GRR ANALYSIS AND UNCERTAINTY MEASUREMENT

Ariff Iqmal1, Assadullah Hakimi2, Nuruljannah3, Wan Iznifaiznur4

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Quality Engineering Department,Universiti Kuala Lumpur, Malaysian Institute of Industrial Technology,
Persiaran Sinaran Ilmu, 81750 Bandar Seri Alam, Johor Bahru, Johor, Malaysia,

Introduction of Metrology Ambient Conditions

The conditions existing at the time of a
It is the science of measurement. Intrinsically
measurement can influence its outcome. The
provides and understanding of what we are
temperature, lighting conditions and the quality of
measuring and how it can be interpreted by
the electricity supply are possible influence
customers or end-users.
quantities in the value of a measurement.
Importance of Metrology Human Error
The limitation of human perfection is a reality that
The Flaws
impacts on the reliability of measurements.
Measuring instruments all have a flaw, some
Despite training and carefully written procedures
intrinsic limitation that does not allow for the
conscientiously applied the effects of human error
results it gives to be the absolute truth. The method
can only be minimised.
and science of the measurement along with the
design and construction of the instrument, even the With the best of intentions metrology is needed to
way in which the measurement is defined can all ensure that measurements can be trusted.
contribute to the limit of correctness of a Metrology can even be applied in some situations
measurement. A ruler cannot measure a length where intentions are not the best to give
shorter than the thickness of its lines and values acceptable results.
between the lines must be visually estimated these
are both limitations on its use. Procedure and preparation to conduct the
measurement
Degradation Preparation:
Manmade objects are always subject to natural
degradation and to deterioration through wear and 1 Make sure that the equipment use has
tear from use. Measuring instruments are no been calibrated to avoid zero error
different and the results that they give tend to be
less reliable with the passage of time. A ruler with
worn out lines is useless and a crooked edge is a
sure cause of error.

Variation
Variation is another phenomenon that acts against
the correctness of measurements. Along with the
factors mentioned above there are several natural
and technological factors that can influence the
outcome of a measurement.

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 2 Clean the surface of the equipment and Data collection for 20 measurement
sample using ethanol to avoid wrong
measurement
3 Make sure that the sample used is the same
to another until 20th measurements
4 Labelled the dimension with 1,2,3 and so
on to ease the measurement work
5 Avoid the equipment from falling down

Procedure:
1 Check the equipment condition. Make sure
it is in good condition.
2 Make a table of measurement in a paper
3 Do the measurement using several types of Comparison between Vernier Caliper and Dial
equipment Caliper
4 Repeat the measurement for 5 times for
each of the dimension and do the average
to get the much accurate measurement
5 Make sure the level of eyes is parallel to
the reading of the equipment to avoid
parallax error

6 Complete the measurement until 20th

measurement. Then do the average and
standard deviation
7 Do the GR&R Analysis
8 Clean the equipment and keep it back on
the rack
From 5 measurements take, the readings when using
dial caliper are more accurate and precise than
standard caliper.
Error and how to avoid
Error might be happened when conduct the
equipment with wrong technique. Calipers common
error is parallax error. Its occur when an object is
observed from and angle. To avoid parallax error the
observer should position his eyes directly above the
scale when taking the readings.
Micrometer - Zero error occurs when the flat end of
the screw touches the stud or anvil and the gauge
read other than zero. The gauge need to be adjust to
restore accuracy.

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A major error in the design of a basic height gage is Determine the average range for the four
taking a design that was meant to measure 12 appraisers
inches and simply extending the post to measure 36
inches, without changing the base design or the R 1+ R 2+ R 3+ R 4
cross-area of the measuring post. 4 =
A normal step in trying to increase the performance
of the gage is to beef up the column to reduce the 0.025+ 0.024+0.027+ 0.022
flexure of the post. 4 = 0.025
Decreasing the ratio of the post to the base will
significantly improve performance.
Surface of the block might be dirty. A small metal
chip or even a hair, while almost impossible to see,
could throw off the measurement by 0.020 inch at a
height of only 10 inches. = 35.122 35.109
To avoid it make sure clean the surface of the block = 0.013
that want to measure.

