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FORCE MOTORS LIMITED DOC NO : GL /III/01

PUNE REVISION NO.: 00


ISSUE NO / DT: 00/05.12.2017
GUIDE LINES Pg 1 of 16

TITLE: PROCEDURE FOR MEASUREMENT SYSSTEM ANALYSIS.

PURPOSE: This procedure is established to follow MSA system across


the organization.

SCOPE: It is applicable to all MSA parameters as identified in Control Plan,


Inspection plan where decision may be involved.

RESPONSIBILITY: Responsibility of implementation of this procedure lies


with each HOD. Operational responsibility lies with SIC.

PROCEDURE: The procedure will be applicable for all measurement


system used for measuring the special characterstics mentioned in the
control plan.

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FORCE MOTORS LIMITED DOC NO : GL /III/01
PUNE REVISION NO.: 00
ISSUE NO / DT: 00/05.12.2017
QUALITY MANUAL Pg 2 of 16
MEASUREMENT SYSTEM ANALYSIS – FLOW CHART

Identify product special characterstics & the Ref doc;


gauges for MSA study as per control plan. Control plan

Resp: SIC

Identify the type of MSA study to be carried Ref doc :


out, MSA matrix
Resp: SIC enclosed, pg 3

Prepare annual plan for MSA considering the Ref doc :


frequency. MSA plan
Resp: SIC / HOD GP/00/57

Conduct MSA study Ref doc: GL/III/01


,pg 04 to 09
Resp: SIC

Feed the data


If results are in Pro MSA If results are not
conditionally software. acceptable.
accepted, based
upon importance of
application
Take necessary action to
measurement,cost
improve the measurement
of measurement
system as indicated
device,cost of
rework or repair,etc. If MSA results are
MSA results Should Acceptable
be approved by
customer for use.

Update the status in the


plan & maintain record.

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REV ISSUED BY REV DATE: 05.12.2017


DOC No : GL/III/01
FORCE MOTORS.LIMITED REV No: 00
PUNE. Measurement system applicable Matrix ISSUE NO DATE:00/05.12.2017
Pg 3 of 16

Frequency : Once in a Year and after any repair in measurement instrument.


Variable G.R&R Attribute
Sn GAUGE TYPE Range Crossed Nested Cross tab OTHERS
Bias Linearity stability
Average Anova Annova (Kappa)
1 Vernier caliper √ √
2 Vernier depth gauge. √ √
3 Vernier height gauge √ √
4 Inside groove caliper √ √
5 Pistol caliper √ √
6 Micrometer √
7 Flat plug gauge. √
8 Plug gauge √
9 Spline plug gauge √
10 Thred plug gauge. √
11 Taper plug gauge √
12 Wire thred plug gauge √
13 Dial gauge √
14 Cyl bore gauge √
15 Air gauge unit √
16 Limit ring gauge √
17 Passometer √
18 Snap gauge √
19 Special Gauges
a) Variable √
b) Attribute √
20 Spline ring gauge √
21 Taper ring gauge. √
22 Taper thread ring √
23 Thread ring gauge. √
24 Width gauge √
25 CMM √ √ √
26 Trimos √ √
Engine/Gear
27 Box/Axle /vehicle test √
stand(rig)
28 Leakage test stand. √
29 DFT meter √
30 Visual Inspection √
31 Hardness Tester. √
32 Noise Testing √
NOTE
While preparing MSA plan prepare family for measurement analysis Eg: If there are many instruments with same type (all dial type
or all digital)same make ,same range ,same least count and used for measuring same parameters then they come under same
1
family. It is possible to conduct MSA study on sample basis.After 6 Months other instrument can be selected.

2 In case of change in appraiser apply range method as per MSA/GL/III/01, pg07.

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FORCE
MOTORS.LIMITED DOC No : GL/III/01 REV
PUNE. GUIDE LINES FOR GAUGE BIAS STUDY NO ; 00
Issue NO/ date; 00/05.12.2017
Page 4 of 16

1 Select a sample piece for the study.

Measure this piece by a method superior to the measurement system under study [instrument of
2 smaller LC, expert inspector, controlled conditions etc]. Take ten readings and calculate the
average. This is called the reference value
Measure the same piece fifteen times by the same appraiser using the measurement system
3 understudy. Take the average of these readings. This is called the observed value.

