Measurement Systems Analysis: What is it and why should I care? Dec. 11, 2012 Barry Kulback Global Lean Six Sigma Leader Trane and Thermo King, brands of Ingersoll Rand

Feel free to ask questions at any time! Agenda About Ingersoll Rand Measurement systems and Measurement System Error What is Measurement System Analysis Types of Measurement Systems Analysis and examples Lessons Learned Feel free to ask questions at any time!

About Ingersoll Rand A $14 billion diversified industrial company Publicly-held; NYSE:IR Operations in every major geographic region Strategic brands are #1 or #2 in their markets Products and services for commercial, industrial and residential markets

What do you think about my measurement system? What’s wrong with a beer can measurement system? -- cans can be dented -- cans can be out of alignment -- can be gaps between cans -- are these 12 oz or 16 oz tall boys? -- measuring to nearest can – insufficient discrimination Many of the measurement ssytems we use day in and day out have similar issues – but we just don’t know it.

We do a lot of measuring in our businesses and in any process improvement methodology… Running the business Monitor process performance Improving the business Baseline Set the levels of the adjustments Getting better or worse Validate improvement results … and many of the measurement systems we use for this have similar problems as the one shown! To assess or monitor process performance To establish a baseline To set the levels of the adjustments we are making to the process To see if we are getting better or worse To validate improvement results

When not measuring well… Current process performance may be misjudged Process improvement results may be misinterpreted Missed opportunities Wasted effort, $

5 years of college in physics & chemistry labs…. Not once was it ever discussed… how does your ability to measure influence the results you think you are seeing?

My ‘aha’ moment came in my Six Sigma Black Belt Training DMAIC process improvement methodology Define Measure Analyze Improve Control Measurement System Analysis Collect data Six Sigma practitioners are known as Green Belt, Black Belts and Master Black Belts

Premise for Six Sigma Methods Sources of variation can be Identified Quantified Eliminated by control or prevention Y = f(x) WAYNE SAYS KEEP THIS ONE Explain Y=f(x) My weight KPOV, I can measure it, track it over time, it varies from day to day, week to week, month to month Is a function of several KPIVs How much I eat How much I exercise The types of food I eat Data driven decisions with a known level of confidence… … we do a lot of measuring in Six Sigma

What is an MSA? When measuring there is always Measurement System Error An MSA is a procedure to assess a Measurement System Quantifies the Measurement System Error Acceptable? Yes or no If ‘no’  improve the measurement system MSA output can tell you where to look When measuring things, we would know that there is always a certain amount of Measurement System Error An MSA is a procedure to assess a Measurement System Conducting an MSA will quantify the amount of Measurement System Error, so an assessment can be made as to if it is acceptable or not If not acceptable, steps should be taken to improve the measurement system MSA output can help identify how to improve a poor performaing measurement system

Conducting an MSA For 2 of the 3 types of MSA’s we’ll cover today Guidelines Trained Operator(s) Proper Method Representative Samples Generally two to three operators Each unit is measured or assessed 2-3 times by each operator Results are then analyzed Often with statistical software like Minitab Analytical and graphical outputs explain the results

Types of Data Continuous Data (Quantitative) Decimal subdivisions are meaningful Time (seconds) Pressure (psi) Conveyor Speed (ft/min) Rate (inches) Temperature (degrees) Attribute Data (Qualitative) Categories Good / Bad Inventory Classification Code A, B or C Shift number Counted things (# receipt errors, # units shipped, etc.)

Types of Measurement Systems Analysis Continuous Data Gage R&R Attribute Data Attribute Agreement Analysis Data Scrub MSA

… but first just a wee bit of ‘technical’

so… = =

Types of Measurement Systems Analysis Continuous Data Gage R&R Attribute Data Attribute Agreement Analysis Data Scrub MSA

How does measurement system error appear? LSL USL Actual process variation - No measurement error LSL USL Observed process variation - With measurement error

Why do we care? Can’t really understand the true variation present! And if it isn’t understood, it can’t be fixed. LSL USL x x x x A ‘bad’ part can measure good A ‘good’ part can measure bad Observed process variation - With measurement error

Possible Sources of Process Variation Observed Process Variation Actual Process Variation Long Term Short Term Within Sample Measurement Variation Due to instrument Repeatability Calibration Stability Linearity Due to operators

Possible Sources of Process Variation Observed Process Variation Actual Process Variation Long Term Short Term Within Sample Measurement Variation Due to instrument Repeatability Calibration Stability Linearity Due to operators

Possible Sources of Process Variation Observed Process Variation Actual Process Variation Long Term Short Term Within Sample Measurement Variation Due to instrument Repeatability Calibration Stability Linearity Due to operators

Possible Sources of Process Variation Observed Process Variation Actual Process Variation Long Term Short Term Within Sample Measurement Variation Due to instrument Repeatability Calibration Stability Linearity Due to operators ‘Repeatability’ and ‘Reproducibility’ are the two main contributors to Measurement System Error – hence ‘Gage R&R’

-- That depends on what you are using the measurement system for! If Measurement System Error always exists, when should we be concerned with it? -- When it it too large. Too large compared to what? -- That depends on what you are using the measurement system for!

