Paper #99

Analyzing Manufacturing System’s Precision, Variation, Stability Through Measurement System Analysis, Gage R&R, and Statistical Process Control

Fahad Sajid, Sawkat Sifat, Ifaz Ahmed, Niamat Ullah Ibne Hossain, Raed Jaradat and Fazla Rabbi

Presenting author: Ifaz Ahmed

Session: O03

Abstract

High manufacturing precision requires reliable measurement systems that provide accurate, repeatable, and reproducible results within specified tolerances. In this study, a detailed Measurement System Analysis (MSA) was performed using Minitab based on experimental data collected from three operators. Gage Repeatability and Reproducibility (Gage R&R) was evaluated using the ANOVA method. Results showed that part-to-part variation accounted for 99.65% of the total variation, while overall Gage R&R was below 1%, indicating that the measurement system can effectively distinguish differences between parts. The number of distinct categories exceeded 10, satisfying industry standards. Gage Linearity and Bias regression analyses showed no significant operator or equipment bias. Exponentially Weighted Moving Average (EWMA) charts were applied for advanced process monitoring and indicated no evidence of process drift or instability. Capability Sixpack analysis demonstrated Cp and Cpk values above 0.90, confirming acceptable process capability and normal data distribution within tolerance limits.