Enter the readings in the software program. The program indicates whether the study is
4
acceptable or not.
5 Bias values should be close to zero, ZERO should lie in confidence interval of bias.

6
If the study is not acceptable then investigate for the possible causes as follows:
a) Instrument needs calibration
b) Worn out instrument, equipment or fixture.
c) Worn or damaged master, error in master
d) Improper calibration or use of setting master
e) Poor quality instrument – design or conformance
d) Linearity error
f) Wrong gauge for application
g) Different measurement method – setup, locating, clamping, technique.

h) Distortion of gauge or part.

i) Environment – temperature, humidity, vibration, cleanliness.

j) Violation of an assumption, error in an applied constant

k) Application - part size, position, operator skill, fatigue, observation error [readability, parallax.]

7 Once the source of error is identified and eliminated repeat the study as above.

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FORCE DOC No : GL/III/01
MOTORS.LIMITED REV NO ; 00
PUNE. GUIDE LINES FOR GAUGE LINEARITY
STUDY Issue NO/ date;
00/05.12.2017
Page 5 of 16

Linearity study is to be conducted for measuring systems in which a


1 particular instrument is used for measuring different dimensions over its
range.
Select 5 parts that can be measured at different operating ranges of
2 measurement system. For eg select 5 parts of 5 different sizes measured by
the same 0 – 150 mm vernier. This sample should cover the extreme sizes
being measured by the instrument.
Determine value for each part using a method superior to the measurement
system under study [instrument of smaller LC, expert inspector, controlled
3 conditions etc]. These are called the reference values

Take 12 repeated measurements on each part randomly by the same


4
appraiser using the measurement system understudy.

5 Enter the readings in the software provided.

6 For linerity to be acceptablethe bias=0 line must lie entirely within the
confidence bands of the fitted line
a) Instrument needs calibration – increase the calibration frequency.
b) Worn out instrument, equipment or fixture
c) Poor maintenance – air, power, hydraulic, filters, corrosion, rust cleanliness.
d) Worn or damaged master, error in master – minimum/maximum
e) Improper calibration [not covering operating range] or use of setting
d) Poor quality instrument – design or conformance
f) Instrument design or method lacks robustness.
g) Wrong gauge for application
h) Different measurement method – setup, locating, clamping, technique.
i) Distortion of gauge or part [changes with part size].
j) Violation of an
Environment assumption, error
– temperature, in an vibration,
humidity, applied constant
cleanliness.
Application - part size, position, operator skill, fatigue, observation error
k) [readability, parallax.]

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FORCE DOC No : GL/III/01
MOTORS.LIMITED REV NO ; 00
PUNE. GUIDE LINES FOR GAUGE STABILITY
STUDY Issue NO/ date;
00/05.12.2017
Page 6 of 16

Stability is the change in bias over time. Stability study is to be conducted


1
for measuring systems where there is a possibility of a natural change in the
measuring system w.r.t. time for eg. deterioration of the measuring
instrument [wear and tear due to usage].

2 The study should be carried out within the calibration frequency of the
measuring instrument
Decide the frequency of measuring the sample within the existing
calibration frequency of the instrument being used for the study. For eg. If
3 the calibration frequency is one month then decide the frequency of the
study to be such that 20 – 25 sub-groups of readings are taken during this
period. Throughout the study there should be no change in the
measurement system [instrument, appraiser, method, sample piece,
Measureetc.].
location master sample five times as per the determined frequency.
4

5 If master sample for reference value is not available then select production
part at mid range side and designate as a master for stability analysis.

