Dmaic - GRR Template [PDF]

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Gage R&R Average & Range Method Operator 1 Enter your data here->

Operator 2 Enter your data here->

Operator 3 Enter your data here->

Range Average XDiff UCL LCL Repeatability(EV) Reproducibility(AV) Gage Capability(R&R) Spec Tolerance Acceptability(%)

Trial 1 Trial2 Trial3 Trial4 Trial 5 Total Average-Appraiser 1 Range1 Trial 1 Trial2 Trial3 Trial4 Trial 5 Total Average-Appraiser 2 Range2 Trial 1 Trial2 Trial3 Trial4 Trial 5 Total Average-Appraiser 3 Range3

1 0.2150 0.2160 0.2150 0.2160 0.2165 1.0785 0.2157 0.0015 0.2160 0.2165 0.2150 0.2160 0.2150 1.0785 0.2157 0.0015

0.0013 0.0000 0.0028 0.0000 0.0006 0.0000 0.0006 0.0050 0.11

% Using % Using AIAG - Automotive Industry Action Group Formula TV Tolerance Equipment Variation (Repeatability) 0.0006 %EV 82.3% 68% Appraiser Variation (Reproducibility) 0.00000

2 0.2140 0.2145 0.2140 0.2145 0.2160 1.073 0.2146 0.002 0.2170 0.2160 0.2140 0.2145 0.2140 1.0755 0.2151 0.003

3 0.2150 0.2145 0.2150 0.2145 0.2150 1.074 0.2148 0.0005 0.2155 0.2150 0.2150 0.2145 0.2150 1.075 0.215 0.001

4 0.2140 0.2150 0.2140 0.2150 0.2155 1.0735 0.2147 0.0015 0.2145 0.2155 0.2140 0.2150 0.2140 1.073 0.2146 0.0015

Part Number 5 0.2165 0.2160 0.2165 0.2160 0.2150 1.08 0.216 0.0015 0.2150 0.2150 0.2165 0.2160 0.2165 1.079 0.2158 0.0015

6 0.2145 0.2155 0.2145 0.2155 0.2150 1.075 0.215 0.001 0.2160 0.2150 0.2145 0.2155 0.2145 1.0755 0.2151 0.0015

Constants 3 Trials 2 Trials # Trials 2.11 2.28 2.58 3.27 0 0 0 0 0.577 0.729 1.023 1.88 0.4299 0.4857 0.5908 0.8862 0.7071 0.5231 2 Ops 3 Operators 5 Trials

4 Trials

D4 D3 A2 K1 K2

7 0.2155 0.2155 0.2155 0.2155 0.2145 1.0765 0.2153 0.001 0.2155 0.2145 0.2155 0.2155 0.2155 1.0765 0.2153 0.001

5 2.11 0 0.577 0.4299 0.7071

%AV R&R (Gage Capability) %R&R PV (Part Variation) %PV TV (Total Variation)

0.0% 0.0006 82.3% 0.0004 56.8% 0.0007

0% 68% 47%

Conclusions / Recommendations Gage system needs improvement Gage may need maintenance, redesign, or better clamping

# Parts

#Trials 10

Calculate GageR&R using Anova Anova Source Appraiser

df

SS 1

MS -4.4473

#Ops 5

2

With Interaction Without Interaction P P F F Err:502 -88.99934 Err:502 -4.4473 -8.999998

9 0.0000 1.834E-006 3.71E-006 9 4.4473 0.49414234 1227683 80 0.0000 0.0000 89 4.4473 0.0500 99 4.9728E-005

Parts Appraiser x Part Gage w AP Interaction Gage w/o AP Interaction Total

Estimate of Variance

Repeatability Appraiser AppraiserxPart R&R Part

0.00000 0.0988284472 0.0988283872 0.19766 0.04941

Std. Dev

0.000634429 0.314369921 0.314369826 0.444586591 0.222292714

5.15* Stdev

EV AV INT R&R PV TV

1.00000 3.67E-005 0.00000

% Study Variation

0.00326731 1.61900509 1.6190046 2.28962094 1.14480747 2.5598727

1.00000

% Contribution

0% 63% 63% 89% 45%

0% 40% 40% 80% 20%

Part by Appraiser Plot (Stacked) 0.2165

0.216

0.2155 Ave ragge 0.215

0.2145

0.214

0.2135 1

2

3

4

5

6 Part

Part by Appraiser Plot 0.2165

7

8

0.2165

0.216

0.2155 Ave ragge 0.215

0.2145

0.214

0.2135 1

2

3

4 51 Appraiser

6

7

8

9

10

1

2

3

4

5

6

7

8

9

10

1

2

3

App

Appraiser 2

Range of Parts by Appraiser (Stacked) 0.0035

0.003

0.0025

0.002 Range 0.0015

0.001

0.0005

0 1

2

3

4

5

6 Parts

Range of Parts by Appraiser

7

8

Range of Parts by Appraiser 0.0035

0.003

0.0025

0.002 Range 0.0015

0.001

0.0005

0 1

2

3

4Appraiser 5

1

6

7

8

9

10

1

2

3

4

5

6

Appraiser 2

7

8

9

10

1

2

3

App

0.0025

0.002 Range 0.0015

0.001

0.0005

0 1

2

3

4Appraiser 5

1

6

7

8

9

10

1

2

3

4

5

6

7

8

9

10

1

2

3

App

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=80% Unacceptable