6s

For Internal Use Only Six Sigma Green Belt Training

Page 1

1. When and how will the device be calibrated?

Each operator must clearly understand and consistently apply the calibration procedure to the
measurement tool.
Ideally, the device should be calibrated before the study begins and not recalibrated until the
study has ended.
- If it is necessary to recalibrate after each measurement, then calibration variation and
repeatability are combined (compounded).
- If each operator must calibrate before beginning a trial, then calibration and reproducibility
variation are combined (compounded).

2. How many operators? N
op

If only one operator exists (e.g., automatic machine): N
op
= 1 (it is not necessary to force N
op
> 1).
In this case, R&R is just repeatability.
The minimum is: N
op
= 2
If several exists, N
op
= 3 or 4 (it is not necessary to have more).
Should represent the skills of the operators that would utilize the measurement system.

3. How many samples? N
parts

If possible: N
parts
= 10
General rule: N
parts
*N
op
> 15. If not possible, increase the number of trials.

Reference Material
Planning A Gage R&R Study
1
6s
For Internal Use Only Six Sigma Green Belt Training
Page 2

Reference Material
Planning A Gage R&R Study
2
4. How should the samples be selected?

The sample should be representative of the actual family of parts.
If from this same family there are 2 or more distinct groups, it is best to form 2 or more groups of
samples for the Gage R&R study, with specific ranges of values.

5. How many trials should be run? N
trials

A trial is one measurement on all the samples by each operator.
In the cases as noted:
N
trials
= 2 where N
op
*N
parts
<= 15
N
trials
= 3 where N
op
*N
parts
<= 7
N
trials
= 4 where N
op
*N
parts
<= 4
N
trials
= 5 where N
op
*N
parts
<= 3

6. How do I minimize the variation within the sample?

If the trials are destructive, select parts from the same lot or from as compact an area as possible
and assume that they are identical.
If it is not possible to eliminate within parts variation, the calculation of repeatability will include
the effect of this variation.
If you know or strongly suspect variation within the sample, run a study on special standards first,
then follow up with a study using production samples.
6s
For Internal Use Only Six Sigma Green Belt Training
Page 3

Reference Material
Planning A Gage R&R Study
3
7. Do I use individual measurements or averages?

If the measurement in production is a single measure, then perform the gage study with a single
measurement.
If the measurement in production is the average of several measurements, then perform the
gage study with the average of several measurements.
Make sure all operators report the measurements in the same manner.

8. How do I analyze the results?

Use Minitab tables and graphs to compare operators, parts and operator*part interaction

9. What do we do about one-sided specification limits?

Use the discrimination ratio and % contribution; or calculate the standard deviation (= s) and
consider the tolerance = 6*s. Realize that each case is often a unique case. But each case is
often a particular case, so use sound judgment.
6s
For Internal Use Only Six Sigma Green Belt Training
Page 4

Reference Material
Planning A Gage R&R Study
4
10. How can we tell if there is inadequate instrument measurement discrimination
(resolution)?

If the ranges calculated on the R&R form have three or fewer possible values < UCL, or
If more than 25% of the ranges = 0

11. What can be done about inadequate measurement discrimination?

Measure and report as many decimal places as possible. Limit calculations to one decimal
place more than the measured values.
Look for a better measuring device that can measure smaller units.

12. What is an acceptable gage?

The Gage R&R study is designed for a project, not for an auditor. Establishing internal
guidelines requires judgment on the degree of precision required for that instrument.