Calculate the average and the range of the five readings and plot on X bar
6
and R chart
7 Evaluate as per normal SPC requirements with due considerations.
8 Possible causes of instability include:
a) Instrument needs calibration - increase calibration frequency.
b) Worn out instrument, equipment or fixture.
c) Normal ageing or obsolescence
d) Poor maintenance – air, power, hydraulic, filters, corrosion, rust cleanliness.
e) Worn or damaged master, error in master.
d) Improper calibration or use of setting master
f) Poor quality instrument – design or conformance
g) Instrument design or method
Different measurement method lacks robustness.
– setup, locating, clamping, technique.
h) Distortion of gauge or part.
i) Environmental drift – temperature, humidity, vibration, cleanliness.
Violation of an assumption, error in an applied constant
Application - part size, position, operator skill, fatigue, observation error
j)
[readability, parallax.]

8 Repeat the study after the causes are eliminated.

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FORCE
MOTORS.LIMITED Guide lines for Gauge Repeatability and DOC No : GL/III/01
PUNE. Reproducibility REV NO ; 00
[Variable measurement type]. Issue NO/ date; 00/05.12.2017
Page 7 of 16

1 Select three appraisers who are users of the measurement system [preferably an
operator, and inspector and a Production supervisor].
2 Obtain a sample of 10 pieces from a lot.
3 Select instrument with Least Count 1/10 of the tolerance
4 Number parts 1 through 10.
5 Measure the 10 parts in random order by appraiser ‘A’; record results
Repeat step 4 with other appraisers [‘B’ and ‘C’]. The appraisers should not be
6
aware of each other’s readings in order to avoid biased observations.
7 readings by 3 appraisers.

Enter all the readings in the cross annova software. The software indicates the
result based on the following guidelines
• If % R & R < 10%, system is acceptable
• If 10% < % R & R < 30%, system may be acceptable based on importance
8
of application, cost of gage, cost of repair, etc.,
• If % R & R > 30%, not acceptable - system needs improvement
• If ndc more than 5--Acceptable

9
If not acceptable then identify causes and eliminate them. Possible actions are:
When repeatability is large compared to reproducibility
o Instrument needs maintenance
9.1
o Redesign gage for more rigidity
o Improve clamping or location of gauging
o Excessive within – part variation

When reproducibility is large compared to repeatability


o Appraisers need better gage use training
o Need better operational instruction.
9.2
o Incremental divisions on instrument are not readable
o Need fixture to provide consistency in gage use.

10 Repeat the study after the causes are eliminated.


11 The MSA is acceptable only if the GRR and NDC both are OK.

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FORCE DOC No : GL/III/01
MOTORS.LIMITED
PUNE. Guide lines for gauge Repeatability and REV NO ; 00
reproducibility ( Attribute type) Issue NO/ date;
00/05.12.2017
Page 8 of 16

1 outside the tolerance [undersize and oversize]


2 Number the parts [1 to 50]
3 Select 3 appraisers
4 The first appraiser ‘A’ should check the 50 parts at random.

5 Record the readings “0” for not ok decision and “1” for ok decision

6 Repeat step 4 with other appraisers [‘B’ and ‘C’]. The appraisers should not
be aware of each other’s observations in order to avoid bias.

Repeat step 4 and 6 using a different random order of measurement. Thus


7 each appraiser measures the 50 pieces three times i.e. 150 readings per
appraiser and 450 readings by 3 appraisers.

Enter all the readings in the cross tab (kappa) software. The software indicates the
result based on the following guidelines :
Kappa > 0.75 – excellent agreement
0.40 < Kappa < 0.75 - acceptable agreement
Kappa < 0.40 – poor agreement; not acceptable. Missed
rate below 2 % - accetable, 2 % - 5 % - Conditionaly acceptable and above 5% not
8 acceptable
False Rate up to 5% Acceptable, 5% to 10% Conditionaly accetable,
Above 10% Not acceptable.

If the agreement is poor then identify the causes and eliminate them. Possible
actions are
o Redesign gage for more rigidity
o Improve clamping or location of gauging
9 o Excessive within – part variation
o Appraisers need better gage use training
o Need fixture to provide consistency in gage use.

