GR&R on Automated Inspection Cell

John Predmore

Trusted Information Resource
#11
The classical GR&R studies the variability of the measuring device separate from the variability from the human operator. With an automated test station, the influence of the human operator (the textbook definition of “reproducibility”) is meaningless if the operator does nothing but press the cycle start button.

However, the GR&R approach can still provide valuable information, for example, what portion of variability is due to the instrument (electronics may have drift or non-linearities, even with no moving parts) versus the part loading cycle (which often involves mechanical motion, and a single part is not positioned in precisely the same position with repeated loading). You can call the part loading cycle “reproducibility” even though untouched by human hands. Many times, the automatic test station in setup mode can retest the part 3 times without unclamping the part. Running repeat measurements without unclamping does not randomize the measurement order, so if there are bias effects over time such as changes in ambient temperature, your analysis might conclude spurious effects. Repeating the automatic test in a different order would be one way to detect confounding of bias-over-time.

If you wanted to study whether the automated station gives the same result on 3 separate days (or 3 different hours, if you suspect ambient temperature is a factor) you could run the same set of parts in pre-determined random order at different times, and call that “reproducibility”. What you hypothesize is each part will test the same way. If not, the difference will be highlighted once you examine the results graphically.
 
Elsmar Forum Sponsor
#12
GR&R on changed Tool

I have to re-PPAP a tool that had been dimensionally changed. Would I have to do Gage R&R on the new sample pieces made from the new tool?
 

Ninja

Looking for Reality
Staff member
Super Moderator
#13
Re: GR&R on changed Tool

Sorry to answer a question with a question...but...

GRR is to test your test system, not your tool.
Does the GRR you already did reasonably cover parts from the new tool size?

If your parts used to be 11mm +/- 1, and now its 11.2 +/- 1...I likely wouldn't re-GRR.
If your parts used to be 11mm, and now they are 25mm...I likely would.

Next question: Did your customer give guidance? If not, I would comment in the re-PPAP why the old GRR is still valid.
 
#14
parts went from 32-32.3 up to 32.5-32.8
we recently got a new vision system that was not included in our first PPAP. I was going to include it into this one. I'm still kinda new to this so I wasn't sure if I had to go back and re-do the old stuff as well.
 

Ninja

Looking for Reality
Staff member
Super Moderator
#15
You gave two different answers...fair enough...I asked two questions ;)

parts went from 32-32.3 up to 32.5-32.8
If it were only this, I would review the initial GRR and the vision measurement system capability (likely calibrated up to 150mm or more) and call it a day...old GRR still valid...off you go.

we recently got a new vision system that was not included in our first PPAP.
But now you've put in a new piece of equipment.
Do your GRR over...no question in my mind.
It will give you data to support (prove in) your new equipment, and handle your PPAP requirements as well.
If it is the same brand and model, I would likely do a 2x3x5 GRR...more of a validation than a full out "are we ok?" test.
If it is a different style, brand or model, I would do a 3x3x10...

But at the end of the day, what your customer requires will rule the day.

HTH
 

optomist1

A Sea of Statistics
Trusted Information Resource
#16
Amen, when and doubt and available, continuous data is best. One can do much more with continuous data v. attribute. Generally continuous data provides a degree of "early warning"....proactive v. reactive
 
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