Measure 08 Continuos

1
InProducción al
Análisis del Sistema de Medición (ASM):
Objetivos del Análisis del Sistema de Medición (ASM) 2
 Reconocer que la variación observada de un producto/proceso

incluSe además la variación del sistema de medición
 Identificar S describir posibles fuentes de variación en un
sistema de medición
 Describir la importancia de un sistema de medición valido
 Establecer los términos: Precisión, Exactitud S Resolución en
relación al ASM
 Utilizar herramientas apropiadas para validar, analizar e
interpretar los resultados del sistema de medición
– “Gage R&R” para datos continuos
– “AtPribute R&R” para datos discretos
Posibles fuentes de Variación 3
 Observaciones
Salida EnPradas Proceso de  Mediciones
EnPradas Proceso Salida
Medición  Datos
Variación observada del proceso
Variación real del Proceso Variación del Proceso de Medición
Variación a Variación a Variación Variación OPras

Largo Corto del del fuentes
Plazo Plazo InsPrument Operador (ambiente)
o
Apego Precisión Discriminación

(Bias) (Error de (Resolución)
Medición)
Para conocer la variación real del proceso, la variación del sistema de medición
debe primero identificarse S separarse, de aquella del proceso real
Error de Medición vs. Variación del Proceso 4
 Llamada telefónica S= Tiempo para Responder (Tiempo de Respuesta)

– Variación del Proceso: El tiempo para responder una pregunta difiere por
operadores, ubicaciones, horarios, etc.
– Error de Medición: Error al capturar el tiempo de la llamada debido a un vaga
definición de “cuándo termina la llamada”
 Procesamianto de Solicitudes S= Tiempo de decisión
– Variación del Proceso: Diferentes tipos de solicitud toman diferente tiempo para
ser revisadas. Los revisores varían en su productividad.
– Error de Medición: Hora de llegada de la solicitud no regisPrada
consistentemente.
 Aprobación de ConPratos S = Tiempo para Completar
– Variación del proceso: Ciclos de vida diferentes. Diferentes clientes son Pratado
de manera diferente.
– Error de Medición: Inconsistencias en la definición de inicio del proceso.
 Aprobación del ConPratos S = Terminos S Condiciones del Acuerdo
– Variación del Proceso: Valor del ConPrato (utilidad neta generada).
– Error de medición: Errores al calcular S grabar la utilidad neta.
Desarrollar el Análisis del Sistema de Medición (ASM) 5
 Un ASM puede ser conducido para datos continuos o para

datos discretos (revisaremos ambos)
 Sugerencias para desarrollar un ASM
– Seleccionar 2-3 “operadores” que normalmente realicen las mediciones.
– Para datos continuos, selecciona 10 partes/muesPras (solicitudes,
llamadas, conPratos, camiones, etc) para medir. Las partes deben ser
tan diversas diversas como sea posible (denPro del rango normal del de
medición). Estas mismas 10 partes serán usadas durante todo el
estudio ASM.
– Para datos discretos, selecciona 30-40 partes/muesPras (mienPras más
muesPras mejor).
– Las muesPras deben ser etiquetadas con números. El numero asignado
a cada muesPra permanecerá constante durante todo el estudio ASM.
– Cada operador medirá las muesPras 2-3 veces. Una hoja nueva para
colección de mediciones debe ser usada para cada sesión de medición.
– El InsPrumento debe ser “calibrado” siguiendo un procedimiento
estándar de calibración antes de iniciar con el estudio ASM.
Análisis del sistema de Medición 6
Exactitud–La diferencia enPre el promedio de las mediciones observadas

respecto a un estándar
Repetibilidad–Variación cuando una persona realiza mediciones sobre la

misma parte/unidad con el mismo insPrumento
Reproducibilidad– Variación cuando dos o más personas miden la misma

parte/unidad con el mismo insPrumento de medición
Estabilidad– Variación obtenida cuando la misma persona mide la misma

unidad con el mismo inPrumento a lo largo de un periodo de tiempo
Linealidad– La consistencia de la exactitud a Pravés de un rango completo del

Gage R&R For AtPribute Data 7
“Gage R&R” para datos discretos (aPributos)

Flujo del Proceso del ASM 8
Conducir ASM
Acciones preventivas
OK?
S correctivas
No
Si
Continuar Mejora del

Proceso
Para “Gage R&R” de datos discretos (aPributos):
OK = Ajuste de al menos 90% para cada análisis de Repetibilidad,

Reproducibilidad S exactitud.
Analisis de “Gage R&R” con datos discretos (DR&R’s) 9
 La repetibilidad, reproducibilidad S la exactitud se definen tal como en el

“Gage R&R” para datos continuos
– Repetibilidad: ¿Las mediciones son las mismas con el mismo operador?
– Reproducibilidad: ¿Las mediciones son las mismas con operadores diferentes?
– Exactitud: ¿Las mediciones se ajustan a un estándar?
 Para datos discretos, se utiliza un análisis diferente
 Un ASM nos apoSa en determinar si nuesPro sistema de medición debe
ser mejorado, S si es el caso, nos dice cómo mejorarlo
Guías para Evaluar un “DR&R” 10
 Repetibilidad: 90% de las mediciones repetidas (misma unidad,

mismo insPrumento) con el mismo operador, se ajustan
 Reproducibilidad: 90% de las mediciones repetidas con
diferentes operadores, se ajustan
 Exactitud: 90% de las mediciones individuales se ajustan al
estándar
Determinación del tamaño de la muesPra en un “DR&R” 11
Cuantas partes/unidades deben ser tomadas para un “DR&R”?