10 Repeat the study after the causes are eliminated.

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FORCE DOC No:GL/III/01
MOTORS.LIMITED REV NO ; 00
PUNE. Guide lines for Visual inspection Issue NO/ date;
MSA 00/05.12.2017
Page 9 of 16

1 Select 10 nos of parts randomly for visual MSA.


2 In selected lot three to four parts should be on border case ,where there is scope
of wrong interpretation.
3 Identify samples, with sr. Nos.and record the reading as reference value
4 Select 3 appraisers ,Engineer, inspector, operator who check parts daily.
5 Confirm their eye sight is OK with/without spectacle.
6 The first appraiser ‘A’ should check above 10 parts at randomly.
7 Record the readings “0” for not ok decision and “1” for ok decision
8 Repeat step 6&7 with other appraisers [‘B’ and ‘C’]. The appraisers should not be
aware of each other’s observations in order to avoid bias.
9 Repeat step 6 to 8 using a different random order of measurement. Thus each
appraiser measures the 10 pieces three times i.e. 30 readings per appraiser and
90 readings by 3 appraisers.

10 Enter all the readings in the software NEW cross tab study. The software indicates
the result based on the following guidelines :
Kappa > 0.75 – excellent agreement
0.40 < Kappa < 0.75 - acceptable agreement
Kappa < 0.40 – poor agreement; not acceptable.
Missed rate below 2 % - accetable, 2 % - 5 % - Conditionaly acceptable and
above 5% not acceptable
False Rate up to 5% Acceptable, 5% to 10% Conditionaly accetable,
Above 10% Not acceptable.

11 If the agreement is poor then identify the causes and eliminate them. Possible
actions are-
• Redesign Lighting for more clarity
• Reduce Excessive within – part variation
• Appraisers need retraining
• Need fixture to provide consistency in inspection.

12 Repeat the study after the causes are eliminated.

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FORCE DOC No:GL/III/01
MOTORS.LIMITED REV NO ; 00
PUNE. Guide lines for noise Testing MSA Issue NO/ date;
00/05.12.2017
Page 10 of 16

1 Select 10 nos of parts randomly for Noise testing MSA.


2 In selected lot three to four parts should be on border case ,where there is scope
of wrong interpretation.
3 Identify samples, with sr. Nos.and record the reading as reference value
4 Select 3 appraisers ,Engineer, inspector, operator who check parts daily.
5 Confirm their ears are ok with/without machine by noise hearing ability test
6 The first appraiser ‘A’ should check above 10 parts at randomly.
7 Record the readings “0” for not ok decision and “1” for ok decision
8 Repeat step 6&7 with other appraisers [‘B’ and ‘C’]. The appraisers should not be
aware of each other’s observations in order to avoid bias.
9 Repeat step 6 to 8 using a different random order of measurement. Thus each
appraiser measures the 10 pieces three times i.e. 30 readings per appraiser and
90 readings by 3 appraisers.

10 Enter all the readings in the software NEW cross tab study. The software indicates
the result based on the following guidelines :
Kappa > 0.75 – excellent agreement
0.40 < Kappa < 0.75 - acceptable agreement
Kappa < 0.40 – poor agreement; not acceptable.
Missed rate below 2 % - accetable, 2 % - 5 % - Conditionaly acceptable and
above 5% not acceptable
False Rate up to 5% Acceptable, 5% to 10% Conditionaly accetable,
Above 10% Not acceptable.

11 If the agreement is poor then identify the causes and eliminate them. Possible
actions are-
• Confirm machine callibration is ok.
• Confirm components/assly parameter are as per specs.
Reduce Excessive within – part variation
• Appraisers need re training
• Improve clamping of component.

12 Repeat the study after the causes are eliminated.

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FORCE
MOTORS.LIMITED DOC No : GL/III/01
PUNE. REV NO ; 00
Range Method. Issue NO/ date;
00/05.12.2017
Page11 of 16

When to apply range method for GRR% calculation ?


> To quickly find out GRR% approximately.
In between 2 GRR average and range method studies to quickly check whether
> GRR is changed.

Typical method to collect the data.


