What is a gage linearity and bias study?

A gage linearity and bias study determines whether your gage is measuring accurately. The study
assesses linearity (how accurate your measurements are through the expected range of
measurements) and bias (how well your measurements compare to a reference value).

When you conduct a gage linearity and bias study, Minitab displays a graph of the best fitted line
of the biases across the reference values.

In the linearity section of the output, Minitab shows how consistently the gage measures across
the reference values. When the slope is small, the gage linearity is good.

Bias indicates how close your measurements are to the reference values. A positive bias indicates
that the gage overestimates. A negative bias indicates that the gage underestimates. The %Bias
value indicates how much gage bias explains the overall process variation.

If the gage measures low at small reference values and high at large reference values, there may
be a statistically significant slope (the p-value for slope shows the significance), which indicates
large linearity. In this situation, the bias values are positive at one extreme and negative at the
other, making the overall bias impractical to interpret.
 Description:

Measurement system analysis (MSA) uses scientific tools to determine the amount of variation
contributed by the measurement system. It is an objective method to assess the validity of
a measurement system and minimize the factors contributing to process variation that is actual
stemming from the measurement system. The steps below are generally followed with a goal of
obtaining acceptance for each of the five criteria.

Objective:

Confirm that the measurement system used to collect the data is valid. The first goal is to quantify
the:

1. Process variation
2. Appraiser variation

and the Total measurement system variation.

Secondly, minimize the measurement system variation and its impact on the Total Variation so
the amount of Process Variation can be understood as precisely as possible.

The following components of measurement error need to be studied and quantified before
establishing process capability and making decisions from the data.

 ACCURACY / BIAS
 RESOLUTION / DISCRIMINATION

 LINEARITY
 STABILITY

 REPEATABILITY & REPRODUCIBILITY (Gage R&R)

The MSA is often a very time consuming component of the project and can slow the team’s quick
progression through the process.

Continue to focus on low hanging fruit that may be momentum "sustainers" and work vigorously
through the MSA process. Most of this work can be done by the GB/BB outside of the team
meetings.
Accuracy / Bias

The difference from the true value and the value from the measurement system. Accuracy
represents the closeness to a defined target. Precision is different than accuracy and is covered in
Gage R&R under Repeatability.

For best accuracy of the data:

1) Accept all data as it is collected. Assigning special cause and scrutinizing the data can come
later.

2) Record the data at the time it occurs.

3) Avoid rounding off the data, record it as it is.

4) On the data collection plan, record as many details around the data such as the exact source,
machine, operator, conditions, collector’s name, material, gage, and time. Record legibly and
carefully.

The data should be screened for misplaced decimal points, duplicate data entries by mistake or
improper recording procedure, missing date points if frequency is important, and other obvious
non-representative data.

5) Verify the gage is accurate. If using a weigh scale, verify it with a known and calibrated weight.
Use gage blocks for calipers or micrometers. Use hardness blocks to verify hardness testers.

Resolution / Discrimination

The goal is to have at least 5 distinct values or categories of readings.

Adhere to the 10-bucket rule. If your measurement system requires measurements to the
hundredths (x.xx), then divide that by 10. Collect and record the data to the nearest thousandths
(x.xxx). The measurement system shall be sensitive to change and capable of detecting change.

The lack of resolution will not allow a measurement system detect change. If you are measuring
the downtime and using measurement to the nearest hour and most downtime is less than an hour
then most of the reading will either be a 0 (for 0 hours) or a 1 (for 1 hour).

However, using a stop watch and recording data to the nearest minute will provide 60x more
resolution and allow better distribution of data points, more variety of data, with fewer repeat
measurements. You could have 60 different readings. Actually recording the nearest 6 minutes
would satisfy the 10-bucket rule, but it is a guide to help ensure resolution in the measurement
system.

This part of the MSA is usually the easiest to fix such as finding a micrometer, caliper, hardness
tester that can capably read to the next nearest decimal.

TROUBLESHOOTING:
Try acquiring a larger samples size, with the idea that some of these may create new observations
or measurements.

Measure to as much resolution as possible and practical.

Linearity

When gathering data only collect with the acceptable limits where there is proven linearity. This is
a test to examine the performance of the measurement systemthroughout the range of
measurements.