 Tipicamente, 30-40 unidades deben dar un buen indicador del
 Si obtener 30-40 unidades es muS costoso o consume mucho
tiempo, entonces 10 unidades pueden ser suficientes. Utiliza el
“sentido común del negocio” S aprende del ASM. Asegurate
siempre de escoger unidades representativas del proceso.
Hoja de datos del “DR&R” (ejemplo) 12
Ejemplo de Repetibilidad “DR&R” 13
Operador 1 Operador 2 Operador 3

Unidad Pr1 Pr2 Pr3 Match? Pr1 Pr2 Pr3 Match? Pr1 Pr2 Pr3 Ajusta?
1 N N N S N N N S N N N S
3 N N N S N N N S D N N N
4 D D D S D D D S D D D S
5 D D D S D D D S D N D N
7 N D N N D D D S D D D S
8 N N N S D N D N N N N S
10 N N N S N N N S D N D N
12 N N N S D D D S D D D S
16 D D D S N N N S N N N S
19 N N N S D D D S N N N S
20 N N N S N N N S D D N N
21 D D D S D D D S D D N N
24 N N N S N N N S D D D S
30 N D N N D D D S D D D S
33 D N N N D D N N N N N S
35 N N N S N N N S N D N N
37 N N N S N N N S D N N N
38 N N N S N N N S N N D N
Operador 1 0.925 Operador 2 0.950 Operador 3 0.800
Ejemplo Reproducibilidad “DR&R” 14
Operador 1 Operador 2 Operador 3

Unidad Pr1 Pr2 Pr3 Pr1 Pr2 Pr3 Pr1 Pr2 Pr3 Ajusta?
1 N N N N N N N N N S
3 N N N N N N D N N N
4 D D D D D D D D D S
5 D D D D D D D N D N
7 N D N D D D D D D N
8 N N N D N D N N N N
10 N N N N N N D N D N
12 N N N D D D D D D N
16 D D D N N N N N N N
19 N N N D D D N N N N
20 N N N N N N D D N N
21 D D D D D D D D N N
24 N N N N N N D D D N
30 N D N D D D D D D N
33 D N N D D N N N N N
35 N N N N N N N D N N
37 N N N N N N D N N N
38 N N N N N N N N D N
Operador 1 Operador 2 Operador 3 0.525
Ejemplo de Exactitud del “GR&R” 15
Valor Operador 1 Operador 2 Operador 3 No

Unidad est Pr1 Pr2 Pr3 Pr1 Pr2 Pr3 Pr1 Pr2 Pr3 Ajusta?
1 N N N N N N N N N N 0
3 N N N N N N N D N N 1
4 D D D D D D D D D D 0
5 D D D D D D D D N D 1
7 D N D N D D D D D D 2
8 N N N N D N D N N N 2
10 N N N N N N N D N D 2
12 D N N N D D D D D D 3
16 N D D D N N N N N N 3
19 N N N N D D D N N N 3
20 N N N N N N N D D N 2
21 D D D D D D D D D N 1
24 N N N N N N N D D D 3
30 D N D N D D D D D D 2
33 N D N N D D N N N N 3
35 N N N N N N N N D N 1
37 N N N N N N N D N N 1
38 N N N N N N N N N D 1
# of N 5 2 4 6 5 5 5 4 4 40
Ejemplo de Exactitud del “GR&R” (continuación) 16
Resumen del ASM “DR&R”

 Repetibilidad:
No ajustaron 13/120 = 100 (1-.1083) = 89.17% (pasa)
 Reproducibilidad:
No Ajustaron 19/40 = 100 (1-.475) = 52.50% (no pasa)
 Exactitud:
No ajustaron 40/360 = 100 (1-.1111) = 88.89% (pasa)
Hoja de trabajo de ASM “DR&R” 17
Fecha del
Estudio : Oct 2002

√ AtPribute Gage R&R
1). % Repetibilidad [ >90% ] 89.17% OK

2). % Reproducibilidad [ >90% ] 52.50% Necesita mejorar. Ver Plan
3). % Exactitud [ >90% ] 88.89% OK
Pasó “Gage R&R”? S √ N, Si no:
Plan de mejora:
Trabajar en el problema de Reproducibilidad y conducir reuniones con el equipo de los tres
operadores y discutir las diferencias en sus métodos de medición.
Para los operadores menos experimentados, ya que los datos muestran que ellos tienen
mediciones diferentes, debemos entrenarlos adicionalmente. También investigar si hay algo
único en cada una de las unidades que se midieron.
Causas de Variación del ASM 18
Algunos factores que generan variación en el ASM son:

repetibilidad
 Definiciones operacionales
 Mantener Estabilidad
Reproducibilidad
 Consistencia en el uso de los instrumentos de medición
 Entrenamiento de los operadores
 Ambiente de trabajo cambiante
 Auditorías de seguimiento en entrenamiento
 Características físicas humanas
 Mediciones de desempeño
 Requerimientos no claros
Exactitud
 Estándar erroneo
 Uso incorrecto del instrumento por parte del operador
 Estándar malentendido
Otras consideraciones 19
Efectos relacionados con el Tiempo

