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OBJECTIVE
To provide
Basic concept of measurement system Detail application methodology of all statistical studies for variable and attribute data Methods to meet QS9000 & ISO/TS16949 requirements
Introduction
Uses of measurement data are Decision to adjust a manufacturing process Determine the significant relationship between two or more variables using statistical studies The result of analytical studies is depends upon the Quality of data produced by measurement system
PURPOSE OF MSA
Quantify Variation present in the Measurement system Compare the Consistency of inspectors Provide methods for Validation of Measurement System
Measurement Systems
Process to assign a number or decision to a characteristic Process
Terminologies
Statistical properties of MS
Ideal Measurement system is the one Which produces always only the correct measurements Always agree with the standard Statistical data produced over time
Statistical properties of MS
Properties of GOOD Measurement Systems : Adequate discrimination & Sensitivity System is always under statistical control Variability of the measurement system is small compared to Manufacturing process variation and Tolerance
Team members Purpose of use Frequency of use Part specification Sensitivity required Contact? Non contact/ Auto? Manual?
Statistical properties of MS
Classification Measurement system errors are: Bias Linearity Stability Repeatability Reproducibility
Statistical properties of MS
Determination of these errors will help us to: Criteria to accept new MS Compare one against another To evaluate a suspect gage To evaluate the effectiveness of repair
Define a process for implementation of MS Identify all types of measurement systems Cover all systems covered in Control Plan Perform Appropriate statistical study Use MSA ( or Customer approved) Manual Obtain Customer approval for use of methods other than MSA manual
Discrimination
1/10th of Tolerance 1/3rd Considering the cost/ criticality 1/10th of Process variation Resolution 1/10th of Process variation
PRECISION
Closeness to reference or master value Required where two or more MS measuring a same characteristic Same parameters are checked at Suppliers end or at Customer end
Ability of MS to repeat the same reading Required where MS is repeatedly used to assess and adjust the process In process inspection as per control plan
PRECISION Captured by
REPEATABILITY REPRODUCIBILITY
BIAS WHAT IT IS ?
Ref. Value
bar
BIAS - STEPS
1. Capture reference value Use masters calibrated traceable to standards
BIAS - STEPS
3. Calculate BIAS for individual reading & draw histogram 4. Calculate , bias, t limits APPENDIX C t distribution table
ACCEPTANCE CRITERIA Zero must lie between t Limits of Bias distribution or Bias should be within acceptable gage error as defined in Calibration Proc.
bar
bar
Error in Master
Instrument Worn
LINEARITY
Difference in Bias over the Operating range of the Gage
ve
Bias
+ve Bias
X bar
X bar
Linearity Steps
1. Collect 5 parts / masters over the operating range of the gage through process variation
Linearity Steps
5. Calculate Average, BIAS and enter the data in a Spread sheet 6. Draw Best fit line for the average, Lower limit and Higher limit of Bias
0
- VE
Lower t limits
Is this MS acceptable ?
LINEARITY - CASES
T1
T2
T3
Stability How?
No.of Samples/ Masters Subgroup Size 1 or 3 at Minimum, Mid and Higher Specification limits 1 or 3 times over a period in the Morning, Noon and Evening
Frequency
Charts
Daily,Weekly, Monthly based on the stability assessment of instrument One chart for each sample, XMR , or X bar& R or X bar & S
No trend
Zero must lie within two limits of bias variation
Stability Applicability
To compare two or more measurement systems measuring a same characteristic e.g Bore dial gage & Air gage
Total variation
ANOVA Method
Reproducibility
Same equipment Same Parts
Several trials
Different Appraiser
Range method
No.of Samples 5 nos. gives 80 % chance of detecting a wrong MS. 10 nos gives 90% chance No.of Appraisers Min. 2 Formula Sigma = R bar / d2*
0.00
% R&R 10 30 % OF TOL OR TV ACCEPTABLE SUBJECT TO ANALYSIS AND JUSTIFICATION W.R.T COST OF REPAIR AND CRITICALITY
No.of Appraisers 3 From personnel actually performing on a day to day operation No.of trials Min 2 . Preferably 3
% R&R 10 30 % OF TOL OR TV ACCEPTABLE SUBJECT TO ANALYSIS AND JUSTIFICATION W.R.T COST OF REPAIR AND CRITICALITY No. of distinct data categories
ndc > 5 where SPC is used ndc >2 where no SPC is used
R chart interpretation
CONDITION One or more than one point of one appraiser out of UCL R One or more than one point of all appraisers out of UCL R In one part all appraisers points are out of UCL R
INTERPRETATION His method is different from others Measurement System is sensitive to appraisers skill Part is deformed or Damaged
X chart interpretation
CONDITION More than 50 % of readings are out of control limits INTERPRETATION Measurement system is adequate enough to capture process variation
ATTRIBUTE MEASUREMENT
COMPARES EACH PART TO A SPECIFIC SET OF LIMITS AND ACCEPTS THE PART IF THE LIMITS ARE SATISFIED
II
III
II
Select the gage to be studied Calibrate the gage to know the actual size of the gage Understand the distribution and location of the process Decide the on which side of specifications samples to be taken and the measurement method Select samples (8) and repeat minimum 20 times on a random manner and count no.of accepts ( a )
Select Minimum 8 samples out of that One sample on lower than specification, no.of accepts a = 0 One sample on higher specification, no of accepts a = 20 Six parts on the gray area where, a is more than or equal to 1 and less than or equal to 19 Select sample repeat the study till we meet the above criteria
Calculate Probabilities of acceptance using formulae Plot Probabilities of acceptance as % in normal probability paper Calculate Bias & Repeatability Conclude the decision on the acceptability of gage
Take 50 parts representing entire process variation having bad, marginally bad, good & marginally good parts Mark as 1 to 50 Select 3 appraisers Conduct study in a random manner and record the decisions, 1 as OK and 0 as Not ok
Get the reference value for all the 50 parts using layout inspection/ variable instrument and decide its status as 0 or 1 Compare each trial of each inspector with the another inspector for their decision Complete the cross tabulation table Calculate Kappa for
Effectiveness
More than 90 % More than 80%
Less than 80 %
MSA TRAINING
ANY QUESTIONS ?
Thank You