> 5 parts and 2 appraisers are selected for the study
> 5Parts are measured by both the appraisers only 1 time.
Analysis
> Range is calculated for the same part between 2 appraisers
> Average range is calculated

> GRR= Rbar/d2 *vailue of d2 can be obtained from appendix C of MSA manual. For
5 parts and apprises it is 1.19
> % GRR= 100XGRR/(process standard Deviation)

> process standard deviation is known based on standard deviation calculated from
past data for the same parameter on the same product.
Example:
Appraiser
Part Range
A B
1 0.85 0.8 0.05
2 0.75 0.7 0.05
3 1.00 0.95 0.05
4 0.45 0.55 0.1
5 0.50 0.6 0.1

Average range: R bar = (0.05+0.05+0.05+0.1+0.1)/5=0.07


GRR= 0.07/1.19=0.0588
Process standard Deviation= 0.0777 from previous study
% GRR= 100x(0.0588/0.0777)=75.7%

Conclusion : In the above example since MS variation is 75.7% of total variation.It needs
improvement.

Detail MSA is required.

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FORCE MOTORS.LIMITED PUNE.
DOC No : GL/III/01
Important points for MSA REV NO ; 00
from AIAG Manual
Issue NO/ date; 00/05.12.2017
Page 12 of 16
Important Points form MSA AIAG manual fourth edition

S.No Extracts from Manuals. Remark Reference


1 Staststical studies shall be conducted to analysie the variation present in a)Presently measurement system is ISO/TS 16949:2009 Clause
the results of each type of meassuring and test equipment system. This not mentioned in control plan. No 7.6.1
requirment shall apply to measurement system referenced in the control b) Measurement
plan. The analytical methods and acceptance criteria used shall conform system to be mentioned in control
to those in customer reference manuals on measurement system plan.
analysis. Other analytical methods and acceptance critreia may be used if c)Hence now we can plan MSA for
approved by the customer. all special characterstics where we
are carring out SPC.

2 Not all product and process characterstics require measurement system With this reference we can plan Key point from MSA AIAG
whose development falls under this type of scrutiny. Simple MSA for all special characterstics manual 4th edtion. Chapter I
measurement tools like micrometers or calipers may not require this in identified in control plan also where -section C. Measurement
-dept strategy and palnning . A basic rule of thumb is whether the we are carring out SPC. strategy and planning
characteristic being measured on the compont or sub asystem has been ( Page no 25)
identified in the control plan or is important in the determining the
acceptance of the product or process .Another guide would be the level
of tolerance assigned to a specific dimension.
Common sense is the guide in any case.

3 Prepare MSA plan for each type of measurement system,considering all Mahesh Hegde. ( Course
the measurement systems addressed in control plan. material )
Control plan is the input to prepare MSA plan.
It is important to consider all the measurement system addressed in the
control plan while preparing MSA plan.It is not necessary that every
instrument or every parameter mentioned in control plan to be covered
under MSA plan.

4 The type, complexity,and purpose of a measurement system may drive various MSA AIAG manual 4th
levels of program management, strategic planning, measurement system edtion. Chapter I -section C.
analysis orother special consideration for measurement selection,assessment Measurement strategy and
and control.Simple measureing tools and devices (ie.,Scales,measureing planning (Complexity)
tapes,fixed-limit or attribute gages)may not require the level of ( Page no 25)
management,planning,or analysis that more complex or critical measuring
systems demand(ie., master or reference, CMM, test stand,automated on-line
gaging,etc.) Any measurement system may require more or less strategic
planning and scrutiny depending on a given product or process situation.The
decision as to the appropriate level shall be left to the APQP team assigned to
the measurement process and customer.The actual degree of involvement or
implimentation in many of the activities below should be driven by the particualr
measurement system,consideration of the supporting gage control and
calibration system,profound process knowledge,and common sense.

