GRR Basic Training

GRR,Cp,Cpk Basic Training
Le Tran Trieu Tuan

MTE Engineering
01.Oct.2015
Mean
• Mean
Also known as the arithmetic mean , the mean is typically what is meant by the word average. The mean
of variable is given by ( the sum of all values )/(number of values ). Despite its popularity, the mean may
not be an appropriate measure of central tendency . This is generally in case of populations, having
outliers or extreme values .
Example : Calculate the standard deviation and variance for the given data ; 1,2,3,4,5
m = (1+2+3+4+5)/5 = 3
Variant
• Variant
Variation occurs in everything. No two things are exactly the same.
Variation is the sum total of all minute changes that occur every time a process is performed . Variation is
always present at some level.
Variance is a measure of how spread out a distribution is. The formula for the variance in population is :
s2 = ∑(X-m)2 / n-1 [If sample size > 30, in that case n-1 is replace by n]
Where m is the mean and n is the number of scores or population size
X X-m (X-m)2
Example : Calculate the variance for the given data ; 1,2,3,4,5
1 (1-3) = -2 4
2 (2-3) = -1 1
Solution : m= ( 1+2+3+4+5 )/5 = 15/5 = 3
3 (3-3) = 0 0
s2 = ∑(X-m)2/n-1= 10/(5-1) = 2.5 4 (4-3) = 1 1
5 (5-3) = 2 4
TOTAL(SUM) s2 10
Standard Deviation
• Standard Deviation
Standard Deviation also indicates the spread in the population. It is the square root of variance. Standard
Deviation is denoted by “s”
Example : Calculate the standard deviation for the given data ; 1,2,3,4,5
Solution : m= ( 1+2+3+4+5 )/5 = 15/5 = 3
s2 = ∑(X-m)2/n-1= 10/(5-1) = 2.5
Standard Deviation = sqrt(2.5)=1.581

What is 6 Sigma
The goal of Six Sigma is to increase profits

by eliminating variability , defects Inflection Point :
and waste that undermine customer In this the distance of first inflection
point to mean is 1σ.
loyalty . It is a disciplined data driven
We in this case say that process
approach and methodology for Has 3 sigma capability as 3 std
deviations are fitted between
eliminating defects
Target & specification limit
1σ.
Six Sigma can be understood / perceived 1σ.

2σ.
at three levels : 2σ.
3σ 3σ.
(σ = Standard Deviation) . USL

LSL
X
Dissecting Process Capability (Cp)
Inadequate
Measurement Supplied Cp = (USL-LSL)/6 σ
Capability Material
Variation
Inadequate Inadequate
Process Design Margin
Capability LSL USL
Non-conformances
Process Capability
Process Capability (Cpk)
Cpk = min(CpkU, CpkL)

Process Capability Indices
Cp ( Process Capability) : Cpk (Process Capability Index) :

The capability index is defined as: Cp = (allowable Even though process capability show how well a
range)/6s = (USL - LSL)/6s process is able to meet its specification. But it does so
The capability index show how well a process is able to in terms of spread only. It does not covers the shift of
meet specifications. The higher the value of the index, the process. So as to account for shift, process
the more capable is the process: capability index is used.
Cp < 1 (process is unsatisfactory)

For a process to be a Six Sigma process Cpk =
1 < Cp < 1.6 ( process is of medium relative capability)
1.5
Cp > 1.6 (process shows high relative capability)
For a process to be a Six Sigma process
Cp = 2 In this case it is evident that the spread of the process is very less, but it is shifting from the
mean. This process will have a good Cp value but poor Cpk value.
Reference (Six Sigma Measures and Formulas)
Reference (Six Sigma Measures and Formulas)
GRR
Every manufacturing company that gets audited, anywhere in the world, is required to do gauge repeatability
and reproducibility (R&R) studies. In some cases, this one study is the only chance to find unknown problems with
measurement quality. (When problems do occur, it is often downstream from calibration)
Hint: Gage R&R doesn't evaluate your product,
it evaluates your ability to measure your product accurately and consistently.
Gage R&R Study Basics
Gage repeatability and reproducibility calculates the total variation (TV) from: 1.
appraisers (AV), 2. equipment (EV, i.e., gages) and 3. part variation (PV). It then uses total
variation to determine how much variation is attributable to appraisers and equipment
(%R&R).
If your parts are identical, there is NO Part Variation and all of the variation falls to the
appraisers and equipment.
GRR Report Study (i.e1)
As you can see in report item 6,7,31,39 %GRR_to > 30%
From here can see:

Item 6: Reproducibility not good (Operator issue/In our
factory we can understand operator as Tester).
Then we can see Tester 1 not good  Need corrective
Action as calibration/check cable/test equipment
As you can see in report item 6,7,31,39 %GRR_To > 30%
From here can see:

Item 193: Repeatability not good (Test measure
equipment issue).
Then we can see Tester 1 not good  Need corrective
Action as calibration/check cable/test equipment
This case item 24,26,30 not good %GRR_To>30% and Repeatability issue  Check detail
data we can see 2 part with same 2 Tester have abnormal(ko binh thuong) data  Suspect during
GRR have some issue happen --> we can get Condition Accept after verify tester.
We can do loop test with 1 phone to verify tester before Accept this tester.
Tester Acceptance Condition
Some case can accept need

verify tester before accept
Some case can accept need

verify tester before accept
OK

GRR Basic Training

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GRR Basic Training

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GRR,Cp,Cpk Basic Training

Le Tran Trieu Tuan

Solution : m= ( 1+2+3+4+5 )/5 = 15/5 = 3

s2 = ∑(X-m)2/n-1= 10/(5-1) = 2.5

Standard Deviation = sqrt(2.5)=1.581

The goal of Six Sigma is to increase profits

Six Sigma can be understood / perceived 1σ.

(σ = Standard Deviation) . USL

Cpk = min(CpkU, CpkL)

Cp ( Process Capability) : Cpk (Process Capability Index) :

the more capable is the process: capability index is used.

Cp < 1 (process is unsatisfactory)

For a process to be a Six Sigma process

Gage R&R Study Basics

As you can see in report item 6,7,31,39 %GRR_to > 30%

From here can see:

As you can see in report item 6,7,31,39 %GRR_To > 30%

From here can see:

Some case can accept need

Some case can accept need

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