 “Gage R&R” depende de nuestra habilidad de medir
“unidades/partes” multiples veces
 Si la “unidad/parte” es un evento, posiblemente no sucederá de
la misma manera dos veces. Por esta razón, “Gage R&R”
puede llegar a ser imposible para eventos.
 Si el evento es filmado, puede ser conducido el “Gage R&R”
 Si el evento no puede ser filmado, pero multiples “jueces”
pueden observarlo al mismo tiempo, la reproducibilidad puede
ser estimada pero no la repetibilidad.
Ejemplo de Efectos relacionados con el tiempo

 Muchos deportes olimpicos pueden ser medidos basados en
hojas de resultados numéricos llenadas por un juez. Las
diferencias entre las diferentes lecturas de los jueces de un
evento en vivo una medición de la reproducibilidad.
 Para este mismo caso, la repetibilidad puede ser estimada solo

si la competencia es filmada. Una muestra aleatoria de 10
mediciones mostrada por cinco jueces, dos veces cada uno,
permitirá hacer estimados tanto de repetibilidad como de
reproducibilidad.
Ejemplo 2 de Efectos relacionados con el tiempo

 Centro de atención de servicio global a clientes en localidades
centralizadas, la calidad y duración de las llamadas son
registradas y monitoreadas muy de cerca.
 La calidad de la llamada se calcula con base en una hoja de

registro llenada por un monitor de calidad. Las llamadas son
calificadas con una escala de 1-100 que se puede considerar
continua para propósitos del calculo de un estudio “Gage
R&R”.
Ejemplo 2 de Efectos relacionados con el tiempo (cont.)

 Un escenario de monitoreo es que el monitor escucha la
llamada en vivo y la califica. Para la “escucha en vivo” es
imposible calcular la repetibilidad, pero si dos monitores
escuchan al mismo tiempo, es posible calcular la
reproducibilidad.
 Otro escenario de monitoreo, las llamadas son grabadas

aleatoriamente y calificadas posteriormente. Para este
escenario la repetibilidad y reproducibilidad si pueden ser
calculadas.
Gage R&R For Continuous Data 23
Test-Retest StudS
Test–Retest StudS 24
Best Practice Hint: Do Test-Retest before Gage R&R–a quick look at the
situation.
WhS: Determine the precision of the sSstem, insPrument, device, or gage–

where Precision = Measurement Error = RepeatabilitS
How:
 RepeatedlS measure the same item
 Same conditions, Operador, device, and location on item–same, same,
same
 CompletelS mount and dismount item for each measurement–exercise gage
through full range of normal use
Data: TwentS (20) or more measurements is an adequate sample size. If

measurements are difficult or expensive, then 10-15 maS be OK. More is better.
Calculate the sample mean (Χ) and standard deviation (s) of the repeated
measurements.
Test–Retest StudS Guidelines 25
 Device precision should be less than 1/10 of the tolerance:
s < 1/10 x tolerance
If s exceeds 1/10 x tolerance, then the measurement sSstem is

unacceptable because it lacks precision. Action is required to find
and remove the sources of this error, including the replacement of
the device.
 Device accuracS maS be estimated if Sou know the Prue

value of the test unit:
InaccuracS = Bias = X - Prue Value

Measurement SSstem AnalSsis (MSA) 26
MSA is a set of methods

for estimating the
current amount of variation
in the measurement process.
Process Flow For MSA 27
Conduct MSA
Take Preventive And

Corrective Actions OK?
No
Ses
Continue Process
Improvement
Precision & AccuracS 28
Target AnalogS
== Xbar
Prue Value = Bull's ESe
I. Precise, not accurate

Xbar
==
Prue Value
II. Accurate, not precise

Xbar
==
Prue Value
III. Precise and accurate

Measurement SSstem 29
 Observations
Inputs Outputs Inputs Measurement Outputs  Measurement
s
Process Process
 Data
Product Measurement Total

Variation Variation Variation
(Actual (Observed
Example variation) variation)
#1
Example Actual (Part) +  Meas. SSstem = Observed (Total)

#2
Measurement
SSstem VariabilitS
- Investigated
through “R&R
StudS”
30
Validate Measurement SSstem:
Gage R&R Technique

for Continuous Data
TSpes Of Variation Estimated BS The Gage R&R 31
Equipment Variation
(EV)
(Sources of variation from within the process)
Within Gage–Within Operador–Within Part/Process–Etc.
The variation inProduced into the measurement process
from within one or more elements of the measurement
process–such as: within Operador variation–within gage
variation–within part variation–within method variation.
Appraiser Variation
(AV)
(Source of variation from across the
process) Across Gages–Across Operadors–
Across Parts/Process–Etc.
The variation inProduced into the measurement process
bS effects going across the measurement process–such
as different appraisers–different part configurations–
different checking methods.
Relationship Between EV, AV And R&R 32
R&R is the ReproducibilitS (AV) and RepeatabilitS (EV) of the

Measurement SSstem. It represents the total variation in the
Measurement SSstem.
R&R
EV AV
Equipment +  Appraiser = Total (R&R)

Relating R&R To Specification Window 33
How much of the tolerance is used up bS the Measurement

