Measurement System Analysis

By
Mr. D Roy
Email :
[email protected] Ph no
– 9204058839
07.06.2021
Content
1. MSA Definition
2. MSA Parameter
3. MSA Tools & Methods
4. MSA Plan & Execution
Part - 1
MSA basics
What is MSA : Measurement System Analysis

Measurement : Expressing a parameter in terms of number or decision, Eg 60 mm, 100 bar,

Good, Not ok, etc.
Measurement System : Collection of instruments / gauges, standards, operations, methods,
fixtures, software, personnel, environment and assumptions used for assessment of the feature
characteristic being measured (Measurement Systems are complete Process, not only restricted to
gauges)
Analysis : Expressing data in manner so that meaningful conclusions can be drawn, Eg. Pareto,
histogram, charts, etc.
MSA : Measurement System Analysis is a quantitative evaluation of the tools and pKrocess used
in making discrete or variable observations

Part -1 : MSA basics

Why MSA?

Decision depends on Data which is

Quality of Decision
captured through measurement system.

Quality of Data MSA – Helps analyzing goodness of

measurement system.

Quality of MSA
Measurement System

Part -1 : MSA basics

Why MSA ?

Some Consequences of Error in Measurement Systems

• Saying good product as bad and bad as good.

• Stable process treated as unstable or/and capable process as incapable, working

unnecessarily improving the process.

• Wrong conclusion from DOE/regression analysis.

• Wrong solution for your problem.

Part -1 : MSA basics

MSA Process Flow
Input Activities Output
Control Plans, List of
Instruments, new Preparation/Updating of MSA Plan
product

MSA Manual,
Identification of statistical studies to
Competency
meet the requirement of the MSA Plan
On concept of MS and
measurement and decide the frequency
Statistical studies

MSA Plan, WI & MSA

Perform MSA studies Study Report
manual
Prepare summary
YES
It is acceptable ? Report & submit to
NO
customer If required

Analyze the data using graphical tools /

brainstorming & find out causes for
variation

Initiate & implement corrective action

Part -1 : MSA basics

 Calibration Vs MSA

Calibration MSA

• Conducted in ccontrolled • Conducted in actual working condition.

environment. • Conducted using actual products/Parts
• Conducted using masters. • Conducted by actual users
• Conducted by qualified/ trained (operators/inspectors)
people. • Checks accuracy and precision
• Checks accuracy only.

Can calibration replace MSA?

Part -1 : MSA basics

Objectives of MSA

1. Quantify variation in the measurement system (MS).

2. Decide whether MS is capable for the study.

3. Ensure stability of the measurement system, Can we detect process improvement if and
when it happens ?

4. Validate measurement system.

5. Compare consistency between inspectors.

6. Identifying causes for variation in MS & Initiating appropriate actions to reduce variation.

Part -1 : MSA basics

Part - 2
MSA parameters
Parameters

1. Variation.
2. Accuracy and precision.
3. Discrimination.
4. Uncertainty.
5. Bias.
6. Uncertainty.
7. Stability or drift.
8. Repeatability.
9. Reproducibility.

Part -2 : MSA parameters

Variation

1. Variation is the Law of Nature.

2. Variation cannot be eliminated; it can only be reduced.

3. Goal is to achieve maximum possible reduction in variation.

Part -2 : MSA parameters

Variation

Part -2 : MSA parameters

Variation

Part -2 : MSA parameters

 Total Variation

Manufacturing Process Measurement System

Variation, MPV Variation, MSV

Variation within different Variation due to process of measurement

parts under the method of instrument. This can be due to error
measurement due to by the operator, use of wrong type of instrument
variation in process or problem in instrument

To have a good measurement system, the Measurement System

Variation should be minimum

Part -2 : MSA parameters

 Total Variation

Actual Process Variation Measurement Variation

Long-term Short-term Variation Variation due Variation due

Process Variation Process Variation within Sample To instrument To appraisers

Repeatability Bias Stability Linearity Reproducibility

Part -2 : MSA parameters

Sources of Measurement System Variation(MSV)

Measurements Materials Men

Mechanical Integrity Cleanliness Procedure
Temperature Fatigue
Wear Dimension Attention
Weight Calibration Error
Electrical Instabili Corrosion Interpretation
Hardness Speed
Conductivity coordination

