1

Gage Studies for

Continuous Data

Objectives
• Determine the adequacy of measurement systems.
• Calculate statistics to assess the linearity and bias of a measurement system.

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 Contents

Contents
Examples and Exercises Purpose Page
Assessing Measurement System Variation
Example 1 Assess how the precision of a measurement system 1-3
Fuel Injector Nozzle Diameters affects the variability of a measurement using a crossed
gage R&R study.
Example 2 Design a gage R&R study to identify problems in a 1-22
Muffler Pipe Thickness measurement system using a crossed gage R&R
analysis and a gage run chart.
Exercise A Identify problems in a measurement system using a 1-35
Assessing Consistency in Color Readings crossed gage R&R study.
Exercise B Determine the adequacy of a measurement system with 1-36
Paper Breaking Strength measurements obtained from a destructive test using a
crossed gage R&R study.
Nested Gage R&R (destructive tests with small
batch sizes)
Example 3 Determine the adequacy of a measurement system with 1-37
Impact Testing of Stainless Steel measurements obtained from a destructive test using a
nested gage R&R study.
Exercise C Determine the adequacy of a measurement system with 1-47
Improving the Measuring System measurements obtained from a destructive test using a
nested gage R&R study.
Gage Linearity and Bias Study
Example 4 Determine the linearity and bias of a measurement 1-48
Floor Tile Flatness system using a gage linearity and bias study.

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 Assessing Measurement System Variation

Assessing Measurement System Variation

Example 1 Fuel Injector Nozzle Diameters

Problem Tools
A manufacturer of fuel injector nozzles installs a new digital • Gage R&R Study (Crossed)
measuring system. Investigators want to determine how well
the new system measures the nozzles.

Data collection Variable Description

Technicians randomly sample, across all major sources of Nozzle Fuel injector nozzle measured
process variation (machine, time, shift, job change), 9 Operator Operator who measured
nozzles that represent those that are typically produced. They
code the nozzles to identify the measurements taken on each Run Order Original run order of the experiment
nozzle. Diam Measured diameter of nozzle (microns)
The first operator measures the 9 nozzles in random order.
Then, the second operator measures the 9 nozzles in a
different random order. Each operator repeats the process
twice, for a total of 36 measurements.
Note For valid measurement system analyses, you must randomly
sample and measure parts.

The specification for the nozzle diameters is 9012 ± 4

microns. The tolerance is 8 microns.

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 Assessing Measurement System Variation
Measurement systems analysis

What is measurement systems analysis Why use measurement systems analysis

Measurement systems analysis assesses the adequacy of a Measurement systems analysis answers questions such as:
measurement system for a given application. When • Can the measurement system adequately discriminate
measuring the output from a process, consider two sources of between different parts?
variation:
• Is the measurement system stable over time?
• Part-to-part variation
• Is the measurement system accurate throughout the range
• Measurement system variation of parts?
If measurement system variation is large compared to For example:
part-to-part variation, the measurements may not provide
useful information. • Can a viscometer adequately discriminate between the
viscosity of several paint samples?
When to use measurement systems analysis • Does a scale need to be periodically recalibrated to
accurately measure the fill weight of bags of potato chips?
Before you collect data from your process (for example, to
analyze process control or capability), use measurement • Does a thermometer accurately measure the temperature
system analysis to confirm that the measurement system for all heat settings that are used in the process?
measures consistently and accurately, and adequately
discriminates between parts.

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 Assessing Measurement System Variation
Gage R&R study (crossed)

What is a gage R&R study (crossed) Why use a gage R&R study (crossed)
A crossed gage R&R study estimates how much total process This study compares measurement system variation to total
variation is caused by the measurement system. Total process process variation or tolerance. If the measurement system
variation consists of part-to-part variation plus measurement variation is large in proportion to total variation, the system
system variation. Measurement system variation consists of: may not adequately distinguish between parts.
• Repeatability—variation due to the measuring device, or A crossed gage R&R study can answer questions such as:
the variation observed when the same operator measures
the same part repeatedly with the same device • Is the variability of a measurement system small
compared with the manufacturing process variability?
• Reproducibility—variation due to the measuring system,
or the variation observed when different operators • Is the variability of a measurement system small
measure the same part using the same device compared with the process specification limits?
• How much variability in a measurement system is caused
When you estimate repeatability, each operator measures by differences between operators?
each part at least twice. When you estimate reproducibility,
at least two operators must measure the parts. Operators • Is a measurement system capable of discriminating
measure the parts in random order, and the selected parts between parts?
represent the possible range of measurements.
For example:

When to use a gage R&R study (crossed) • How much of the variability in the measured diameter of a
bearing is caused by the caliper?
• Use gage R&R to evaluate a measurement system before • How much of the variability in the measured diameter of a
using it to monitor or improve a process. bearing is caused by the operator?
• Use the crossed analysis when each operator measures • Can the measurement system discriminate between
each part (or batch, for a destructive test) multiple times. bearings of different size?