SSstem variation?
R&R
Lower Spec. Limit Upper Spec. Limit

Specification Window (tolerance)
About 50% of the tolerance in this example is used up

bS the Measurement SSstem variation
This leaves onlS 50% for the Process variation
Gage R&R For Continuous Data 34
Gage R&R Example for Continuous

Data Example
Gage R&R For Continuous Data: Example 35
GB Case StudS: On Time DeliverS of Shipments to Customers
Background: The dispatchers for “Capital Logistics” keep a

record of the time when Pruck drivers radio in to report deliverS of
the shipment was made to the customer (this is a requirement from
the customers). Since there are 3 dispatchers recording the
deliverS time and 10 Pruck drivers calling in, the Green Belt needs
to validate these deliverS times for repeatabilitS, reproducibilitS &
accuracS.
Gage ReproducibilitS & RepeatabilitS (GR&R) StudS: Steps 36
1. Set up a Minitab Worksheet

2. Perform studS–collect & enter Data. (use file: “Gage
R&R-Continuous Data.mtw)
3. Perform calculations & prepare Charts.
– Perform Gage R&R StudS–ANOVA method (ANOVA =
AnalSsis of Variance)
4. AnalSze–interpret & draw conclusions.
5. Investigate variation in measurement sSstem, take action,
make recommendations–keep, improve, or replace the
measurement sSstem.
If measurement sSstem is changed, repeat above steps to
validate accuracS, repeatabilitS & reproducibilitS of new
measurement.
Case StudS Setup 37
Does mS measurement sSstem provide me a clear view of mS process...
To help answer this question the GB

established the following analSsis:
1. The GB developed a master maPrix which listed the times

each Pruck was supposed to arrive at the customer. The GB
gave a copS of the maPrix to each of the three dispatchers.
2. The GB had each of the Pruck drivers radio a message

from a radio Pruck, identifSing himself as one of the 10 units
listed in the maPrix..
3. So that the GB could get repeatabilitS & reproducibilitS

data, the GB had the message recorded and then sent to the
dispatchers throughout a 3 daS period. The GB was able to
program the phone sSstem to deliver the messages preciselS
at the same time both daSs. The dispatchers were able to
hear the call-in simultaneouslS via speakerphone.
4. Therefore, throughout the 3 daSs, the dispatchers, all in

the same room at the same time, would receive the radio
message and record the difference in minutes, from the target
time listed on the maPrix. At the end of the daS, the GB would
collect the data collection sheets from each dispatcher and
give them a blank form for the following daS. This procedure
was then repeated the second daS.
5. The GB then consolidated the data into a single Minitab file

for analSsis. (Gage R&R–continuous data.mtw).
…or does it cloud what I see?

Gage R&R For Continuous Data: Example 38
Step 1: Set up Minitab data sheet.

 GB asked 3 dispatchers to record the Pruck driver call-in time for the 10 different Pruck drivers.
 Data sheet for recording the data was set up in Minitab to keep Prack of the 10 Prucks
(Part/Pruck), 3 dispatchers (Oper), 2 runs (Prial) and the “S” of Difference from Target (Meas).
Step 2: Perform StudS–Collect & Enter Data.

 Pruckers called in to report deliverS and dispatchers recorded the difference from target time.
 The data was collected and recorded on a data sheet and was input into Minitab (see Data
column).
Minitab File: Gage R&R – Continuous Data.mtw
Gage R&R For Continuous Data: Example (continued) 39
Step 3: Perform Calculations & Prepare Charts

Perform Gage R&R StudS–ANOVA method
Gage R&R For Continuous Data: Example (continued) 40
 Minitab Output will generate the following items which we will

use to determine if our measurement sSstem is acceptable:
1. Graphical SummarS
2. Two-WaS ANOVA Table with Interaction (p-values)
3. % Comparisons Table (% ConPribution)
4. % Comparisons Table (% Tolerance)
5. % Comparisons Table (% StudS)
6. Discrimination Index
The CenPral Question In A Gage R&R StudS 41
There are 2 waSs to (1) FUTURE STATUS: (2) PRESENT STATUS:

answer the question Will mS measurement Is mS measurement
“Is mS measurement variation be too large variation too large right
variation too big?” when I reach the 6-Sigma now, compared to a
goal (i.e., with small process realistic estimate of current
spread, good capabilitS)? process spread (which
maS be narrow next Sear)?
Number of
R&R % StudS
R&R R&R Distinct
Variation
%Tolerance %ConPribution Categories (Ratio of StdDev’s
(Ratio of Variances) (Discrimination
-- AIAG)
Index)
Red
30% 8% 4 30%
Sellow
10% 2% 10 15%
Green
CAUTION:
The magnitude of these
%’s are exaggerations
Rules Of Thumb 42
Step 4: AnalSzing Gage R&R Results

A. R&R% of Tolerance
1. R&R less than 10%–Measurement SSstem “acceptable”
2. R&R 10% to 30%–MaS be acceptable–make decision

based on classification of Characteristic, Application,
Customer Input, etc.
3. R&R over 30%–Not acceptable. Find problem, re-visit the

Fishbone Diagram, remove Root Causes. Is there a better
gage on the market, is it worth the additional cost?
Rules Of Thumb 43
B. % ConPribution (or Gage R&R StdDev):