Linearity represents the change in accuracy through the expected operating range of a
measurement device.

For example, does the bathroom scale perform the same when weighing a pet of 10 lbs to a man
of 250 lbs? The scale has an operating range of 0 lbs to 300 lbs but the scales's accuracy may
changes at various levels of measurement.

Sources of linearity error may come from age, wear, or calibration error, or there may be known
linearity error. If there is known error then there may be a calculation to account for it and various
ranges of measurement.

Stability

Stability (also referred to as "drift") of a measurement system can be analyzed using control
charts. Ensuring the measurements taken by appraiser(s) for the process indicate stability and
consistency over time.

Each appraiser should measure the same way every time over a long period of time and each
appraiser should measure the same way as all the others.

Stability is the total variation (spread and shape of the data distribution) of the measurements
using the same parts, measured using the same gauge over a long period of time.

SPC Charts use a variety of tests to determine stability. Many software programs will have these
as options to include when analyzing data and will even indicate the point(s) and test that each
failed.

Some of the corrective measures once again include Standard Operating Procedures and re-
calibration. Sometimes the gauge will have wear from use over a long period of time and this can
not be repaired or re-calibrated. Other times, there may be a build up of dirt, dust, or
contamination.

Reminder:

Special cause variation can also occur within the process control limits and these must be given
corrective action before proceeding to validate the measurement system.
The I Chart below shows stability in this measurement system example, assuming this is a
"longer" period of time that represents actual conditions as close as possible.

Gage R&R
Variable Gage R&R
In a Variable Gage R&R there are generally two to three operators appraisers with 5-10 process
outputs measured by each appraiser. Each process output is measured 2-3 times by each
operator. Depending on the cost and time involved you can add more appraisers and
measurements and replications.

When performing the replicated appraisals it is critical that the measurement are randomized so
that no patterns or predictability can be entered in by the appraiser. This bias will mislead the
team and create a useless Gage R&R.

For example, an appraiser may remember the 7th part that was measured was borderline and
made a decision to give it one measurement. The appraiser may have spent a lot of time on that
part in the initial assessment and if the 2nd round of measurements are not randomized, that
person will remember the measurement (appraisal) they concluded during the first round.

So the message is to move the parts around each repetitive set of measurements. However, the
parts must be identified so the person entering the data into the statistical software enters the
reading under the correct part.

Four Criteria in Variable Gage R&R

The following four areas will be assessed. A statistical software program will produce these values
once the data is entered. The GB/BB will be responsible for finding these values and determining
whether each passes and if the entire measurement system is adequate to determine process
capability. Process capability can not be determined with reliability if the measurements (the data)
are suspect.

1) % Study Variation is based on standard deviation

2) % Tolerance is based on USL and LSL
3) % Contribution is based on variance
4) The number of distinct categories based on process variation
Ideally, all four categories should be in the GREEN zone. Examining the visual aids below shows
commonly used judgement criteria for each category.

2) % Tolerance

Shown below is an example of a % TOLERANCE calculation. In this case we are using 3 appraisers
measuring 6 different parts.

This study shows the measurement error as a percent of tolerance in short period of time. It
includes both repeatability and reproducibility, can not be separated.

5.15 Study Variation = 99% (constant)

The TOP TABLE at the top is a part of the d2 distribution. This value is a constant that is found by
looking at the column with 3 appraisers and going across with the row with 6 parts. In this
example the d2 value is 1.73.

The LOWER TABLE shows that actual measurements that each of the appraisers cam up with using
their variable gage. The range of the three measurements for each part is shown on the right.
Then the average range is shown (=0.69) and this is carried on to the Gage Error formula.
To convert this gage error of 2.05 to a percentage of tolerance multiply by 100 and divide by the
process tolerance for the analysis.

The process tolerance is the difference in the specification limits. For example, if the USL is 27 and
the LSL is 2, then the tolerance is 25.

With the tolerance being 25, then:

Referring back to the RED/YELLOW/GREEN criteria display for % TOLERANCE, it shown that 8.2%
is a passing value and this part of the Variable Gage R&R is acceptable.

