Range or Range methods do not. Refer to the AIAG published SPC manual, and the ANOVA method is
available through commercial statistical software packages and the AIAG APQP forms disk.
The organization shall report the number of distinct categories. All variable gauge R&R studies should have a
minimum of 5 distinct categories (See Measurement Systems Analysis Reference Manual published by AIAG,
refer to "ndc" in the index). The organization shall report gauge R&R as both a percent of study variation and a
percent of tolerance.
Guidance on selection of the appropriate (rational) samples (including sample sizes) for Gauge R&R is
available through https://web.lean.ford.com/cqdc/doc/Course_Mats/Book_7.pdf (search for “rational”).
Guidance for acceptable Gauge R&R analysis
For additional guidance, see the Measurement Systems Analysis and Statistical Process Control manuals from
AIAG:
a) At least one half of the averages should be outside the control limits on the average chart
b) On the range charts, all values should be within the control limits
Note: in the special case where the manufacturing process is very capable, stable and in control (e.g. Ppk > 2.5),
percent tolerance is used, the number of distinct categories is not applicable, and the values on the range chart
are not always within the control limits.
For any special situations, please contact your STA site engineer.
Acceptability criteria for Gauge R&R
Gauge R&R as a percent of study variation < 10% is acceptable (the parts used for the Gauge R&R study must
be representative of a production run with all known sources of variation). If Gauge R&R as a percent of study
variation is greater than or equal to 10%, but less than or equal to 30%, contact the STA site engineer to
determine if the Gauge R&R is acceptable. If Gauge R&R as a percent of study variation > 30%, it is
unacceptable and the organization shall implement a containment actions and a corrective action plan to
improve measurement capability until the Gauge R&R requirements are met.
Number of Operators, parts and trials for Gauge R&R studies:
As stated in Ford's ISO/TS 16949 Customer Specific Requirements
Variable gauge studies should utilize, at a minimum 10 parts, 3 operators and 3 trials.
Attribute gauge studies should utilize, at a minimum, 50 parts, 3 operators, 3 trials.
In general, the gauge R&R should use the full range of part to part variation from the process – representing all
expected sources of manufacturing variation, while providing enough resolution around the upper and lower
specification limits.
Where attribute gauging is used, the following section applies:
Criteria for Attribute Gauge R&R Study (Measurable Characteristic)
• Gauge must reject all parts that are outside the specification limits
• Rejecting good parts may be acceptable if any throughput or efficiency losses are acceptable to the team.
• All Kappa values should be greater than 0.75. Please note that if the gauge limits are less than the
specification limits (Guard Banding) it may be acceptable for the Kappa values to be less than 0.75 if the
reduced Kappa values are due to operators rejecting good parts. If the gauge limits are the same as the
specification limits then all Kappa values (between appraiser, within appraiser, appraiser to standard)
should be greater than 0.75.
• Training on Gauge R&R is available through https://web.lean.ford.com/cqdc/doc/Course_Mats/Book_7.pdf
Parts for Attribute Gauge R&R Study
• 25% of the parts should be near the lower specification limit (on both sides of the specification).
• 25% of the parts should be near the upper specification limit (on both sides of the specification).
• 30% of the parts should represent the expected process variation.
• 10% of the parts should be outside the upper gauge specification limit and beyond the 25% of
the parts near the specification as described above.
Range or Range methods do not. Refer to the AIAG published SPC manual, and the ANOVA method is
available through commercial statistical software packages and the AIAG APQP forms disk.
The organization shall report the number of distinct categories. All variable gauge R&R studies should have a
minimum of 5 distinct categories (See Measurement Systems Analysis Reference Manual published by AIAG,
refer to "ndc" in the index). The organization shall report gauge R&R as both a percent of study variation and a
percent of tolerance.
Guidance on selection of the appropriate (rational) samples (including sample sizes) for Gauge R&R is
available through https://web.lean.ford.com/cqdc/doc/Course_Mats/Book_7.pdf (search for “rational”).
Guidance for acceptable Gauge R&R analysis
For additional guidance, see the Measurement Systems Analysis and Statistical Process Control manuals from
AIAG:
a) At least one half of the averages should be outside the control limits on the average chart
b) On the range charts, all values should be within the control limits
Note: in the special case where the manufacturing process is very capable, stable and in control (e.g. Ppk > 2.5),
percent tolerance is used, the number of distinct categories is not applicable, and the values on the range chart
are not always within the control limits.
For any special situations, please contact your STA site engineer.
Acceptability criteria for Gauge R&R
Gauge R&R as a percent of study variation < 10% is acceptable (the parts used for the Gauge R&R study must
be representative of a production run with all known sources of variation). If Gauge R&R as a percent of study
variation is greater than or equal to 10%, but less than or equal to 30%, contact the STA site engineer to
determine if the Gauge R&R is acceptable. If Gauge R&R as a percent of study variation > 30%, it is
unacceptable and the organization shall implement a containment actions and a corrective action plan to
improve measurement capability until the Gauge R&R requirements are met.