MSV
Algorithm Instabilit Density Vision

Temp Fulxctuation Operator Technique Wear

Standard Procedure Stability
Sufficient Work time Resolution
Line Voltage Variati Maintenance Standard Calibration
Calibration Frequency Precision
Cleanliness Operator Training Design
Ease of use temperature
Humidity Cleanliness

Environment Methods Machines

Part -2 : MSA parameters

Accuracy & Precision

Not precise Not precise Precise Precise Not

Not Accurate Accurate Accurate
Accurate

Accuracy (Deals with Location) Precision (Deals with Spread)

• Closeness to reference or master value • Ability of the MS to Reproduce or
• Required where two or more MS Duplicate readings
measuring a same characteristic • Required where MS is repeatedly used to
• Same parameters are checked at assess and adjust the process
Suppliers or Customer end • In process inspection as per control plan.
• Captured by Bias, Linearity, • Captured by Repeatability & reproducibility
Stability Part -2 : MSA parameters
Accuracy - Closeness of mean to target
Precision - Adherence to mean

A P

A
P

A P

A P

Part -2 : MSA parameters

 Discrimination (or resolution or least count)

• Ability of the Measurement System to detect small changes in measured values.

• Measurement system is not fit for controlling process if it cannot detect process variation effectively.

Traditional approach Best-in-class approach

Least count = 1/10th of Tolerance Least Count = 1/10th of Process variation
(This is used when we want to know that product is ok or (This is used when we want to know about process
not ok.) variation.)

Part -2 : MSA parameters

 Uncertainty
• True value is unknown and CAN’T be known.

• We can only know the reference value.

• The difference between the true value and the measured value is the error.

• We can only go closer to the true value.

• Uncertainty is a band within which true value is expected to lie. It is measured at

defined confidence level (generally 95%)

True Measured

Error Uncertainty

X-U X X+U

Part -2 : MSA parameters

Uncertainty

Range of uncertainty

Error
D = Cmeasured –Ctrue

Ctrue-U Ctrue+U Measurand,C

Ctrue Cmeasured

True value Measured value

Part -2 : MSA parameters

 Uncertainty

• Random Uncertainties
Results from the randomness of measuring instruments.They can be dealt with by making
repeated measurements and averaging. One can calculate the standard deviation of the data to
estimate the uncertainty.
• Systematic Uncertainties
Results from a flaw or limitation in the instrument or measurement technique. Systematic
uncertainties will always have the same sign.For example, if a meter stick is too short, it will always
produce results that are too long.

Part -2 : MSA parameters

Uncertainty
Uncertainty of measurement

Standard uncertainty Extended uncertainty

U where we Up(p is the

Type A Type B need not to confidence
give Up where level of
K = 2 -3 probability)

Part -2 : MSA parameters

Bias
• Difference between the average of measurements and the reference value
• A systematic error component of the measurement system

True
Value

B
i
BIAS = X bar – Ref. Value
a
s

Measured Measured value with master

value with instrument
regular -Slip gauge, or
instrument -Part measurement on CMM,
etc
Observed
• It is an instrument
Average error (10% Acceptable)

• Applied where you have your own designed gauge

• For Vernier & micrometer instruments Bias study not required

Part -2 : MSA parameters

Linearity

• The change in Bias over the normal

operating range
• Defined as the maximum deviation
from the linear characteristics as a
percent of full scale output.
• It is normally desirable that the
output reading of an instrument is
directly proportional to the
quantity being measured.

Part -2 : MSA parameters

 Stability or drift

• The change in Bias over time

• Also known as “Drift”

• Used to determine calibration frequency

Part -2 : MSA parameters

 Repeatability

• Variation in measurement obtained with one measuring instrument when used several times by an
appraiser while measuring the identical characteristic on the same part.
• The variation in successive (Short Term) trails under fixed and defined conditions of measurement.

• Commonly referred to as Equipment Variation (EV), Instrument (gauge) capability.

• Indicates within-system variation.

Part -2 : MSA parameters

Repeatability -example

Repeatability Example:
Appraiser A
Appraiser B
Appraiser C

Average for Appraiser A

Average for Appraiser B
Average for Appraiser C

Part -2 : MSA parameters

Repeatability -example

Repeatability Example:
Appraiser A
Appraiser B
Appraiser C

Average for Appraiser A

Average for Appraiser B
Average for Appraiser C

Part -2 : MSA parameters

Reproducibility
Reproducibility

Appraiser

• Variation in the average of the measurements made by different appraisers using the same gauge
when measuring a characteristic on one part.
• For product and process qualification, error may be appraiser, environment (time), or method.

