Using the Monte Carlo Simulation Methods in Gauge Repeatability and Reproducibility of Measurement System Analysis

Abstract

Measurements are required to maintain the consistent quality of all finished and semi-finished products in a productionline. Many firms in the automobile and general precision industries apply the TS 16949:2009 Technical Specificationsand Measurement System Analysis (MSA) manual to establish measurement systems. This work is undertaken toevaluate gauge repeatability and reproducibility (GR&R) to verify the measuring ability and quality of the measurementframe, as well as to continuously improve and maintain the verification process. Nevertheless, the implementation ofGR&R requires considerable time and manpower, and is likely to affect production adversely. In addition, the evaluationvalue for GR&R is always different owing to the sum of man-made and machine-made variations. Using a Monte Carlosimulation and the prediction of the repeatability and reproducibility of the measurement system analysis, this study aimsto determine the distribution of %GR&R and the related number of distinct categories (ndc). This study uses two casestudies of an automobile parts manufacturer and the combination of a Monte Carlo simulation, statistical bases, and theprediction of the repeatability and reproducibility of the measurement system analysis to determine the probability densityfunction, the distribution of %GR&R, and the related number of distinct categories (ndc). The method used in this studycould evaluate effectively the possible range of the GR&R of the measurement capability, in order to establish aprediction model for the evaluation of the measurement capacity of a measurement system.