GR&R Variance should be “small” compared to Part-to-Part Variance–applies in cases where
Tolerance Width is not meaningful, and %Tolerance is unavailable–such as one sided specs.
1. % ConPribution < 2%–Measurement SSstem “acceptable”
2. % ConPribution 2%-8%–Measurement SSstem “marginal”
3. % ConPribution > 8%–Measurement SSstem “unacceptable”
C. Number of Distinct Categories
A “Signal-to-Noise” Ratio = (StdDevparts/process/StdDevGR&R) x 1.41 and rounded
Guidelines:
< 2 =>no value for process conProl, parts all “look” the same
= 2 =>can see two groups–high/low, good/bad
= 3 =>can see three groups–high/mid/low
≥ 4 =>acceptable measurement sSstem
(higher is better)
D. Effective Resolution
50%, or more, of Xbar Chart outside conProl limits–implies part variation “exceeds” Measurement
SSstem variation
Minitab Gage R&R ANOVA Graphical Output 44
(1) Graphical Output

•ANOVA simplS stands for “ AnalSsis of Variance”
•It is a tool used to analSze the total variabilitS among different sources.
•It partitions the total variation into “buckets”, and then allocates each bucket to each source
(part, Operador, oper*part interaction).
Gage name:
Date of study :
Gage R&R (ANOVA) for Meas Reported by :
Tolerance:
Misc:
Xbar Chart by Oper Oper*Part/Truck Interaction

110 1 2 3 110 Oper
100 100 1
Sample Mean
90
1
3.0SL=87.96 90 2
4
Average
80 X=80.75 80
-3.0SL=73.54 3
70
70
60
60
50
40 50
30 40
0 Part/Truck 1 2 3 4 5 6 7 8 9 10
R Chart by Oper By Oper

15 1 2 3 110
100
Sample Range
3.0SL=12.52
10 90
80
70
5
2 R=3.833 60
50
5
0 -3.0SL=0.00E+00 40
0 Oper 1 2 3
Components of Variation By Part/Truck

500 110
%Total Var 100
400 %Study Var 90
Percent
300 %Toler 80
70
3 200
60 6
100 50
0 40
Gage R&R Repeat Reprod Part-to-Part Part/Truck 1 2 3 4 5 6 7 8 9 10
Average of 2 measurements
taken bS Operador 1. Gage name:
Date of study :
Tolerance:
Misc:

110 1 2 3 110 Oper
100 100 1
Sample Mean
90 3.0SL=87.96 90 2
Average
80 X=80.75 80
-3.0SL=73.54 3
70
70
60
60
50
40 50
30 40
0 Oper 1 Oper 2 Oper 3 Part/Truck 1 2 3 4 5 6 7 8 9 10

15 1 2 3 110
100
Sample Range
3.0SL=12.52
10 90
80
70
5
R=3.833 60
50
0 -3.0SL=0.00E+00 40
0 Oper 1 2 3

500 110
%Total Var 100
Range of 2 measurements 400 %Study Var 90
Percent
taken bS Operador 1. 300 %Toler 80

70
200
60
100 50
0 40
Gage name:
Date of study :
Tolerance:
Misc:

110 1 2 3 110 Oper
100 100 1
Sample Mean
90 3.0SL=87.96 90 2
Average
80 X=80.75 80
-3.0SL=73.54 3
70
70
60
60
50
40 50
30 40
0 Part/Truck 1 2 3 4 5 6 7 8 9 10

15 1 2 3 110
100
Sample Range
3.0SL=12.52
10 90
80
70
5
R=3.833 60
50
0 -3.0SL=0.00E+00 40
0 Oper 1 2 3

500 110
%Total Var 100
400 %Study Var 90
Percent
300 %Toler 80
70
200
60
100 50
0 40
A B C D
Gage name:
Date of study :
Tolerance:
Misc:

110 1 2 3 110 Oper
100 100 1
Sample Mean
90 3.0SL=87.96 90 2
Average
80 X=80.75 80
-3.0SL=73.54 3
70
70
60
60
50
40 50
30 40
0 Part/Truck 1 2 3 4 5 6 7 8 9 10

15 1 2 3 110
100
Sample Range
3.0SL=12.52
10 90
80
70
5
R=3.833 60
50
0 -3.0SL=0.00E+00 40
0 Oper 1 2 3

500 110
%Total Var 100
400 %Study Var 90
Percent
300 %Toler 80
70
200
60
100 50
0 40
Minitab Gage R&R ANOVA Table 48
(2) ANOVA TABLE

Two-WaS ANOVA Table With Interaction
Source DF SS MS F P
Part/Pruck 9 20587.1 2287.45 39.7178 0.00000

Sources of Oper 2 480.0 240.00 4.1672 0.03256
VariabilitS Oper*Part/Pruck 18 036.7 7.59 4.4588 0.00016
RepeatabilitS 30 387.5 12.92
Total 59 22491.2
P< 0.05 indicates statisticallS
significant!
Are anS of these “p-values” less than 0.05?

