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R&R
Calibration alone wont produce quality measurements; even when perfectly
accurate, a gage can be unacceptable for measuring a product or process. Thats
where Gage R&R studies come in. Nearly every manufacturing company is required
to conduct these studies, the many benefits gleaned from which range from product
acceptance measurements and reliable control charts to objective equipment
selection criteria and identifying the need for operator training. More importantly,
however, this single study may be the only chance to find measurement quality
problems. Todays software makes Gage R&R data entry and calculation easy, but
learning to effectively interpret the results is imperative.
The Basics
The method is to measure variables of production measuring processes. The
primary variables are repeatability and reproducibility (R&R). The purpose is to
confirm that variation is not excessive or to take action if variation is found to be
excessive. This is required for each production measuring process, but not for each
gage - you might have 3,000 gages and only 200 production measuring processes.
Description of Variables
Repeatability: Variation that is observed when one or more operators repeat the
same measurement, on the same part and characteristic, using the same gage. This
particular measure of variation does not distinguish between operators.
Repeatability is not always influenced by human (operator) variation. To see
whether human variation may be a repeatability issue, view the softwares
repeatability range control chart. Reproducibility: Additional variation that is
observed when multiple operators are unable to reproduce the same test-group
average within limits predicted by repeatability. Appraiser Part Interaction:
Additional variation that is observed when multiple operators are unable to
reproduce the same pattern of part variation within limits predicted by repeatability.
Part-to-part: Either the actual variation (% TV column), or the allowable variation (%
Tol column), in the test parts the gage is trying to measure.