<p>The manufacturing industry has employed lean Six Sigma (LSS) principles to streamline processes and increase profitability. Through the use of DMAIC (Define, Measure, Analyze, Improve, Control), the variation in the manufacturing process can be reduced and eliminate unneeded processes and increase the cycle time in the process. Measurement System Analysis (MSA) is critical for the LSS and DMAIC principles. A reliable MSA influences the process variation reduction implementation and longevity. A crucial component of MSA is gage accuracy and precision. Gage accuracy is measured using the Type 1 Gage R&amp;R (Repeatability and Reproducibility) method and the Type 2 Gage R&amp;R method. Gage error and confidence interval for the error values heavily rely on the sampling size and part variation. Gage R&amp;R method has been studied to determine that at least a sampling size of ten parts with three operators taking two measurements is required. The process mentioned above is used in this study to determine the gage error and the part variation using Minitab®. In the manufacturing environment, this time-consuming process is, in some cases, used with reduced sample size and reduce the number of operators. This study focuses on finding the effectiveness of the reduced sampling size and number of operators. The part variation affects the Gage R&amp;R method; a larger part variation can reduce the gage error percentage compared to the lower part variation. Thus, in this study, three sets of parts, one with large part variation, the second with smaller part variation, and the third set with close to zero-part variation, are used. Gage blocks, which have minimal part variation, are used to represent zero-part variation. The sampling sizes are varied from five samples to twenty samples, while the number of operators is varied from two to five operators. A design of experiments methodology is used to conduct the gage studies with different sampling sizes, operators, and part variation sets. The study is focused on identifying the gage error associated with varying rates of sampling and part variation. The study has shown that the gage error confidence significantly reduces with the number of operators. To a lesser extent, the confidence of the gage error reduces with the reduction in sample size. Part variation study has shown the gage R&amp;R value is significantly influenced. The gage error value confidence is not affected by the part variation. This study has highlighted the effective sampling size, the number of operators, and part variation on gage error and confidence values. This study provides a roadmap for selecting the appropriate sampling size and parts to verify the gages.</p>

Effects of Part Variation and Sampling Size on the Accuracy of Gage Repeatability and Reproducibility

Paper Proceedings: https://asmedigitalcollection.asme.org/IMECE/IMECE2021/volume/85543

ASME 2021 International Mechanical Engineering Congress and Exposition (IMECE2021)

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