5 The instrument should have a least count of at least one-tenth of the expected
process variation of the characteristic to be read directly.
FORCE
MOTORS. DOC No : GL/III/01
LIMITED List of Gauges where MSA not REV NO ; 00
PUNE.
necessary
Issue NO/ date; 00/05.12.2017
Page 13 of 16

List of Gauges where MSA not necessary

1 AIR GAUGE SETTING PLUG 113


2 SURFACE PLATE 37
3 BENCH CENTRE 20
4 ROUGHNESS MASTER 2
5 SURFACE FINISH MASTER 3
6 O.D.SETTING MASTER 21
7 TORQUE WRENCH CLIBRATOR(MBI) 8
8 ANGLE PLATE 1
9 COMPARATOR STAND 24
10 RIGHT ANGLE 19
11 RADIUS GAUGE 55
12 SINE BAR 5
13 V BLOCK 41
14 SPIRIT LEVEL 4
15 STANDARDS ROOM EQUIPMENTS 30
16 STANDARDS ROOM MASTERS 42
17 STEEL TAPE 13
18 SCALE 8
19 CHECK PLUG MASTER 46X2
20 SPL.GAUGE MANDREL 6
21 TORQUE WRENCH 227
22 COMBINATION SET 6
23 MASTER AIR RING GAUGE 125
24 MASTER RING GAUGE 269
25 WEAR CHECK PLUG GAUGE 77
26 THREAD PITCH GAUGE 21
27 SLIP GAUGE BOX 16
28 MORSE TAPER RING GAUGE 9
29 TAPER WEAR CHECK PLUG 9
30 FEELER GAUGE 26
31 MORSE TAPER PLUG GAUGE 8
32 BEVEL PROTRACTOR 27
FORCE DOC No : GL/III/01
MOTORS. REV NO ; 00
LIMITED Gauge population spread,Akurdi Issue NO/ date; 00/05.12.2017
PUNE. Page 14 of 16

GAUGE POPULATION SPREAD


Sn Gauge type Abbrivation Total Qty
1 SURFACE PLATE SFP 37
2 BENCH CENTRE BCBT 20
3 SLIP GAUGE BOX SLBT 16
4 SPL.GAUGES SPL. 1614
5 ROUGHNESS MASTER RMBT 2
6 SURFACE FINISH MASTER SFMFML 3
7 AIR GAUGE UNIT BTAG 115
8 FLAT PLUG GAUGE FG 19
9 DIAL GAUGE DGBT 503
10 AIR GAUGE SETTING PLUG MPA 113
11 MASTER RING GAUGE MR 269
12 MASTER AIR RING GAUGE MRA 125
13 LIMIT RING GAUGE MRL 7
14 O.D.SETTING MASTER ODSM 21
15 SPLINE PLUG GAUGE SPGIP/SPGKP/ 43
16 SPLINE RING GAUGE SPIP/SPKP/SPSP
SRGIR/SRGSR/ 43
17 TAPER PLUG GAUGE TG
SRIR/SRKR 17
18 MORSE TAPER PLUG GAUGE TGMT 8
19 TAPER RING GAUGE TI 10
20 MORSE TAPER RING GAUGE TIMT 9
21 WIDTH GAUGE WG 6
22 PLUG GAUGE PG 1399
23 SNAP GAUGE SG 1282
24 TORQUE WRENCH TWBTT 227
25 CHECK PLUG MASTER CPM 46X2
26 SPL.GAUGE MANDREL MANDREL 6
27 THREAD PLUG GAUGE TP 330
28 THREAD RING GAUGE TR 130
29 TAPER THREAD RING TTR 10
30 TAPER WEAR CHECK PLUG TWCP 9
31 WEAR CHECK PLUG GAUGE WCP/WCPM 77
32 WIRE THREAD PLUG GAUGE WTP 1
33 TORQUE WRENCH CLIBRATOR(MBI) TWCMBI 8
34 ANGLE PLATE APBT 1
35 BEVEL PROTRACTOR BPBT 27
36 CYL.BORE GAUGE CBBT 150
37 COMBINATION SET COBT 6
38 COMPARATOR STAND CSBT 24
39 FEELER GAUGE FLBT 26
40 INSIDE GROOVE CALIPER ICBT 13
41 MICROMETER MOBT 269
42 PISTOL CALIPER PCBT 8
43 PASSOMETER PMBT 19
44 THREAD PITCH GAUGE PTBT 21
45 RIGHT ANGLE RABT 19
46 RADIUS GAUGE RGBT 55
47 SINE BAR SBBT 5
48 V BLOCK VBBT 41
49 VERNIER CALIPER VCBT 192
50 VERNIER DEPTH GAUGE VDBT 15
51 VERNIER HEIGHT GAUGE VHBT 47
52 SPIRIT LEVEL SPLBT 4
53 STANDARDS ROOM EQUIPMENTS SRE 30
54 STANDARDS ROOM MASTERS SRM 42
55 STEEL TAPE STEEL TAPE 13
56 SCALE SCAL 8
TOTAL 7514
FORCE MOTORS.LIMITED PUNE.
DOC No : GL/III/01
Divisionwise Gauge population REV NO ; 00
Issue NO/ date; 00/05.12.2017
Page 15 of 16