REPRODUCIBILITY:

Ability of one appraiser to get the same result and another appraiser or the ability of all appraisers
to get the same results AMONG each other.

To optimize reproducibility in ATTRIBUTE Gage R&R:

1) Create visual aids, templates, definitions, or other specific criteria for each to meet a certain
rating, value, or appraisal. Pictures of good, bad, in the middle, and colors, will help each
appraiser standardize their response, improving the reproducibility.

Note: If these corrective actions are needed to pass the Gage R&R, it should be instituted as a
formal work instruction and everyone involved throughout the company or plant should adhere to
same instructions.

To optimize reproducibility in VARIABLE Gage R&R:

1) Create a Standard Operating Procedure with visual aids and definitions. When using humanly
subjective "touch" devices such as micrometers and calipers it is important that all appraisers
"squeeze" the same amount. Too little or much pressure at higher levels of resolution can be
enough to alter the Gage R&R.

2) Visual aids also help. When using an optical comparator to get a higher resolute data point
there is subjectivity where to place the template or the starting and end point(s) on the shadow.
Pictures of acceptable and non-acceptable will help reduce this variation. Templates of complex
figures or shapes also help reduce subjectivity and improve R&R.

REPEATABILITY

This describes the ability for an appraiser to repeat his/her measurements each time when
analyzing the same part, unit, etc. In destructive testing (such as tensile testing) these reading
will not be possible and some statistical software programs have options to select for destructive
testing.

The goal is to have an appraiser repeat unit readings at least three times. The person
administering the test should randomize the sequence each time to prevent and patterns and bias
(the appraiser may remember or try to remember what a measurement was and tend to alter real
measurements to get the Gage R&R to pass). It is important for the administrator to record
carefully to ensure readings correlate the correct part/unit each time.

Avoid writing down measurements and then typing them into a statistical program. The fewer
times measurements are recorded and copied the lower the risk for human error to add even more
variation and possibly fail (or pass) the Gage R&Rwhen it shouldn't have.
Precision is the ability to have the same repetitive result (or appraisal in this case). Visually, it
means that all your shots of an arrow are very close to one another. It does not mean that they
are near the bulls eye. In other words, it does not mean that your shots are accurate.

If your shots are accurate and precise, then they are tight circle centered around the target.

It is also possible to be accurate without being precise. For example, there may be several shots
all around the bulls eye (target) but they may be scattered all around it in a large diameter cluster
(area).

If you take a look at the group the center (mean) may be the bulls eye but the shots are not in
control or precise. In others words, there is a lot of unpredictability or variation. So this would
represent a set of data with an acceptable mean (on target) but too much variance (high standard
deviation).

This is the essence of Six Sigma. The methodology focuses on VARIATION REDUCTION as
primary goal and then with the inputs under control, the mean can be shifted if it is necessary. It
is NOT possible to shift the mean with sustainability without having process control (control over
sources of variation).

Attribute Gage R&R Example

Using the example of data gathered from two appraisers assessing 20 samples as Good (G) or No-
Good (NG) draw your conclusions on the outcome.
Variable Gage R&R Example
Examining the output of a measurement system analysis below what conclusions can be drawn?
As mentioned before, cleaning up a measurement system can elevate hidden causes of scrap,
rework, customer concerns and a lot of cost itself....and it can turn into a project itself.

Expect to update or create new Standard Operating Procedures (or work instructions) at a
minimum to mistake-proof the appraisal process and robust measurement methods so that as
much variation as possible is PART to PART.

MSA Training Download

This module provides additional insight in measurement systems analysis. This is critical
component of the MEASURE process that is often overlooked or skipped and could lead to incorrect
conclusions and rework in the later stages of the DMAICjourney.

Click here to purchase the MSA module and view others that are available.

ANOVA
Analysis of Variance is another technique to analyze sources of variation of measurement error (and for any
sources of variation - hence the name).
With statistical software, the method has the advantage over the "average and range" technique since it provides
more information, such as interactions between the parts being measured and appraisers.

The variation can be distinguished between four categories:

1) Appraisers (those that are measuring)

2) Parts or item being measured

3) Interaction of Appraisers and Parts

4) Replication error from the gauge

Return to the MEASURE Phase

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