If so, their sources of variation can be considered statisticallS significant (i.e,
Active, Influential).
For this gage... parts, Operadors and the interaction between parts & Operadors
are statisticallS significant sources of variation!
Minitab Gage R&R % Tolerance 49
(3) % Comparisons Table

Source %ConPribution %StudS Var %Tolerance
P/T Ratio
(Precision-to-Tolerance Ratio) Total Gage R&R 10.67 32.66 171.53
RepeatabilitS 3.10 17.62 92.54
ReproducibilitS 7.56 27.50 144.43
Oper 2.19 14.81 77.76
Oper*Part/Pruck 5.37 23.17 121.70
Part-To-Part 89.33 94.52 496.41
Total Variation 100.00 100.00 525.21
“R&R as a % of
Tolerance”
% Tolerance
Acceptable Ranges
Not Acceptable 30%

Questionable
10%
Acceptable
If Sou wanted to calculate %Tolerance bS hand:

5.15   R & R ( Meas.Syst .)
% Tolerance  100%
Tolerance
Minitab Gage R&R % Tolerance GraphicallS 50
%Tolerance: GraphicallS
LSL USL
%Tolerance = 10%
%Tolerance = 30%
%Tolerance = 70%
Minitab Gage R&R % ConPribution 51
Variation due to the gage Variation due to the parts

(4) % Comparisons Table + = 100%
Source %ConPribution %StudS Var %Tolerance

%R&R ConPribution (Total
Variation) Total Gage R&R 10.67 32.66 171.53
RepeatabilitS 3.10 17.62 92.54
ReproducibilitS 7.56 27.50 144.43
Oper 2.19 14.81 77.76
Oper*Part/Pruck 5.37 23.17 121.70
Part-To-Part 89.33 94.52 496.41
Total Variation 100.00 100.00 525.21
“R&R as a % of Total Process
Variation”
Further Explanation:
Source %ConPribution
Total Gage R&R 10.67

RepeatabilitS 3.10 3.10 + 7.56 = 10.67
ReproducibilitS 7.56
% ConPribution
Acceptable Ranges Oper 2.19 Now, we know that
Oper*Part/Pruck 5.37 ReproducibilitS is our bigger
Not Acceptable Part-To-Part 89.33 issue (conPributing more than
8.0% Total Variation 100.00
RepeatabilitS).
Questionable
2.0%
Acceptable 2.19 + 5.37 = 7.56
Now, we know that of the ReproducibilitS, the Oper to

Part/Pruck interaction is our bigger issue than the
ReproducibilitS of Operadors. Check with the Oper*Part/Pruck
Interaction Graph to find out which parts maS be the issue.
Minitab Gage R&R Discrimination Index 52
(5) Discrimination Index

Number of Distinct Categories = 4
Discrimination Index
For this gage: the Discrimination Index = 4
• This saSs that the gage has reached the minimum acceptable
level.
Discrimination Index:
•Provides the number of divisions that the Measurement SSstem can accuratelS
measure across the process variation.
“Number of Distinct
•Indicates how well a gage can detect part-to-part variation -- process shifts and
Categories” improvement.
Discrimination Index Acceptable Values

•Less than 2, inadequate
•Equal to 2, equal to a go/nogo gauge.
•Minimum acceptable value = 4.
•Optimal = 10 or more.
If Sou wanted to calculate
Discrimination Index bS hand:
 
  2Total 
Std Dev (Parts) Discrim  2 2  1
x 1.41   R &R 
Std Dev (GRR)  (Meas.Syst .) 
Minitab Gage R&R KeS Indices 53
3 KeS Indices for Measurement SSstem CapabilitS
1 2 3
P/T Ratio %R&R ConPribution Discrimination Index

(Precision-to-Tolerance Ratio)
“R&R as a % of “R&R as a % of Total “Number of Distinct

Tolerance” Measure Variation” Categories”
%Tolerance GRR = 171.53% % R&R ConPribution = 10.67% Discrimination Index = 4

Gage R&R Acceptable Ranges 54
Acceptable Ranges- ANOVA METHOD

This tells us the ratio of each
This tells us how much of the component of variation (the
This tells us how much
tolerance is being taken up bS standard deviation for each
variation the gage itself is
the variation the gage. component divided bS the
conPributing to the variation.
total standard deviation).
%Tolerance % Discrimination Index

%ConPribution
Not Acceptable
8.0% 30% 4 30%
Questionable
2.0% 10% 10 15%
Acceptable
• Provides the number of divisions that the Measurement SSstem can accuratelS
measure across the process variation.
• Indicates how well a gage can detect part-to-part variation--process shifts and
improvement.
Measurement SSstem AnalSsis (MSA) Worksheet 55
TSpe of Gage R&R Conducted (Check One): Date


√ Gage R&R (Continuous Data) Conducted: 1/2/02
Gage R&R Results
1). Two-WaS ANOVA Significant?
Part p-value 0.00000 √ S N
Oper p-value 0.03256 √ S N
Oper & Part p-value 0.00016 √ S N
Pass?
2). % Tolerance 171.53% [ <30% ] S √ N

3). % ConPribution 10.67% [ <8% ] S √ N
4). % StudS 32.66% [ <30% ] S √ N
5). # Distinct Categories 4 [ >4% ] √ S N
Graphical Output OK?
1). Effective Resolution [ >50% ] √ S N

2). StabilitS [R Chart] √ S N
3). ConsistencS Between Xbar consistencS S √ N
Between Oper
4). SSstematic Shift [Oper/Part Inter. Plot] S √ N
Gage R&R Pass? S √ N, If NO:

Plan for improvement:
 Look at the gage and possiblS change to a digital clock.
 Review/implement a driver call-in procedure. Suspect there is variation between drivers.
 Review/develop a new spreadsheet for calculating the time.
 Talk with Operadors to determine whS Oper 2 measures differentlS than Operadors 1 & 3
 Talk with customer about the light specification, if possible.
 Prain all Operadors and Pruck drivers on new procedures.
 Re-run Gage R&R to verifS improvement.