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 Assessing Measurement System Variation
Measurement system error
Measurement system errors can be classified into two Accuracy
categories:
The accuracy of a measurement system has three
• Accuracy—the difference between the part’s measured components:
and actual value
• Bias—a measure of the inaccuracy in the measurement
• Precision—the variation when the same part is measured system; the difference between the observed average
repeatedly with the same device measurement and a master value
Errors of one or both of these categories may occur within • Linearity—a measure of how the size of the part affects
any measurement system. For example, a device may the bias of the measurement system; the difference in the
measure parts precisely (little variation in the measurements) observed bias values through the expected range of
but not accurately. Or a device may be accurate (the average measurements
of the measurements is very close to the master value), but • Stability—a measure of how well the system performs
not precise (the measurements have large variance). Or a over time; the total variation obtained with a particular
device may be neither accurate nor precise. device, on the same part, when measuring a single
characteristic over time

Precision

accurate and inaccurate but accurate but inaccurate and

Precision, or measurement variation, has two components:
precise precise imprecise imprecise
• Repeatability—variation due to the measuring device, or
the variation observed when the same operator measures
the same part repeatedly with the same device
• Reproducibility—variation due to the measuring system,
or the variation observed when different operators
measure the same part using the same device

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 Assessing Measurement System Variation
Assessing the measurement system
Use a Gage R&R study (crossed) to assess: Gage R&R Study (Crossed)
• How well the measuring system can distinguish between 1 Choose Stat ➤ Quality Tools ➤ Gage Study ➤ Gage R&R
parts Study (Crossed).
• Whether the operators measure consistently 2 Complete the dialog box as shown below.

Tolerance
The specification limits for the nozzle diameters are 9012 ± 4
microns. In other words, the nozzle diameter is allowed to
vary by as much as 4 microns in either direction. The
tolerance is the difference between the specification limits:
9016 – 9008 = 8 microns.
By entering a value in Process tolerance, you can estimate
what proportion of the tolerance is taken up by the variation
in the measurement system.
3 Click Options.
4 Under Process tolerance, choose Upper spec - Lower
spec and type 8.
5 Check Draw graphs on separate graphs, one graph per
page.
6 Click OK in each dialog box.

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 Assessing Measurement System Variation
Interpreting your results

Analysis of variance tables Gage R&R Study - ANOVA Method

Minitab uses the analysis of variance (ANOVA) procedure to Two-Way ANOVA Table With Interaction
calculate variance components, and then uses those Source DF SS MS F P
components to estimate the percent variation due to the Nozzle 8 46.1489 5.76861 769.148 0.000
measuring system. The percent variation appears in the gage Operator 1 0.0400 0.04000 5.333 0.050
R&R table. Nozzle * Operator 8 0.0600 0.00750 0.675 0.707
Repeatability 18 0.2000 0.01111
The two-way ANOVA table includes terms for the part Total 35 46.4489
(Nozzle), operator (Operator), and operator-by-part Alpha to remove interaction term = 0.25
interaction (Nozzle∗Operator).
Two-Way ANOVA Table Without Interaction
If the p-value for the operator-by-part interaction is ≥ 0.25,
Minitab generates a second ANOVA table that omits the Source DF SS MS F P
Nozzle 8 46.1489 5.76861 576.861 0.000
interaction term from the model. To alter the default Type I Operator 1 0.0400 0.04000 4.000 0.056
error rate of 0.25, click Options in the main dialog box. In Repeatability 26 0.2600 0.01000
Alpha to remove interaction term, type a new value (for Total 35 46.4489
example, 0.3).
Here, the p-value for Nozzle∗Operator is 0.707. Therefore,
Minitab removes the interaction term from the model and
generates a second ANOVA table.

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 Assessing Measurement System Variation
Interpreting your results

Variance components Gage R&R

Minitab also calculates a column of variance components %Contribution
Source VarComp (of VarComp)
(VarComp) and uses the values to calculate %Gage R&R Total Gage R&R 0.01167 0.80
with the ANOVA method. Repeatability 0.01000 0.69
Reproducibility 0.00167 0.11
The gage R&R table breaks down the sources of total Operator 0.00167 0.11
variability: Part-To-Part 1.43965 99.20
Total Variation 1.45132 100.00
• Total Gage R&R consists of:
– Repeatability—the variability from repeated
measurements by the same operator.
– Reproducibility— the variability when the same part is
measured by different operators. (This can be further
divided into operator and operator-by-part
components.)
• Part-to-Part—the variability in measurements across
different parts.