• Commonly referred to as Appraiser Variation (AV).

• Indicates between-system (conditions) variation

Part -2 : MSA parameters

Repeatability vs Reproducibility

 2  2
 2R&R
(Meas.System
Repeatability
Reproducibility
)

Two Components

Repeatability Reproducibility
(Equipment Variation) (Appraiser Variation)
• One Appraiser • Different Appraiser
• One Equipment • Same equipment
• Same part • Same Parts
• Several trials

Part -2 : MSA parameters

Measurement terminology
Performance Quantitative expression of
Type errors
characteristics performance characteristics

Systematic error Trueness Bias

Total error Accuracy Measurement of

uncertainty

Random error Precision Standard deviation

Repeatability / Within lab
reproducibility /
Reproducibility

Part -2 : MSA parameters

Part - 3
MSA tools and methods
Steps in Measurement System Analysis

“MSA” (R&R)?

Calibration?

Stability?

Linearity?

Bias?

Resolution?

Part -3 : MSA tools and methods

MSA Methods
Qualitative

Attribute
For Attributes Data

Quantitative

Variable
When MSA to be done for
When MSA to be done for a Gauge Inspection method of a parameter
which is used for inspection of a which cannot be measured
variable parameter

Snap Gauge, Limit Gauge, Any Dent, Crack, Fouling, etc

special gauge, etc

Signal Detection method Visual inspection method

Kappa method
MSA Methods

For Variables For Attributes

1. Bias study • Signal Detection
2. Linearity study • Cross Tabulation (Kappa)
3. Stability study • Visual inspection study
4. R & R (Range Method) • Gauge Performance Curve
5. GRR (X bar - R Method)

6. ANOVA

Part -3 : MSA tools and methods

Part - 3
MSA tools and methods – Variables , Gauge R&R method
Steps of performing MSA

1st appraiser to take

Select 3 appraisers. Arrange 10 samples. readings of all 10
samples.

2nd appraiser then 3rd appraiser next Follow steps 3 – 5, 3

takes reading of takes readings of times; total 90
10 samples. 10 samples. reading to
populate the data
table.

Calculate GRR wrt

Calculate EV and AV Total variation Plot Average
(TV) and graph and Range
Tolerance (Tol) graph
both.

Part -3 : MSA tools and methods - GRR (X bar - R Method)

Steps for calculating MSA results

Specification: USL: LSL: Tol: 0.0000 Gauge ID: Date:

PART
APPRAISER TRIAL AVERAGE
1 2 3 4 5 6 7 8 9 10
1

2
Appraiser 1
3

Average #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! Xa= #DIV/0!

Range 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 Ra= 0.0000

2
Appraiser 2
3

Average #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! Xb = #DIV/0!

Range 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 Rb= 0.0000

2
Appraiser 3
3

Average #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! Xc= #DIV/0!
Range 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 Rc= 0.0000
X p= #DIV/0!
Part Average #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0!
Rp= #DIV/0!

Average of Range = (Ra + Rb + Rc / No. of Appraiser) R= 0.0000

Range of Average = (Max. X - Min. X) XDIFF =

#DIV/0!

Upper Control Limit for Range Chart UCLr = R x D4 0.0000

Part -3 : MSA tools and methods - GRR (X bar - R Method)

Steps for calculating MSA results
From Data
Sheet R= 0.0083 0.0024 Rp= 0.1434
X diff =
Repeatability (Euipment Variation) % Repeatability

EV = R x K1 Trials K1 % EV = 100 [ EV / TV ] = 10.8434

= 0.0049 2.0000 0.8862
3.0000 0.5908 % EV = 100x[EV/(TOL/6)] = 7.3850
K1 = 1/d2* (at m = no of trials, g = no of part x no of appraisers = greater than
15)
Reproducibility (Appraiser Variation) % Reproducibility

= % AV = 100 [ AV / TV] = 1.9303

AV [( X diff x K2 )2 - (EV 2/ nr)]

= 0.0009 Change value of K2 as per % AV = 100x[AV/(TOL/6)] = 1.315

your case
n = No of Parts = 10.0000 r = Appraisers 2.0000 3.0000
No of Trials = 3.0000 K2 0.7071 0.5231
K2 = 1/d2* (at m = no of
appraisers, g = 1) & Reproducibility (R & R)
Repeatability % Repeatability & Reproducibility (R & R)

