southwest test conference - swtw corporate support
TRANSCRIPT
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Introduction toGage R&R Studies
The Key to UnderstandingMeasurement Systems
ByHank Scutoski & Chander Sekar, Ph.D.
CERPROBE CORPORATIONGilbert, Arizona
Southwest Test Conference
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Speakers
q Hank Scutoski
– VP Quality – 30 Years Experience– TI, Motorola, Cerprobe– Motorola University’s Six Sigma Research Institute– Certified Quality Engineer– Certified Quality Auditor
q Chander Sekar, Ph.D.
– Corporate Statistician– 23 Years Experience– Professor of Statistics at the University of Madras, India– 3 Degrees in Statistics – Certified Quality Engineer
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We must determine the uncertainty ofour measurement systems before wecan compare, control or optimize our
manufacturing processes.
Cerprobe’s Philosophy
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Studies Completed
85 Studies to Date Including:
– Tip Diameter– Tip Length– Contact Force– Probe Tip Alignment– Planarity– Contact Resistance– Leakage
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Benefits
n Validates consistent results between:q Cerprobe’s many manufacturing facilitiesq Cerprobe & customer sites
n Provides for “Dock to Stock” certification
n Provides feedback to Cerprobe’s suppliers.
n Able to provide customer with quality products with statistical consulting support.
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Statistical Applications
Gage R&RGage R&R
ScientificGuard Banding
ScientificGuard Banding
Comparison ofMetrology Tools
Comparison ofMetrology Tools SPCSPC
Design ofExperiments
Design ofExperiments
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PrecisionR = Diameter = 6 Std Dev
True Value X1X2
X3
• The variation obtainedfrom one gage and oneoperator whenmeasuring the samepart several times.
• Machine Variation
• Only Applies to ATE
Gage Repeatability
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Gage Reproducibility
True Value X1X2
X3
Y1Y3
Y2
Precision R&R
• The difference in theaverage of themeasurements made bydifferent operators usingthe same gage whenmeasuring the samepart.
• Operator-to-Operator Variation
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R&R Summary Plot
Operators
-0.00030-0.00025-0.00020-0.00015-0.00010-0.000050.000000.000050.000100.000150.000200.000250.00030
1 2 3
No. of Operators: 3No. of Parts: 32No. of Trials: 3
Dev
iati
on
fro
m A
vera
ge
Microscope
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Operators
-0.00030-0.00025-0.00020-0.00015-0.00010-0.000050.000000.000050.000100.000150.000200.000250.00030
1 2 3
Dev
iati
on
fro
m A
vera
ge
No. of Operators: 3No. of Parts: 32No. of Trials: 3Study #3
R&R Summary Plot
Video System
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Total Variation
q Process Variationq Gage Variation
• Repeatability
• Reproducibility
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Note: q One Gageq 1 Operatorq Repeated Measurements
o o o oooo ooo o ooo o
-3σ +3σ
Repeatability
Nominal
99.73%
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Reproducibility
Operator # 2Distribution
Operator # 1Distribution
Note: q One Gageq 2 Operatorsq Repeated Measurementsq One Part
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Measurement System Capability
n Precision-to-Tolerance Ratio (P/T)
P/T < 0.1 Acceptable System
0.1 < P/T < 0.3 Marginally Acceptable System
P/T > 0.3 Unacceptable System
Ref.: SEMATECH: Introduction to Measurement Capability Analysis #91090709A-ENG
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Interpretation of P/T Ratios
P/T = 0.1
* Measurement system consumes 10% of tolerance
* Effect of T on P/T
P = 1.2 P = 1.2 T = 4.0 T = 3.0 P/T = 0.3 P/T = 0.4
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Repeatability Study
n Single operator performs multiple trials
n No change in the setup between trials
n Provides a quick estimate of measurement capability
n PR/T
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Sample data on Align (x) from a repeatability study
Trial #1 Trial #2 Trial #3 Trial #4 Trial #5 S R
0.0170 0.0180 0.0190 0.0070 0.0930 0.0351 0.0860
0.2090 0.1400 0.1630 0.1540 0.1340 0.0297 0.0750
0.0790 0.1170 0.0600 0.0880 0.0970 0.0211 0.0570
0.0770 0.0750 0.1350 0.0820 0.1380 0.0322 0.0630
0.0840 0.0300 0.0730 0.0780 0.0240 0.0285 0.0600
0.0500 0.0420 -0.0030 0.0380 0.0520 0.0224 0.0550
-0.0480 -0.0510 0.0020 -0.0420 -0.0370 0.0215 0.0530
0.0690 0.0830 0.1360 0.1150 0.0690 0.0299 0.0670
S:Standard Deviation R: Range
Repeatability Study - Data
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Repeatability Study
P/T Calculations
PR/T = 6 * ( R / d2) / (USL - LSL)_
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Gage R&R Study
n Involves multiple operators and trials
n Total tear down of the setup between trials
n Provides separate estimates of repeatability and reproducibility
n PR&R /T
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Sample data on Align (x) from a full gage R & R study
O1-T1 O1-T2 O1-T3 O2-T1 O2-T2 O2-T3
-0.0050 0.0360 0.0330 0.0040 -0.0070 -0.0420
-0.0100 -0.0460 -0.0600 -0.0170 -0.0680 -0.0700
0.0070 0.0110 0.0090 0.0230 -0.0190 -0.0040
-0.0170 -0.0820 -0.1060 -0.0890 -0.0540 -0.0580
-0.0620 -0.1000 -0.1010 -0.0270 -0.1090 -0.1000
-0.0830 -0.1480 -0.1210 -0.1200 -0.1280 -0.1870
-0.1100 -0.1460 -0.1520 -0.1200 -0.1890 -0.1900
-0.0560 -0.1490 -0.1290 -0.0900 -0.1650 -0.1780
O1, O2 - Operators 1 and 2T1, T2, T3 - Trials 1, 2 and 3
Gage R&R Study - Data
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Gage R&R Study
n Repeatability
n Reproducibility
n Operator-Part Interaction
n Part-to-Part Variation
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SignificantOperator-to-Part
Interaction
SignificantOperator-to-Part
Interaction
Bad GageBad Gage Poor OperatorTraining
Poor OperatorTraining
ImproperMeasurement
Study Procedure
ImproperMeasurement
Study Procedure
Operator-to-Part Interaction
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Data Analysis Methods
n Average Range Method
n Analysis of Variance (ANOVA) Method
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P/T Calculations
PR&R/T = 6 * ( R&R Sigma) / (USL - LSL)
Gage R&R Study
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Road Map to Success
MicroscopeP/T0.80
VideoP/T0.23
Interaction with
Suppliers
Feedbackto
Operators
RobustData
Collection
AdvancedStatistical
Techniques
Consistent Product QualityConsistent Product Quality