Why use variance components?

Use variance components to assess the amount of variation
that each source of measurement error and the part-to-part
differences contribute to the total variation.
Ideally, differences between parts should account for most of
the variability; variability from repeatability and
reproducibility should be very small.

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 Assessing Measurement System Variation
Interpreting your results

Percent contribution Gage R&R

%Contribution is based on the estimates of the variance %Contribution
Source VarComp (of VarComp)
components. Each value in VarComp is divided by the Total Total Gage R&R 0.01167 0.80
Variation, and then multiplied by 100. Repeatability 0.01000 0.69
Reproducibility 0.00167 0.11
For example, to calculate the %Contribution for Part-to-Part, Operator 0.00167 0.11
divide the VarComp for Part-to-Part by the Total Variation Part-To-Part 1.43965 99.20
and multiply by 100: Total Variation 1.45132 100.00

(1.43965/1.45132) ∗ 100 ≈ 99.20 Process tolerance = 8

Therefore, 99.2% of the total variation in the measurements Study Var %Study Var %Tolerance
Source StdDev (SD) (6 * SD) (%SV) (SV/Toler)
is due to the differences between parts. This high Total Gage R&R 0.10801 0.64807 8.97 8.10
%Contribution is considered very good. When Repeatability 0.10000 0.60000 8.30 7.50
%Contribution for Part-to-Part is high, the system can Reproducibility 0.04082 0.24495 3.39 3.06
distinguish between parts. Operator 0.04082 0.24495 3.39 3.06
Part-To-Part 1.19986 7.19913 99.60 89.99
Total Variation 1.20471 7.22824 100.00 90.35
Using variance versus standard deviation
Number of Distinct Categories = 15
Because %Contribution is based on the total variance, the
column of values adds up to 100%.
Minitab also displays columns with percentages based on the
standard deviation (or square root of variance) of each term.
These columns, labeled %StudyVar and %Tolerance,
typically do not add up to 100%. Because the standard
deviation uses the same units as the part measurements and
the tolerance, it allows for meaningful comparisons.
Note Minitab displays the column %Process if you enter a historical
standard deviation in Options.

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 Assessing Measurement System Variation
Interpreting your results

Percent study variation Gage R&R

Use %StudyVar to compare the measurement system Study Var %Study Var %Tolerance
Source StdDev (SD) (6 * SD) (%SV) (SV/Toler)
variation to the total variation. Total Gage R&R 0.10801 0.64807 8.97 8.10
Repeatability 0.10000 0.60000 8.30 7.50
Minitab calculates %StudyVar by dividing each value in Reproducibility 0.04082 0.24495 3.39 3.06
StudyVar by Total Variation and then multiplying by 100. Operator 0.04082 0.24495 3.39 3.06
Part-To-Part 1.19986 7.19913 99.60 89.99
%StudyVar for gage R&R is Total Variation 1.20471 7.22824 100.00 90.35

(0.64807/7.22824) ∗ 100 ≈ 8.97%. Number of Distinct Categories = 15

Minitab calculates StudyVar as 6 times the standard deviation

for each source.

6s process variation
Typically, process variation is defined as 6s, where s is the
standard deviation, as an estimate of σ. When data are
normally distributed, approximately 99.73% of the data fall
within 6 standard deviations (± 3 standard deviations from
the mean), and approximately 99% of the data fall within
5.15 standard deviations (± 2.575 standard deviations from
the mean).
Note The Automotive Industry Action Group (AIAG) recommends the use
of 6s in gage R&R studies.

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 Assessing Measurement System Variation
Interpreting your results

Percent tolerance Gage R&R

Comparing the measurement system variation with the Study Var %Study Var %Tolerance
Source StdDev (SD) (6 * SD) (%SV) (SV/Toler)
tolerance is often informative. Total Gage R&R 0.10801 0.64807 8.97 8.10
Repeatability 0.10000 0.60000 8.30 7.50
If you enter the tolerance, Minitab calculates %Tolerance, Reproducibility 0.04082 0.24495 3.39 3.06
which compares measurement system variation to Operator 0.04082 0.24495 3.39 3.06
specifications. %Tolerance is the percentage of the tolerance Part-To-Part 1.19986 7.19913 99.60 89.99
taken up by the measurement system variability. Total Variation 1.20471 7.22824 100.00 90.35

Note If you do not enter a tolerance, the %Tolerance column does not Number of Distinct Categories = 15
appear in the output. If your measurement specification is
single-sided, you do not have a tolerance range for the analysis.