GR & R = (EV2 + AV2 ) %R&R= 100 [ R&R / 11.0139

TV ] =
= 0.0050 7.50
% R & R = 100 x GR&R/(TOL/6)
Part Variation ( PV )
Parts K3 =
PV = Rp x K 3 2.0000 0.7071 % PV = 100 [ PV / TV ] = 99.3916
3.0000 0.5231 % Part Variation ( PV )
= 0.0451 4.0000 0.4467 % PV = 100 x PV/(TOL/6) = 67.69
5.0000 0.4030
Total Variation ( TV ) 6.0000 0.3742 % TV = 100 x TV/(TOL/6) = 68.11
7.0000 0.3534
TV = GRR2 + P V2 8.0000 0.3375 r of distinct Data Categories
Numbe
9.0000 0.3249 = 1.41 [ PV / R&R ]
ndc
= 0.0454 10.0000 0.3146 = 12.7241 ries
Data Catego

Part -3 : MSA tools and methods - GRR (X bar - R Method)

Steps for interpreting MSA results

1. More than 50% points in Average graph should be outside control limits.
2. Average graph reflects the Measurement Capability of the Measurement
System.
3. Range graph reflects the Measurement Consistency of the Measurement
System.
4. All points in range graph should remain within control limit.
5. NDC reflects no of discrete categories permissible in Measurement
System.

4
2

Part -3 : MSA tools and methods - GRR (X bar - R Method)

Steps for interpreting MSA results

1. AVERAGE CHART

X Bar 1 2 3 4 5 6 7 8 9 10
D Sarkar 40.843 40.840 40.847 40.853 40.850 40.863 40.870 40.860 40.850 40.880
S K Sinha 40.840 40.840 40.840 40.850 40.850 40.870 40.870 40.860 40.860 40.870 Xp= X dbar
D Rakshit 40.850 40.837 40.840 40.850 40.850 40.867 40.870 40.860 40.850 40.880 40.855
UCL 40.860 40.860 40.860 40.860 40.860 40.860 40.860 40.860 40.860 40.860
LCL 40.850 40.850 40.850 40.850 40.850 40.850 40.850 40.850 40.850 40.850
A2 = 1.023 for n=3, 1.88 for n=2 (n=number of appraisers) R bar
Range of average 0.010 0.003 0.007 0.003 0.000 0.007 0.000 0.000 0.010 0.010 0.005

Average Chart D Sarkar S K Sinha D Rakshit UCL

LCL

40.890
40.880
40.870
40.860
40.850
40.840
40.830
40.820
40.810
1 2 3 4 5 6 7 8 9 10
4
3

Part -3 : MSA tools and methods - GRR (X bar - R Method)

GRR – Average Chart Interpretations
Condition Interpretation Action
Less than 50% Measurement system is not adequate Improve discrimination of the
of readings are enough to capture process variation, measurement system, or
out of control or Parts does not represent expected Select parts representing
limits process variation entire process variation

In this example, 22 out of 30 points are outside the control

limit
Since this is more than half of total points, the conclusion is
that the measurement system is adequate to detect part-
to-part variations.

More than 50% points outside control limit indicates that MS variation is much smaller as compared to part
variations, hence MS is capable of detecting part-to- part variations
Part -3 : MSA tools and methods - GRR (X bar - R Method)
Steps for interpreting MSA results
1 2 3 4 5 6 7 8 9 10
Range
2.Range chart 0.010 0.000 0.010 0.010 0.000 0.010 0.000 0.000 0.000 0.000
D Sarkar

0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000
S K Sinha

0.000 0.010 0.000 0.000 0.000 0.010 0.000 0.000 0.000 0.000
D Rakshit

0.005 0.005 0.005 0.005 0.005 0.005 0.005 0.005 0.005 0.005
UCL

D Sarkar S K Sinha D Rakshit UCL

Range Chart
0.012

0.010

0.008

0.006

0.004

0.002

0.000
1 2 3 4 5 6 7 8 9 10

Purpose of range chart is to identify whether measurement process is under control (free from special cause)

Part -3 : MSA tools and methods - GRR (X bar - R Method)

GRR – Range Chart Interpretations
Condition Interpretation Action
1 or more point of any There was a special cause Remove these readings and take same reading
appraiser out of UCLr while taking reading again from same part & appraiser and
recalculate