= 154.593 4.250
GR&R Analysis
= 150.343

Equipment variation (EV)

K1 for 5 trials = 0.4299

= 0.4299(0.025)
= 0.011

Appraiser variation (AV)

K2 for 4 appraisers = 0.5051

0.5051
0.013
=

= 0.006

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Repeatability and reproducibility (GRR)
= ( 0.011) +( 0.006 )
2 2
= 0.013
Part variation (PV)
K3 for 20 parts = 0.0760
= (150.343) (0.0760)
= 11.426
( 0.013 ) +(11.426)
2 Step 3: to know the max and min
=
= 11.426
Interpreting the Results
%EV = 100(EV/TV) = 100(0.011/11.426) = 0.10%
% AV = 100(AV/TV) = 100(0.006/11.426) = 0.05%
%GRR=100(GRR/TV)=100(0.013/11.426)= 0.11%
%PV = 100(PV/TV) = 100(11.426/11.426) = 100%
R&R Indices
10% Acceptable Measurement System
10% - 30% May be acceptable based upon
application, cost of measurement
device, cost of repair, etc.
30% Not acceptable. Measurement system
needs improvement
Measurements of Uncertainty
To measure uncertainty:
Step 1: calculate the average of 5 readings taken
Step 2: calculate range of the same 5 readings
E.g:
Value of average = 77.98
Value of range = 0.06
Max value = 77.98 + 0.06
= 78.04
Min value = 77.98 0.06
= 77.92
So, the uncertainty of 5 readings taken must be
between 77.92 ~ 78.04
Conclusion
As the result showed we can conclude that the part
variation is 100% cannot be accepted. It is because
the maximum part that we measured are to bigger
than the other part. So, to avoid this happen again
in future, we must measure the part not too big or
to small than the other part.
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Gage Repeatability & Reproducibility
Quality professionals know that measuring
manufactured products is critical to maintaining the
customer specification. They also know that
measuring products is necessary for statistical
process control systems designed to improve the
manufacturing process itself. What is sometimes
forgotten is that the data is only worthwhile if the
measurement system itself is adequate.
A Gage R&R study will tell operators if the
measurement system is acceptable for its intended
use. The gage study also shows which part of the
measurement system is contributing the most to the
variation of the measurements and helps operators
plan improvements to the system.
Measurement systems contain variation from three
main sources which is the products themselves, the
appraiser taking the measurements and the
equipment used to perform the measurement. The
gage study shows the contribution of each of these
areas.
The two major sources of variability that we are
interested in a Gage R&R study are the
repeatability and reproducibility.
1 Repeatability is the variation in the
measurements obtained by one operator
measuring the same item repeatedly. This
is also called measurement or equipment
variation.
2 Reproducibility is the variation of the
measurement system caused by differences
in the way operators perform the test. It is
the variation in the average values obtained
by several operators while measuring the
same item and is sometimes called the
appraiser variation.
The combined repeatability and reproducibility
make up the Gage R&R variability. The third
major source of variation is the part variation. This
variation is a measure of how much the parts vary
and should be representative of what occurs in
production if you are using the measurement
system to control the process. The last major
source of variation is the total variation which is a
measure of the variation in all the results.
The relationship between the total, part and
measurement system variation is given by the
equation below
where the subscripts represent the source (t = total,
p = part, and ms = measurement system). Note that
this equality is based on variances. Remember that
the variance is the square of the standard deviation
(sigma).
There are 3 techniques for Gage R&R analysis:
1. Average and Range Method
2. ANOVA
3. EMP(Evaluating the Measurement
Process)
For our analysis, we had use the Average and
Range Method.
In an adequate measurement system, one would
expect to find most of the variation within the
products. If the bulk of the variation is created by
the appraisers or the equipment, then the system
may not be suitable.
The gage study consists of several parts that are
repeatedly measured by multiple appraisers. While
the numbers can vary, most studies use 10 parts and
three appraisers who measure the parts at least
three times each. In our cases, we use a Casio
Scientific Calculator as a sample and we have 4
appraisers who measured the trials 5 times each.
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Procedure for Calibration of Each Equipment

a) Calibration of micrometre

1. Clean micrometre and measuring faces careful

with a non-fibrous patch, check flat measuring
faces with plane face glass for planeness and cuts
2. If available, unscrew the grub screw of the inner
sleeve with a screwdriver
3. Temper micrometre minimum 2 hours together
with checking gauges at 20C
4. Screw measuring spindle by slow twisting at the
friction clutch/ratchet against the anvil or against
the checking gauge. For internal micrometre, screw
the measuring faces by cautious twisting at the
thimble and/or at the friction clutch / ratchet if
available against setting ring gauge or
corresponding checking facility
5. Twist the inner sleeve by mean of the supplied
hook spanner as far as the longitudinal line from
the inner sleeve agrees with the zero line of the
external thimble
6. Tighten up again the grub screw of the inner
sleeve
7. Check again zero adjustment as above, repeat
regulation again if necessary
8. Should through repeated reset the longitudinal
line of the inner sleeve come into an unfavourable
reading position, you may loosen the thimble after
unscrewing the rear screw of the friction clutch /
ratchet through a slight knock with a bright plastic
hammer and screwing on after that in the new
position again.