Minitab divides the measurement system variation (6∗SD for

Total Gage R&R) by the tolerance. Minitab multiplies the
resulting proportion by 100 and reports it as %Tolerance.
%Tolerance for gage R&R is
(0.64807/8) ∗ 100 ≈ 8.10%

Which metric to use

Use %Tolerance or %StudyVar to evaluate the measuring system,
depending on the measuring system.
• If the measurement system is used for process improvement
(reducing part-to-part variation), %StudyVar is a better
estimate of measurement precision.
• If the measurement system evaluates parts relative to
specifications, %Tolerance is a more appropriate metric.

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 Assessing Measurement System Variation
Interpreting your results

Total Gage R&R Gage R&R

The %Study Var results indicate that the measurement Study Var %Study Var %Tolerance
Source StdDev (SD) (6 * SD) (%SV) (SV/Toler)
system accounts for less than 10% of the overall variation in Total Gage R&R 0.10801 0.64807 8.97 8.10
this study. The %Tolerance results indicate that the Repeatability 0.10000 0.60000 8.30 7.50
measurement system variation is less than 10% of the Reproducibility 0.04082 0.24495 3.39 3.06
tolerance width. Operator 0.04082 0.24495 3.39 3.06
Part-To-Part 1.19986 7.19913 99.60 89.99
Total Gage R&R: Total Variation 1.20471 7.22824 100.00 90.35

• %Study Var—8.97 Number of Distinct Categories = 15

• %Tolerance—8.10
Remember that Minitab uses different divisors to calculate
%Tolerance and %Study Var. Because the range for tolerance
(8) is greater than the total study variation (7.22824) in this
example, the %Tolerance is lower.

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 Assessing Measurement System Variation
Interpreting your results

Number of distinct categories Gage R&R

The Number of Distinct Categories value estimates how %Contribution
Source VarComp (of VarComp)
many separate groups of parts the system can distinguish. Total Gage R&R 0.01167 0.80
Repeatability 0.01000 0.69
Minitab calculates the number of distinct categories that can Reproducibility 0.00167 0.11
be reliably observed by: Operator 0.00167 0.11
Part-To-Part 1.43965 99.20
S part Total Variation 1.45132 100.00
---------------------------------------- × 2
S measuring system Process tolerance = 8

Minitab truncates this value to the integer except when the Study Var %Study Var %Tolerance
Source StdDev (SD) (6 * SD) (%SV) (SV/Toler)
value calculated is less than 1. In that case, Minitab sets the Total Gage R&R 0.10801 0.64807 8.97 8.10
number of distinct categories equal to 1. Repeatability 0.10000 0.60000 8.30 7.50
Reproducibility 0.04082 0.24495 3.39 3.06
Number of Operator 0.04082 0.24495 3.39 3.06
categories Means… Part-To-Part 1.19986 7.19913 99.60 89.99
Total Variation 1.20471 7.22824 100.00 90.35
<2 The system cannot discriminate between
parts. Number of Distinct Categories = 15

=2 Parts can be divided into high and low

groups, as in attributes data.
≥5 The system is acceptable (according to the
AIAG) and can distinguish between parts.

Here, the number of distinct categories is 15, which indicates

the system can distinguish between parts extremely well.
Note The AIAG recommends that the number of distinct categories be 5
or more. See [1] in the reference list.

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 Assessing Measurement System Variation
Interpreting your results

Components of variation
The Components of Variation chart graphically represents
the gage R&R table in the Session window output.
Note In the Options subdialog box, you can choose to display these
graphs on separate pages.

Each cluster of bars represents a source of variation. By

default, each cluster has two bars that correspond to
%Contribution and %StudyVar. If you add a tolerance or
historical standard deviation, a bar for %Tolerance or
%Process appears.
In a good measurement system, the largest component of
variation is part-to-part variation. If, instead, large variation
is attributed to the measurement system, the measurement
system may need correcting.
For the nozzle data, the difference in parts accounts for most
of the variation.
Note For the %Study and %Tolerance measures, the Repeat and Reprod
bars may not add up to the Gage R&R bar because these
percentages are based on standard deviations, not on variances.