More than 1 point of only His method is Remove these readings. Train appraiser on
one appraiser out of UCLr different from others method of measurement & take readings again

1 or more than one point of Measurement System is Check why measurement is so sensitive stop
all appraisers out of UCLr sensitive to appraisers skill further studies before taking action on
sensitivity

In one part all appraisers Part is deformed or Remove all the reading for particular part and
points are out of UCLr Damaged recalculate or replace the part with new part &
take readings

Part -3 : MSA tools and methods - GRR (X bar - R Method)

GRR-Acceptance Guideline

% R&R Value Decision

< 10% of TOL or TV Gauge is Capable
10 – 30% of TOL or TV Acceptable subject to analysis & justification w.r.t. application, cost of repair
& criticality

> 30% of TOL or TV Measurement system need improvement / corrective

action

Number of distinct data categories should also be checked when doing SPC,
ndc = 1.41 [PV / R&R] > 5 (best = 10)
(this means R&R should always be less that 28% of PV)
< 2, inadequate to provide data for study
= 2, it is equivalent to a go/nogo gauge
GRR % through TV or TOL/6

Product Control
Measurement is used for
deciding product TOL/6
acceptance/rejection

Process Control
Measurement is used to find TV
variation in parts (variation in or
process, identifying special
Process Standard Deviation (If
cause, SPC application)
process variation is known)

Part -3 : MSA tools and methods - GRR (X bar - R Method)

Identify the right cause & solution

When Repeatability > Reproducibility

• Instrument needs maintenance

• Redesign gage for more rigidity

• Improve clamping or location of gauging

• Excessive within-part variation

When Reproducibility > Repeatability

• Appraisers needs training on better way of using the gauge
• Needs better operational definition
• Incremental divisions on instrument are not readable
• Need fixture to provide consistency in gauge use
Part -3 : MSA tools and methods - GRR (X bar - R Method)
Relation of R & R with Cp, Cpk

Actual Cp/Cpk is always more than Observed Cp/Cpk

Part -3 : MSA tools and methods - GRR (X bar - R Method)

Part - 3
MSA tools and methods - Attributes
MSA Methods

For Variables
For Attributes
1. Bias study
• Signal Detection
2. Linearity study
• Cross Tabulation (Kappa)
3. Stability study
• Visual inspection study
4. R & R (Range Method)
• Gauge Performance Curve
5. GRR (X bar - R Method)

6. ANOVA

MSA tools and methods - Attributes

Steps of performing MSA

Take 50 parts randomly Measure all the samples

from the process covering with correct measuring
Select 3 appraisers. the entire variation (ensure instrument to collect the
at least 20% of the parts reference data for each
are defective). sample.

Conduct trial runs as per Populate the table with

nomenclature of 3 Note the readings in table. 450 data in total and
appraisers; perform 3 trials perform calculations as per
for each operator. below method.

MSA tools and methods - Attributes

Steps for calculating MSA results

Reducing variation is goal of SPC

LSL USL Reducing variation
is goal of MSA

I. Bad product is always

rejected
II. Gray area, Some time
good is called bad and
bad is called good
III. Good product is always
accepted

I II III II I
• Signal Detection is used for both Repeatability & Reproducibility

MSA tools and methods - Attributes

Steps for calculating MSA results
1. After collection of all the data assign a code for each row i.e. considering 9 observations of each
row(3 of each appraiser) as per below nomenclature:

+ When the row has only 1

- When the row has only 0
x When the row has both 1
and 0

2. Arrange the reference value & codes in descending orders

3. Calculate top width d1 (distance between last part accepted by all the
appraisers to the first part rejected by all (for all specifications)
4. Calculate top width d2 (distance between last part accepted by all the appraisers to the first
part rejected by all (for all specifications)
5. Calculate average width AW = d1+d2/2
6. Calculate % R & R = (AW/Tolerance)*100

MSA tools and methods - Attributes

Steps for interpreting MSA results
Tolerance 0.1
Top width = d1 = 0.566152 -
0.542704 0.023448

Bottom width = d2 = 0.470832 -

0.446697 0.024135

Average width = AW = (d1+d2)/2 0.023792

% R&R = (AW/Tolerance)X100 23.79%
Decision Remarks
0 called 0 Right Decision,
1 called 1 Effective MS