Causes Of Measurement SSstem Variation 56
If Sou fail the Gage R&R, here are some factors that could cause measurement
process variation (measurement error).
RepeatabilitS
 Operational definitions
 Calibrating too often
 GranularitS of the measure (e.g., nearest hour, minute, second)
 Maintain stabilitS
ReproducibilitS
 Operational definitions
 Consistent use of gage
 Praining
 VarSing work environment
 AUDIT–follow-up on Praining
 Human/phSsical characteristics
 Performance measures
 Unclear requirements
AccuracS
 Error in master
 InsPrument not calibrated
 Worn components/Prend or drift in master
 InsPrument used improperlS bS appraiser
 Calibrating too often
 Operational definition
 Range of the master
Causes OF Measurement SSstem Variation 57
LinearitS
 InsPrument calibrated incorrectlS
 Error in master
 Worn insPrument
StabilitS
 Error in master
 Worn insPrument
 InsPrument measuring wrong characteristic
 InsPrument not calibrated properlS
 InsPrument used improperlS bS appraiser
Gage R&R Action Plan 58
Step 5: Investigate sources of variation in the measurement

sSstem and make recommendations–keep, improve or replace the
measurement sSstem.
After completing the analSsis of the measurement sSstem, the
Green Belt investigated the sources of variation. BS observing the
process, the GB found:
 The % Tolerance is the largest issue (171.53%). With the
current gage and measurement process in place, the gage is
not acceptable. To address this issue the GB has done the
following:
– Changed in the Gage
– Implemented a standardized call-in procedure
– Implemented a new spreadsheet
Gage R&R Action Plan 59
Step 5 Continued
 The % ConPribution also failed (10.67%). From the Minitab data, the GB
found ReproducibilitS to be the larger issue and the interaction between
certain Prucks and certain Operadors was the issue. To address these
issues, the GB has done the following:
– The data indicates that the measuring of the arrival time for Prucks 4 & 10 seem
to varS from Operador to Operador. BS going back and reviewing the data and
talking to the Operadors, the following was found:
 There was a tSpo on the recording of time from Operador 1 on Pruck 4. He
accidentallS tSped in the wrong number. To address this problem, a new spreadsheet
was developed and now the Dispatcher is asked to verifS his data prior to saving it in
the spreadsheet.
 For Pruck 10, the Operadors had a verS difficult time hearing the recording because the
Pruck Driver was using a cell phone with a poor connection. The GB changed the
procedure so that each Dispatcher was now required to repeat-back the time given bS
the Pruck driver. The Pruck Driver then confirms that the correct time is being recorded.
– The data also indicated that Operador 2 seems to measure slightlS lower than
Operadors 1 & 3. The GB found that Operador 2 was sitting on an angle and
when he read the clock his time was distorted. BS converting to the computer
clock, this issue should be resolved.
Gage R&R For Continuous Data-ActivitS (15 minutes) 60
Desired Outcome: Determine if the improved measurement sSstem utilized bS the Capital Logistics dispatchers is “acceptable “ or
not.
What How Who Timing
Preparation  Choose a facilitator, scribe
Conduct  Complete 5 steps for a Gage R&R studS and Team 10 mins.
MSA record results
 Use File: Gage R&R–Continuous Data.mtw and
use Columns C6-C9.
Report  Complete Report SummarS Team 5 mins.

Out
 Present findings to class (see next page for report
summarS)
 Are there anS additional items the GB should
consider to improve the MSA even further?
Measurement SSstem AnalSsis (MSA) Worksheet 61
TSpe of Gage R&R Conducted (Check One): Date

 Gage R&R (Continuous Data)
Conducted:
Gage R&R Results
1). Two-WaS ANOVA Significant?
Part p-value S N
Oper p-value S N
Oper & Part p-value S N
Pass?
2). % Tolerance [ <30% ] S N

3). % ConPribution [ <8% ] S N
4). % StudS [ <30% ] S N
5). # Distinct Categories [ >4% ] S N
Graphical Output OK?
1). Effective Resolution [ >50% ] S N

2). StabilitS [R Chart] S N
3). ConsistencS Between Xbar consistencS S N
Between Oper
4). SSstematic Shift [Oper/Part Inter. Plot] S N
 AtPribute Gage R&R

1). % RepeatabilitS [ >90% ]
3). % AccuracS [ >90% ]
Gage R&R Pass? S N, If NO:

Plan for improvement:
AnalSzing The Gage R&R Results 62
Rules of Thumb
1. R&R (% Tolerance)
 Less than 10%–Measurement SSstem is acceptable
 10% to 30%–maSbe acceptable–make decision based on classification of characteristic, hardware application,

customer input, etc.
 Over 30%–Measurement SSstem is not acceptable. Find problem, re-visit the fishbone diagram, remove root
causes. Validate Measurement SSstem again
2. % ConPribution (or Gage R&R StdDev) :
GR&R Variance should be “small” compared to Part-to-Part Variance–applies in cases where Tolerance Width is
not meaningful, and % Tolerance is unavailable–Such as one-sided specs.
 % ConPribution < 2%-Measurement SSstem “acceptable”
 % ConPribution 2%-8%-Measurement SSstem “marginal”
 % ConPribution > 8%-Measurement SSstem “unacceptable”
3. Number of Distinct Categories = a “Signal-To-Noise” Ratio =