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The repeated measurements are called trials.
Calculations are then made to determine the level
of variation between the appraisers, parts and
across the trials. It is not necessary to go into the
actual calculations here since there are numerous
software programs and templates available to assist
operators. Instead, lets focus on how to perform a
valid study and how to interpret the results.
Selecting part samples is perhaps the most critical
step in performing a successful study and probably
the most misunderstood. Part samples used for
gage studies should represent the true variation of
the production process. A common mistake is
trying to select production samples that are similar.
Some instructions for gage studies even state that
samples must be from the same batch.
The truth is that using products that do not
represent the variation of the process will cause the
gage study results to be worthless. If necessary,
operators may even select samples over a period of
days or weeks to get samples that truly represent
the process. Always remember that it is the
measurement system that is being evaluated here,
not the products.
5. Verify zero setting of calliper by observing the
indicated reading with jaws in the closed position.
If calliper does not read 0.000, dial callipers can be
easily adjusted to zero by loosening the bezel lock
screw, then rotating bezel to align the zero
graduation to the pointer. Some Vernier callipers
have sliding scales that may be adjusted.
6. Check the step-measuring feature using gage
blocks. Note dial readings when checked at zero
and at the measured value of the gage block.
7. Check depth measuring feature using gage
blocks. Note readings when checked at zero and at
the measured value of the gage block.
8. If any defects have been found at this point that
would affect accuracy or function of the gage,
discontinue calibration and refer to the
manufacturer manual for remedial action.

Now it is time to start measuring. Here are a few

guidelines for the measuring process:
1. The operators should share one calibrated
gage or measurement system.
2. Five or more samples that represent the
range of the process variation should be
used. Do not use one part or parts that have
little variation.
3. Samples should be measured in random
order if possible.
4. There should be at least two trials or
measurements taken from each operator.

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c) Calibration for Height Gauge 7. With measurement contact in its lowest
obtainable position, adjust gage to indicate zero.
8. Place the gage block alongside the gauge on
surface plate.
9. Raise sliding member of the gauge and position
in such a manner to verify measurement accuracy
with respect to the gage block.
10. Repeat steps 8 and 9 for remaining check
points.
b) Calibration of Calliper

1. Carefully examine entire gage for nicks, burrs,

scratches, other signs of mishandling or wear.
Check the sliding member of the gauge to assure
smooth movement
1. Carefully examine and all
positive
gaginglocking.
surfaces for nicks,
2.burrs,
Apply sufficient
scratches, amounts
wear or otherof signs
cleaning solution to
of mishandling
dampen a lint free cloth. Carefully
that may affect accuracy of the instrument. clean
Removeall
exposed surfaces removing
any positive surface imperfections all foreign substances
and particulate
2. Apply matter.
sufficient Lightly
amounts apply gage
of cleaning oil to
solution to
cleaned surfaces.
dampen a lint free cloth. Carefully clean all
3.exposed
Place the gaugeremoving
surfaces on the surface platesubstances
all foreign to check Reference
base flatness. Apply pressure at various
and particulate matter. Use brush on pinion track if locations.
There shouldLightly
necessary. be no movement.
apply gage oil to cleaned [1] Dr Adam Cawley FRACI CChem :
4.surfaces.
With sliding member set above zero, slowly slide Adlar Solutions Pty.Limited :
it3.onCheck
surfacetheplate
jawsto again
when check
in thecondition of base.
closed position. atcawley@gmail.com.au
There should at least be a feeling
Hold callipers to light source and visually examineof drag or [2] MSA Reference Manual 4th Edition
suction.
for lightAbetween
base in theexcellent condition
jaws. Light willbe
will not bring
seentoif [3] DMAIC - GRR
ajaws
goodaresurface plate.
parallel.
5.4. IfCheck
any defects have been
knife-edge jaws found
for wearat this pointinthat
when the
would affect accuracy or function
closed position. Calliper must be positioned of gage,
discontinue
squarely in line calibration
of sight to and
detecteither
air gapsrepair or
or surface
recalibrate,
imperfections or between
return as is for restricted use or
jaws.
scrap.
6. Divide the total measurement range into two
equal parts. Randomly select six checkpoints in the
lower half of the measurement range. Select two
additional checkpoints in the upper half of the
measurement range.