Day 1 Day 2 ... Day N
Oper 1 x,x,x x,x,x ... x,x,x
Oper 2 x,x,x x,x,x ... x,x,x
Oper 3 x,x,x x,x,x ... x,x,x
Oper 4 x,x,x x,x,x ... x,x,x
Mat C Day 1 Day 2 ... Day N
Oper 1 x,x,x x,x,x ... x,x,x
Oper 2 x,x,x x,x,x ... x,x,x
Oper 3 x,x,x x,x,x ... x,x,x
Oper 4 x,x,x x,x,x ... x,x,x
Note: Each x is a replication
D. M. Schneider