Number of Operators, parts and trials for Gauge R&R studies:
As stated in Ford's ISO/TS 16949 Customer Specific Requirements
Variable gauge studies should utilize, at a minimum 10 parts, 3 operators and 3 trials.
Attribute gauge studies should utilize, at a minimum, 50 parts, 3 operators, 3 trials.
In general, the gauge R&R should use the full range of part to part variation from the process – representing all
expected sources of manufacturing variation, while providing enough resolution around the upper and lower
specification limits.
Where attribute gauging is used, the following section applies:
Criteria for Attribute Gauge R&R Study (Measurable Characteristic)
• Gauge must reject all parts that are outside the specification limits
• Rejecting good parts may be acceptable if any throughput or efficiency losses are acceptable to the team.
• All Kappa values should be greater than 0.75. Please note that if the gauge limits are less than the
specification limits (Guard Banding) it may be acceptable for the Kappa values to be less than 0.75 if the
reduced Kappa values are due to operators rejecting good parts. If the gauge limits are the same as the
specification limits then all Kappa values (between appraiser, within appraiser, appraiser to standard)
should be greater than 0.75.
• Training on Gauge R&R is available through https://web.lean.ford.com/cqdc/doc/Course_Mats/Book_7.pdf
Parts for Attribute Gauge R&R Study
• 25% of the parts should be near the lower specification limit (on both sides of the specification).
• 25% of the parts should be near the upper specification limit (on both sides of the specification).
• 30% of the parts should represent the expected process variation.
• 10% of the parts should be outside the upper gauge specification limit and beyond the 25% of
the parts near the specification as described above.
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Range or Range methods do not. Refer to the AIAG published SPC manual, and the ANOVA method is
available through commercial statistical software packages and the AIAG APQP forms disk.
The organization shall report the number of distinct categories. All variable gauge R&R studies should have a
minimum of 5 distinct categories (See Measurement Systems Analysis Reference Manual published by AIAG,
refer to "ndc" in the index). The organization shall report gauge R&R as both a percent of study variation and a
percent of tolerance.
Guidance on selection of the appropriate (rational) samples (including sample sizes) for Gauge R&R is
available through https://web.lean.ford.com/cqdc/doc/Course_Mats/Book_7.pdf (search for “rational”).
Guidance for acceptable Gauge R&R analysis
For additional guidance, see the Measurement Systems Analysis and Statistical Process Control manuals from
AIAG:
a) At least one half of the averages should be outside the control limits on the average chart
b) On the range charts, all values should be within the control limits
Note: in the special case where the manufacturing process is very capable, stable and in control (e.g. Ppk > 2.5),
percent tolerance is used, the number of distinct categories is not applicable, and the values on the range chart
are not always within the control limits.
For any special situations, please contact your STA site engineer.
Acceptability criteria for Gauge R&R
Gauge R&R as a percent of study variation < 10% is acceptable (the parts used for the Gauge R&R study must
be representative of a production run with all known sources of variation). If Gauge R&R as a percent of study
variation is greater than or equal to 10%, but less than or equal to 30%, contact the STA site engineer to
determine if the Gauge R&R is acceptable. If Gauge R&R as a percent of study variation > 30%, it is
unacceptable and the organization shall implement a containment actions and a corrective action plan to
improve measurement capability until the Gauge R&R requirements are met.
Number of Operators, parts and trials for Gauge R&R studies:
As stated in Ford's ISO/TS 16949 Customer Specific Requirements
Variable gauge studies should utilize, at a minimum 10 parts, 3 operators and 3 trials.
Attribute gauge studies should utilize, at a minimum, 50 parts, 3 operators, 3 trials.
In general, the gauge R&R should use the full range of part to part variation from the process – representing all
expected sources of manufacturing variation, while providing enough resolution around the upper and lower
specification limits.
Where attribute gauging is used, the following section applies:
Criteria for Attribute Gauge R&R Study (Measurable Characteristic)
• Gauge must reject all parts that are outside the specification limits
• Rejecting good parts may be acceptable if any throughput or efficiency losses are acceptable to the team.
• All Kappa values should be greater than 0.75. Please note that if the gauge limits are less than the
specification limits (Guard Banding) it may be acceptable for the Kappa values to be less than 0.75 if the
reduced Kappa values are due to operators rejecting good parts. If the gauge limits are the same as the
specification limits then all Kappa values (between appraiser, within appraiser, appraiser to standard)
should be greater than 0.75.
• Training on Gauge R&R is available through https://web.lean.ford.com/cqdc/doc/Course_Mats/Book_7.pdf
Parts for Attribute Gauge R&R Study
• 25% of the parts should be near the lower specification limit (on both sides of the specification).
• 25% of the parts should be near the upper specification limit (on both sides of the specification).
• 30% of the parts should represent the expected process variation.
• 10% of the parts should be outside the upper gauge specification limit and beyond the 25% of
the parts near the specification as described above.
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