Article
Authors: David W. Hoffa (Accumold) , Chad Laux (Purdue University)
As engineering tolerances approach the submicron range and customer demands for statistically verified quality levels increase, Accumold, a highly specialized, high-tech manufacturer of injection molded lead-frame and small- and micro-scale plastic parts, has realized a critical need for an improved measurement system. Many measurement technologies (including confocal and dynamic range lasers, scanning electron microscopes, white light inter- ferometers, and precision video) from manufacturers around the world were explored. The ANOVA-based “Gauge R&R” (Repeatability and Reproducibility) study was employed as the main analytical tool for determining the efficacy of a potential measurement system; factors like potential for automation, ease of use and programming, and shop floor robustness were considered. The Gauge R&R studies effectively provided management with quantitative measures for determining whether a candidate system was adequate for measuring the critical feature of interest, which was a 10 ± 2 micron difference between adjacent step heights, and as a result, Accumold has purchased a new multi-sensor system capable of achieving a precision to tolerance ratio (a.k.a. Gauge Capability Ratio, study variance to tolerance ratio, et al.) of 11% and resolving up to 74 distinct categories when measuring these features.
Keywords: lean manufacturing/Six Sigma|metrology|quality|quality control|research methods|statistical methods
How to Cite: Hoffa, D. W. & Laux, C. (2007) “Gauge R&R: An Effective Methodology for Determining the Adequacy of a New Measurement System for Micron-level Metrology”, The Journal of Technology, Management, and Applied Engineering. 23(4).