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 Assessing Measurement System Variation
Interpreting your results

R chart
The R chart is a control chart of ranges that graphically
displays operator consistency. An R chart consists of:
• Plotted points, which represent, for each operator, the
difference between the largest and smallest measurements
of each part. If the measurements are the same, the
range = 0. Minitab plots the points by operator so that you
can compare the consistency of each operator.
• Center line, which is the grand average of the ranges (the
average of all the subgroup ranges).
• Control limits (UCL and LCL) for the subgroup ranges.
Minitab uses the within-subgroup variation to calculate
these limits.
If any points on the R-chart fall above the upper control limit
(UCL), the operator is not consistently measuring the parts.
The UCL takes into account the number of times each
operator measures a part. If operators measure consistently,
the ranges are small relative to the data and the points fall
within the control limits.
Note Minitab displays an R chart when the number of replicates is less
than 9; otherwise, Minitab displays an S chart.

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 Assessing Measurement System Variation
Interpreting your results

Xbar chart
The Xbar chart compares the part-to-part variation to the
repeatability component. The Xbar chart consists of:
• Plotted points, which represent, for each operator, the
average measurement of each part.
• Center line, which is the overall average for all part
measurements by all operators.
• Control limits (UCL and LCL), which are based on the
number of measurements in each average and the
repeatability estimate.
Because the parts chosen for a Gage R&R study should
represent the entire range of possible parts, this graph ideally
shows lack-of-control. It is desirable to observe more
variation between part averages than what is expected from
repeatability variation alone.
For these data, many points are above or below the control
limits. These results indicate that part-to-part variation is
much greater than measurement device variation.

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 Assessing Measurement System Variation
Interpreting your results

Operator by part interaction

The Operator∗Nozzle Interaction plot displays the average
measurements by each operator for each part. Each line
connects the averages for a single operator.
Ideally, the lines are virtually identical and the part averages
vary enough so that differences between parts are clear.
This pattern… Indicates…
Lines are virtually identical. Operators are measuring the
parts similarly.
One line is consistently One operator is measuring parts
higher or lower than the consistently higher or lower than
others. the other operators.
Lines are not parallel, or An operator’s ability to measure a
they cross. part depends on which part is
being measured (an interaction
exists between Operator and
Part).

Here, the lines follow one another closely, and the

differences between parts are clear. The operators seem to be
measuring parts similarly.
Note The significance of this interaction effect was shown in the ANOVA
table on page 1-8. The p-value for the interaction is 0.707, so the
interaction is not significant at the α = 0.05 level.

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 Assessing Measurement System Variation
Interpreting your results

Measurements by operator
The By Operator plot can help you to determine whether
measurements and variability are consistent across operators.
The By Operator graph shows all of the study measurements,
arranged by operator. When there are nine or fewer
measurements for each operator, dots represent the
measurements. When there are more than nine measurements
for each operator, Minitab displays a boxplot. For both types
of graphs, black circles represent the means, and a line
connects them. Asterisks indicate potential outliers.
If the line is… Then…
Parallel to the x-axis The operators are measuring the
parts similarly, on average.
Not parallel to the x-axis The operators are measuring the
parts differently, on average.

Also use this graph to assess whether the overall variability

in part measurements for each operator is the same:
• Is the spread in the measurements similar?
• Do one operator’s measures vary more than the others?
Here, the operators appear to be measuring the parts
consistently, with approximately the same variation.

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 Assessing Measurement System Variation
Interpreting your results

Measurements by part
The By Nozzle plot shows all of the measurements in the
study arranged by part. Minitab represents the measurements
by empty circles and the means by solid circles. The line
connects the average measurements for each part.
Ideally:
• Multiple measurements for each part show little variation
(the empty circles for each part are close together).
• Averages vary enough so that differences between parts
are clear.

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 Assessing Measurement System Variation
Final considerations

Summary and conclusions AIAG guidelines for the gage R&R table are:
The nozzle measuring system contributes very little to the %Tolerance,
overall variation, as confirmed by both the gage R&R table %StudyVar
and graphs. %Process System is…
Under 10% Acceptable
The variation that is due to the measuring system, either as a
percent of study variation or as a percent of tolerance, is less 10% to 30% Potentially acceptable (depends
than 10%. According to AIAG guidelines, this system is on the criticality of the
acceptable. measurement, costs, risks, etc.)
Over 30% Not acceptable
Additional considerations Source: [1] in the reference list.

Graph patterns that show low measuring-system variation: Gage R&R (crossed) studies, like other measurement
Graph Pattern
systems analysis (MSA) procedures, are designed
experiments. For valid results, randomization and
R-bar Small average range representative sampling are essential.
Xbar chart Narrow control limits and many points
out of control
By part Very similar measurements for each
part across all operators, and clear
differences between parts
By operator Straight horizontal line
Operator by part Overlaid lines

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