Gage R&R – case study Process: Compressor Machining Project: Six Sigma Black Belt Project Scrap Reduction $375,000 in scrap / year Capacity bound  lost margins on lost sales Considering $1M CAPX to increase capacity

Measurement system improved  project complete! Inspection; CMM – measures to .000001 inch machined casting assembly into compressor LSL USL Actual Observed Define Measure Analyze Improve Control Measurement system improved  project complete! Works in a special environmentally controlled room. Similar to this one saw used for $145,000.

Types of Measurement Systems Analysis Continuous Data Gage R&R Attribute Data Attribute Agreement Analysis Data Scrub MSA

Attribute Measurement Systems Assessing attribute data often involved judgment … sometimes a little “it’s broke / it isn’t” or “it fits / it doesn’t” … sometimes a lot “ it dented too bad, scrap it”

Attribute Measurement Systems It all starts with an Operational Definition: The ‘spec’ Describes what the defects or categories are Describes how to perform the appraisal assessment Used to train those performing the assessment Should be applied with a high degree of consistency

Attribute Agreement Analysis – case study Process: 2” Copper Tube Bending Project: Six Sigma Green Belt Project Scrap Reduction

Spec = “No Wrinkles” What’s a wrinkle? How bad is bad?

How good are our Operators at assessing if a tube is wrinkled and should not be used? Not wrinkled, use it. Slight wrinkle, use it? That’s not a wrinkle, it’s a tool mark! Use it? Not a wrinkle, a stretch mark! Use it? Wrinkled, scrap it.

An Attribute MSA was conducted: 30 Samples 4 Operators 1 ‘Expert’ 2 Trials

want 90% level of agreement or higher Ted Michael Jim Danny Albner 100 90 80 70 Appraiser P e r c n t Within Appraiser Assessment Agreement Date of study: Reported by: Name of product: Misc: [ , ] 95.0% CI Percent ‘Expert’! want 90% level of agreement or higher

Spec = “No Wrinkles” – OK! Would use Would not use ?

Visual Aid Added Prep for future new employees...

Types of Measurement Systems Analysis Continuous Data Gage R&R Attribute Data Attribute Agreement Analysis Data Scrub MSA

Sometimes we get our data out of the ‘system’ … is it right?

Data Scrub MSA – case study Process: Cooling the office Project: Six Sigma Green Belt Project Reduce Energy Consumption Ed’s project As part of the Office HVAC Control System project an MSA was required. The MSA would consist of verification of system operation. Report logs were generated by the Tracer Summit system stating whether the systems were "on" or "off". Actual system operation would be observed during periods when the Tracer Summit system would cycle the systems "off" to verify that they were actually "off".   The first time the MSA was done, the observed readings did not match the Report Logs that were generated by the system. Units were running even though the computer had them scheduled to be off. It was found that the there was a mechanical problem and the units were switched to a manual mode to perform service work. The units were left in the manual mode after repairs were made which allowed continuous operation. Until the units were switched to automatic mode, the computer could not control the system operation. The MSA allowed verification of computer generated data.

Lessons Learned…

An expensive gage does not always mean good measurements

Remember this? Inspection; CMM – measures to .000001 inch $145,000 used Must operate in a environmentally controlled room Strict procedures on part handling, cleanliness, controlling local conditions, controlling part temperature…

A measurement system is more than a gage or a operational definition (specification)

A continuous variable measurement system is composed of: the gage / measuring device operator techniques set-up and handling techniques the environment in which the measurements are being done (ex. lighting, access) recording of measurement results

The Attribute Measurement System Operational Definition Training of Operators Problems in any of these areas can lead to too high a degree of inconsistent / incorrect assessments Application

Just because a measurement system has been in use ‘forever’ doesn’t mean it is very good

Attribute MSA – case study Process: Invoicing – Application of appropriate tax Project: Six Sigma Black Belt Project Improve DSR

Tax Codes are applied to invoices being sent out to Customers: Sales Tax -- a percentage added to invoice, customer pays Use Tax -- a percentage of the cost of the goods, company pays Non-Tax -- government, hospital, etc., where neither customer or company pays What tax should be applied?