0 called 1 Miss Alarm, Consumer’s risk, 

1 called 0 False Alarm, Producer’s risk, 

< 10 % Acceptable
+ When the row has only 1
Reference value
- When the row has only 0
< 30 % Conditionally Acceptable
Varies from : 0.400
to 0.600 X When the row has both 1 & 0 > 30 % Needs improvement

MSA tools and methods - Attributes

MSA Methods

For Variables
For Attributes
1. Bias study
• Signal Detection
2. Linearity study
• Cross Tabulation (Kappa)
3. Stability study
• Visual inspection study
4. R & R (Range Method)
• Gauge Performance Curve
5. GRR (X bar - R Method)

6. ANOVA

MSA tools and methods - Attributes

Steps of performing MSA

1. Take 50 parts randomly from the process covering the entire variation (ensure at least 20% of the
parts are defective
2. Get measurements on the parts by the operators as 1 (for OK) and 0 (for NOT OK) decisions
3. Similar to X bar R method perform three trial runs for each set of samples for each operator. Total
450 data to populate the table.
4. Get these parts measured / decided by a MASTER (an experienced) person for the results to be used
as REFERENCE
5. Compare each trial of each inspector with the another inspector for their decision
6. Complete the cross tabulation table, shown in next slide
7. Calculate Kappa for
- A vs B, A vs C, B vs C
- A vs Ref, B vs Ref, C vs Ref

MSA tools and methods - Attributes

Steps for calculating MSA results

There are 34 times where

A-1 = 1 and B-1 = 1

(that is, of the 50 parts checked there were 34 matches by

A and B on their FIRST check)

MSA tools and methods - Attributes

Steps for calculating MSA results

There are 32 times where

A-2 = 1 and B-2 = 1

(that is, of the 50 parts checked

there were 32 matches by A and B
on their second check)

MSA tools and methods - Attributes

Steps for calculating MSA results

There are 31 times where

A-3 = 1 and B-3 = 1

(that is, of the 50 parts checked there

were 31 matches by A and B on their
THIRD check)

Total : where A-x = 1 and B-x = 1

= 34+32+31 = 97

MSA tools and methods - Attributes

Count & Expected Count Expected Count =
B (Column Total x Row Total )
A*B Cross Tabulation Total / Grand Total
0 1

Count 44 6 50 For A=1 & B=1

0
Expected Count 15.7 34.3 50 Column Total = 103
A Row Total = 100
Count 3 97 100
1 Grand Total = 150
Expected Count 31.3 68.7 100

Count 47 103 150 Hence,

Total Expected count =
Expected Count 47 103 150
(103 x 100)/150 =
68.7

MSA tools and methods - Attributes

Steps for calculating MSA results

B
A*B Cross Tabulation Total
0 1

Count 44 6 50
0 Where
Expected Count 15.7 34.3 50 po = sum of observed proportions in the
A diagonal cells (left to right direction)
Count 3 97 100 pe= sum of expected proportions in the
1
Expected Count 31.3 68.7 100 diagonal cells (left to right direction)

Count 47 103 150

Total
Expected Count 47 103 150

MSA tools and methods - Attributes

Steps for interpreting MSA results

Effectiveness Decision
More than 90 % Acceptable for the appraiser
More than 80% Marginally acceptable for the appraiser
Less than 80 % Unacceptable for the appraiser-Need improvement

Miss Rate (Consumer’s Risk) Max 2 %

False Alarm rate (Producer’s Risk) Max 5 %

MSA tools and methods - Attributes

MSA Methods

For Variables For Attributes

1. Bias study • Signal Detection
2. Linearity study • Cross Tabulation
(Kappa)
3. Stability study
• Visual inspection study
4. R & R (Range
Method) • Gauge Performance
Curve
5. GRR (X bar - R
Method)

6. ANOVA

MSA tools and methods - Attributes

Limitations:

• 100% subjective inspection is not 100% effective

• 200% inspection is less effective than 100% (no ownership, conflict, multiply individual
effectiveness)
• Rate of improvement noticed will be less than actual improvement for subjective inspections

• There are more chances of mismatch in acceptance criteria between customer &

supplier

MSA tools and methods - Attributes

Steps of performing MSA

1. Collect min 20 samples covering good, bad (include marginal one which is part of process)

2. Decide the reference value-It should be inline with internal / external customer
requirement. Team should come with common consensus on reference value