Divisionwise total ( A)

Grand total (A+B)


Air Plug/Air Caliper/

Jig / Fixtures(B)
Air Gauge units

Special Gauges
Thread Gauges

Spline Gauges
Division %

Air Ring Gauges

Master Rings
Snap Gauges

Instruments
Plug Gauges

Misc.Gauges
Engine 432 117 269 442 2 29 31 42 276 13 1653 21.99 472 2125

Tractor 465 278 135 232 52 31 95 65 547 23 1923 25.59 657 2580

Trans. 401 752 153 463 29 55 106 98 614 11 2682 35.69 885 3567

SCV 68 81 48 117 0 5 6 28 187 15 555 7.38 244 799

Tool Room 40 0 0 369 0 0 0 40 0 12 461 6.13

R&D 0 0 0 135 0 0 0 0 0 0 135 1.79

Others 2 5 0 95 0 0 0 0 3 0 105 1.39

Total 1408 1233 605 1853 83 120 238 273 1627 74 7514 100% 2258 9071

19%
21%
1%

4% 3%
2% 17%

1%

8%
24%
FORCE MSA soft ware verification DOC No: GL/III/01
MOTORS.LIMITED REV NO ; 00
PUNE. Issue NO/ date; 00/05.12.2017
Page 16of 16

1 Validate software results yearly.


2 Add manual standards reading for first time and verify the results as per manual.
Use yearly these set of reading for calibration of all types of MSA software.
3 Compare the results with first / original results.
If results are not matching, call software programer for callibration of same .
4 If results are ok software is ok

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FORCE MOTORS LIMITED DOC NO : GL /III/02
PUNE REVISION NO.: 00
ISSUE NO / DT: 00/05.12.2017
GUIDE LINES Pg 1 of 5

TITLE: PROCEDURE FOR APPLICATION OF STATISTICAL TOOL TO CONTROL PROCESS AND


PRODUCT CHARACTERISTICS.
PURPOSE: These guidelines are established to follow SPC system across
the organization.

SCOPE: It covers all SPC process control parameters established as per control plan.

RESPONSIBILITY: Responsibility of implementation of this procedure lies


with each HOD. Operational responsibility lies with SIC.

PROCEDURE: The procedure will be applicable to control process and product


characterstics through statical tool.

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DOC NO : GL /III/02
Force Motors.Ltd Procedure for Intial process capability study. Rev. No : 00
Pune
Rev. Date : 05.12.2017
Responsibility : PE,Production,QC & Maintenance Page 2 of 5

Identify the special characteristics


(SC/ CC) (product and process) as per REF: Control plan
control plan.

Ensure MSA study is acceptable. Ref: MSA:GL/ III/01

Ensure all process parameters (M/c,


Method & Man)
Significant process events, such
as tool change, material
Collect Data for SPC study. change ,Power off,machine
Sample size =30, repair , shift change ,opertaor
change checking gauge change
sub group size =5, & tea break/lunch break shall be
No of sub group=6 recorded.