(been doing it for years…) How good are the Accountants at applying the correct tax code? (been doing it for years…)

An Attribute MSA was conducted: 10 Samples (more would be better) 3 Operators -- who do the job every day 1 ‘Expert’ 2 Trials

Just because a it came out of the computer doesn’t mean it is accurate

Data Scrub MSA’s – case studies Focused Management Team monthly published results Ed’s project As part of the Office HVAC Control System project an MSA was required. The MSA would consist of verification of system operation. Report logs were generated by the Tracer Summit system stating whether the systems were "on" or "off". Actual system operation would be observed during periods when the Tracer Summit system would cycle the systems "off" to verify that they were actually "off".   The first time the MSA was done, the observed readings did not match the Report Logs that were generated by the system. Units were running even though the computer had them scheduled to be off. It was found that the there was a mechanical problem and the units were switched to a manual mode to perform service work. The units were left in the manual mode after repairs were made which allowed continuous operation. Until the units were switched to automatic mode, the computer could not control the system operation. The MSA allowed verification of computer generated data.

Recap About Ingersoll Rand Measurement systems and Measurement System Error What is Measurement System Analysis Types of Measurement Systems Analysis and examples Lessons Learned

You cannot assume you are measuring well Final lesson: You cannot assume you are measuring well

Measurement error is always present You don’t know if it is small enough to ignore unless you assess it!

Addendum

The P/T ratio quantifies this... A ratio of MSE to the tolerance range If using the measurement system to see if the item being measured is within the spec, you want the Measurement System Error (MSE) to be small compared to that spec: specification range, or tolerance sample observed measurements This.. should be small when compared to this... The P/T ratio quantifies this... A ratio of MSE to the tolerance range LSL USL x MSE

The %R&R quantifies this... A ratio of MSE to process variation If using the measurement system to analyze the variation present or control the process with Statistical Process Control, you want MSE to be small compared to that variation: sample observed measurements LSL USL This.. should be small when compared to this... The %R&R quantifies this... A ratio of MSE to process variation x MSE

Measurement System Analysis: What is it and why should I care? Dec. 11, 2012 Professional Development Meeting TOPIC AREA: MEASUREMENT SYSTEMS Measurement System Analysis: What is it and why should I care? SPEAKER – Barry Kulback, Master Black Belt, Six Sigma For our December Professional Development Meeting we are pleased to have Barry Kulback, Master Black Belt. Measurement System Analysis (MSA) is an often overlooked critical step in any process improvement process and is the linchpin of Six Sigma’s Measure phase in the DMAIC (Define, Measure, Analyze, Improve, and Control) methodology. This non-technical presentation will review what MSA’s are and why they are important. The major components of measurement error will be discussed along with how measurement error may color your perception of process performance. Examples of the three most common types of MSA’s will be shared along with some lessons learned. Come find out why you should assess your measurement systems the next time you embark on a process improvement journey.

Sound interesting? Come join us! We look forward to seeing you! Reserve your place today by clicking here or by emailing programs@apicsnashville.org. DATE: December 11, 2012   PLACE: Holiday Inn Select Opryland Airport/Briley Parkway 2200 Elm Hill Pike Nashville, TN 37214 (615) 883-9770 Click http://www.hinashville.com/directions.html for directions TIME: 5:30 to 8:00 PM COST: $20.00 for Dinner - Free if an unemployed member - bring your resume You do not need to be an APICS member to attend Remember! Attend Four (4) APICS Nashville Professional Development Meetings from September 2012 thru April 2013 (excluding Tours) and attend the 5th PDM free! New members to our chapter attend their first meeting at no charge when they bring their APICS welcome letter! Stay Informed! Click to Join our LinkedIn group APICS Middle Tennessee Chapter Nashville

Speaker Bio: Barry Kulback’s 33 year professional career has been entirely with Trane/American Standard now Ingersoll Rand. He is currently the Global Lean Six Sigma leader for the Climate Solutions Sector of Ingersoll Rand and very engaged in IR’s Lean Transformation. He gained his BS in 1979 at Austin Peay State University majoring in Physics and minoring in Computer Science. After spending 20 years in Information Technology Barry joined Operations as a Six Sigma Black Belt and progressed to a certified Six Sigma Master Black Belt in 2004. He was named Tennessee Academy of Science’s Industrial Scientist of the year in 2006 and is the holder of 4 patents related to algorithms for delivering to customer request by optimizing the match of demand to supply. He maintains his membership in the American Society for Quality as a Senior Member.   Reserve your place today by clicking here or by emailing programs@apicsnashville.org. Stay Informed! Click to Join our LinkedIn group APICS Middle Tennessee Chapter Nashville Thank you for your support of APICS.

Bring 1 copper tube 1 measuring tape PC Remote mouse Backup – on data stick, on disk Pad, pen to take notes re parking lot 45-50 minutes, leaving 10-15 minutes at the end for question/answer

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