(StdDevparts/StdDevGR&R) X 1.41 and rounded
Guidelines:
< 2–no value for process conProl, parts all “look” the same
= 2–can see two groups–high/low, good/bad
= 3–can see three groups–high/mid/low
> 4–acceptable measurement sSstem (higher is better)
4. Effective resolution–50%, or more, of Xbar chart outside conProl limits–implies part variation “exceeds” Measurement
SSstem variation.
SummarS–Measurement SSstem AnalSsis 63
 Variation in the measurement sSstem will conPribute to the

observed variation in a process
 The resolution is the abilitS of the gage to see the variation in
the process
– The gage should be accurate: mean close to the Prue mean of the
process, and precise: small variation.
 Minimize the measurement process variation
 Use MSA (Gage R&R for Continuous Data or AtPribute R&R
for Discrete Data) to identifS the amount of measurement
sSstem variation and process variation
 Understand how measurement error impacts Sour customer
 Measurement error is alwaSs a bigger deal than Sou think!
Make sure Sour MSA is Examining the
Actual Measurement SSstem itself
Measure Step 3–Green Belt Project ActivitS (30 minutes) 64
Desired Outcome: Outline of a Data Collection Plan and MSA for Sour GB project.
What How Timing
Sour Individual 1). Data Collection plan 15 mins.

GB Project.  Review and finalize Sour Data Collection Plan for Sour GB project
Have Sou answered:
 What data will Sou need to collect?
 How will Sou collect it? From where?
 Who will collect the data?
(can refer to the data collection worksheet)
2). MSA 15 mins.

 Develop an MSA for Sour project S data
 List factors that might cause measurement sSstem variation and
how Sou would reduce the impact of those factors

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1

 Reconocer que la variación observada de un producto/proceso

Variación observada del proceso

Variación real del Proceso Variación del Proceso de Medición

Variación a Variación a Variación Variación OPras

Apego Precisión Discriminación

 Llamada telefónica S= Tiempo para Responder (Tiempo de Respuesta)

 Un ASM puede ser conducido para datos continuos o para

Exactitud–La diferencia enPre el promedio de las mediciones observadas

Repetibilidad–Variación cuando una persona realiza mediciones sobre la

Reproducibilidad– Variación cuando dos o más personas miden la misma

Estabilidad– Variación obtenida cuando la misma persona mide la misma

Linealidad– La consistencia de la exactitud a Pravés de un rango completo del

“Gage R&R” para datos discretos (aPributos)

Continuar Mejora del

Para “Gage R&R” de datos discretos (aPributos):

OK = Ajuste de al menos 90% para cada análisis de Repetibilidad,

 La repetibilidad, reproducibilidad S la exactitud se definen tal como en el

 Repetibilidad: 90% de las mediciones repetidas (misma unidad,

Cuantas partes/unidades deben ser tomadas para un “DR&R”?

Operador 1 Operador 2 Operador 3

Operador 1 Operador 2 Operador 3

Valor Operador 1 Operador 2 Operador 3 No

Resumen del ASM “DR&R”

Estudio : Oct 2002

1). % Repetibilidad [ >90% ] 89.17% OK

Pasó “Gage R&R”? S √ N, Si no:

Algunos factores que generan variación en el ASM son:

Efectos relacionados con el Tiempo

Ejemplo de Efectos relacionados con el tiempo

 Para este mismo caso, la repetibilidad puede ser estimada solo

Ejemplo 2 de Efectos relacionados con el tiempo

 La calidad de la llamada se calcula con base en una hoja de

Ejemplo 2 de Efectos relacionados con el tiempo (cont.)

 Otro escenario de monitoreo, las llamadas son grabadas

WhS: Determine the precision of the sSstem, insPrument, device, or gage–

Data: TwentS (20) or more measurements is an adequate sample size. If

 Device precision should be less than 1/10 of the tolerance:

s < 1/10 x tolerance

If s exceeds 1/10 x tolerance, then the measurement sSstem is

 Device accuracS maS be estimated if Sou know the Prue

InaccuracS = Bias = X - Prue Value

MSA is a set of methods

Take Preventive And

Prue Value = Bull's ESe

I. Precise, not accurate

II. Accurate, not precise

III. Precise and accurate

Product Measurement Total

Example Actual (Part) +  Meas. SSstem = Observed (Total)

Validate Measurement SSstem:

Gage R&R Technique

R&R is the ReproducibilitS (AV) and RepeatabilitS (EV) of the

Equipment +  Appraiser = Total (R&R)

How much of the tolerance is used up bS the Measurement

Lower Spec. Limit Upper Spec. Limit

About 50% of the tolerance in this example is used up

Gage R&R Example for Continuous

GB Case StudS: On Time DeliverS of Shipments to Customers

Background: The dispatchers for “Capital Logistics” keep a

1. Set up a Minitab Worksheet

Does mS measurement sSstem provide me a clear view of mS process...