3. Identify the parts with numbers

4. Ask a operator who is regularly checking these product to separate good and
bad parts

5. Record his decision about every part as good and bad

6. Repeat step 4 and 5 with 2-3 operators for at 2-3 times

7. Calculate Effectiveness of inspection, miss & false alarm

8. Decide whether measurement system is accepted

MSA tools and methods - Attributes
Steps for calculating MSA results
APPRAISER:A APPRAISER:B APPRAISER:C
Srl
Reference Trials
1
Trials
2
Trials
3
Trails
1
Trails
2
Trails
3
Trials
1
Trials
2
Trials
3

G B 1 G G G G G G G G G

2 G G B G G G G G G
Correct Miss
G Decision Alarm
3 G B G G G B G G G

4 B B B B B B B B B
Appraiser
False Correct 5 B B B B B B B B B
B Alarm Decision 6 G G G G G G G G G

7 G G G G G G G G G

G=Good; B=Bad 8 G B G G B B G G B

9 B B B B B B B B B

10 G G G G G G G G G

11 G G G G G G G G G

12 B G G G G G G G G

13 B B B B B B G G B

14 B B B B B B B G B

15 B B B B B B B B B

16 G G G G G G G G G

17 G G G G G G G G G

18 B B B B B B B B B

19 G G G G G G G G G

20 G G G G G G G G G

MSA tools and methods - Attributes

Steps for calculating MSA results
Ref Ref Ref
G B G B G B
G 33 2 G 35 1 G 34 5
A B C
B 3 22 B 1 23 B 2 19

Number of samples (N)=20 Number of Good samples (NG)=12

Number of trials (R)=3 Number of BAD samples (NB)=8

Srl DESCRIPTION A B C

1 Number of miss alarm (Nm) 02 01 05

2 Number of false alarm (Nf) 03 01 02

3 Effectiveness of inspection = No of good decisions / Total 55/60=0.92 58/60=0.97 53/60=0.88

Probability of miss P(MISS) = No. miss / No. of opportunities

4 02/(8x3)=0.08 01/(8x3)=0.04 05/(8x3)=0.20
= Nm / (NBxR)
Probability of false alarm P(FA) = No of false alarm / No of
5 03/(12x3)=0.08 01/(12x3)=0.03 02/(12x3)=0.06
Opportunities for false alarm = Nf/ (NGxR)

Miss Rate (Consumer’s Risk) Max 2 %

False Alarm Rate (Producer’s Risk) Max 5 %

MSA tools and methods - Attributes

Steps for interpreting MSA results

Effectiveness (E)
> 0.9 : accepted Note: This the thumb rule.
0.8-0.9 : conditionally Organization & customer has To decide
accepted
< 0.8 : unacceptable who much risk is Acceptable considering
the Importance of the parameter
< 0.05 of False
Probability : Accepted
alarm P (FA)
0.05 - 0.1 : Conditionally accepted
> 0.1 : Unacceptable

Probability of miss P (MISS)

< 0.02 : Accepted
0.02 - 0.05 : Conditionally accepted
> 0.05 : Unacceptable

MSA tools and methods - Attributes

Interaction points

MSA definition

MSA Parameters

MSA Tools & Methods

MSA Plan & Execution

Part - 4
MSA plan and execution
Steps to be followed to IMPLEMENT MSA

• Prepare complete gauge list.

• Categorize all gauges to Major Gauge Groups which need to be covered in given time line.
• Refer control plan of each process to identify importance and criticality of each gauge. Select gauge as per criticality.
• Considering point 2 & 3 prepare MSA Plan.
Plan • Plan not more than 2 MSA per day.

• 100% gauges of the Gauge – list need not be covered.

• Perform MSA as per MSA plan.

Perform

• Analyze and Conclude study with interpretation.

• For MSAs out of acceptable limit, take necessary action and again perform MSA.
• Part with lowest tolerance to be taken for MSA.
Present

MSA plan and execution

Points to be confirmed before starting MSA
1. No of Parts X No of Appraiser should be minimum 15.
2. Appraisers must be the users of the measurement system.
3. Parts to be numbered from 1 to n (10) so that numbers are not visible to
appraisers.
4. Gauge should be calibrated.
5. Parts should be clean and dent free.
6. Measurement should be in random order.
7. All parts should be retained after study till completion of study.
8. Observer should have a ref copy of the MSA readings.
9. 10 samples should represent the maximum process variation; follow Systematic
sampling for selection.

MSA plan and execution

Thank you