If not, special causes


are to be eliminated. Ensure Process is stable,centralised
Not OK and normal on the process control
chart

Calculate Pp and Ppk using


the formulae
Calculate Process Performance index Pp= (USL- LSL) / 6s and
Pp & Ppk Ppk= Min{(USL-X dbar )/ 3s ,
(X dbar -LSL) / 3s)}
100% inspect the lot. where s = √(Σ(x-`x)²/n-1)
Look for the s to be calculated by RMS
processes to detect method
and prevent the
errors which lead to Ppk<1.67
non-conforming No Is process capable ?
product .(e.g., use
for 7 QC tools/ Poka
yoke)

YES Ppk≥1.67

Accept the process, product & update


the records.

STAMP
REV ISSUED BY: DATE:05.12.2017
DOC NO : GL /III/02
Force Motors.Ltd Procedure for on going process capability study. Rev. No : 00
Pune
Rev. Date : 05.12.2017
Frequency : Once in 6 months Page 3of 5

Identify the special characteristics (SC/ CC)


(product and process) as per control plan. REF: Control plan

Prepare Annual Plan for SPC study with


responsibility.

Ensure MSA study is acceptable. Ref: MSA:GL/ III/01

Ensure Process is under control by using Control


Chart Method .Use X bar R chart

Significant process events,


such as tool change, material
Collect Data for SPC study. Sample size change ,Power off,machine
=30, sub group size =5, No repair , shift change
of sub group=6 ,opertaor change checking
gauge change & tea
If not, special causes break/lunch break shall be
are to be eliminated. Not OK Ensure Process is stable, in control recorded.
and normal

Calculate Cp and Cpk using


Calculate Process Capability Index Cp the formulae
& Cpk Cp= (USL- LSL) / 6 Sigma c
and
Cpk= Min{(USL-X dbar )/ 3
Sigma c , (X dbar -LSL) / 3
Sigma c)}
where Sigma c = R bar /d2
100% inspection by Cpk<1.33
operator on M/c. No Is process capable ?
Also detect and
prevent the errors
which lead to non-
conforming product.
YES Cpk≥1.33

Accept the product & update the records.

For ongoing process ,process control charts to be


followed by using same control limits.

Look for Continual Improvement of Process

STAMP
REV ISSUED BY: DATE:05.12.2017
DOC NO : GL /III/02
Force Motors.Ltd Procedure to Monitor OGQL. Rev. No : oo
Pune
Rev. Date : 05.12.2017
page 4 of 5

Identify the special characteristics


(SC/ CC) (product and process) as per REF: Control plan
control plan.

Prepare Annual Plan for OGQL study

Ensure MSA study is acceptable. Ref: MSA:GL/ III/01

Collect Data for OGQL study at the


final inspection of parts.
(3 to 5 samples from lot/day and 50
to 60 Nos total))

Calculate Process Capability Index Cp


& Cpk

Look for
manufacturing
processes & detect Calculate Cp and Cpk
and prevent the No Is process capable ? using the formulae
errors which lead to Cpk<1.33 Cp= (USL- LSL) / 6 Sigma c
non-conforming and
product. Cpk= Min{(USL-X dbar )/ 3
Sigma c , (X dbar -LSL) / 3
YES Cpk≥1.33 Sigma c)}
where Sigma c =
R bar /d2

update the records.

Look for Continual Improvement of


Process

STAMP

REV ISSUED BY: DATE:05.12.2017


FORCE MOTORS LIMITED DOC NO : GL/III/02
PUNE REVISION NO.: 00
ISSUE NO / DT: 00/05.12.2017
GUIDE LINES Pg 6 of 6

Interpretation of control charts for corrections- Ref to Manual

1) One point out of UCL / LCL - Special cause of variation.

2) 2 to 3 points out of 2Sigma - Special cause of variation.

3) 4 points out of 1 sigma - Cause of variation.

4) 7 points on one side of mean - Cause of variation.

5) 7 points either increasing or decreasing - Special cause of variation.

6) Too many points on mean line - Special cause of variation ( Manipulated / Wrong instrument ).

7) Alternate up and down - Cause of variation ( Over adjustment ).

8) Cyclic pattern- cause of variation.

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