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Gage R&R study sheet
A gage R&R study measures how much of the variation you see comes from the measurement system itself. Repeatability, or equipment variation (EV), is the spread when one appraiser measures the same part several times; reproducibility, or appraiser variation (AV), is the difference between appraisers. Together they make GRR, which is compared with the part-to-part variation (PV) and the total variation (TV). This template uses the average and range method of the AIAG Measurement Systems Analysis (MSA) manual with 10 parts, 2 or 3 appraisers and 2 or 3 trials. Page 1 of the PDF is the data sheet, with the averages and ranges for each appraiser and the part averages. Page 2 has every calculation step with the K1, K2, K3 and D4 constants, a column with the worked example, the %GRR guidance and the number of distinct categories (ndc). The Excel version works out the averages and ranges, the average range, the range limit with any range above it flagged, the difference between appraisers, the range of the part averages, EV, AV, GRR, PV and TV, each as a % of total variation, ndc, an optional % of tolerance and the %GRR band, with an Example sheet that matches the worked example on this page.
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Fields for part, characteristic, specification, tolerance and gauge, and a table of 10 parts with three trials, the average and the range for appraisers A, B and C, and a part average row.10 parts × 3 appraisers × 3 trialsAverages and rangesRange limit checkEV, AV, GRR, PV and TV%GRR and ndc% of toleranceWorked example
When to use it
When to run a gage R&R study
- Before a capability study or a control chart, so the data shows the process and not the gauge.
- For a new gauge, a gauge moved to a new process, or after a repair that could change how it reads.
- When a customer asks for measurement system analysis in a PPAP, or the control plan names the gauge for a special characteristic.
- When operators disagree about whether parts are good, or parts pass at one station and fail at the next.
How to fill it in
- 1
Choose 10 parts
Parts from normal production that cover the spread of the process, not all from the middle. Number them where the appraisers cannot see.
- 2
Choose the appraisers
Two or three people who use the gauge on the job, with the same gauge and the usual method.
- 3
Measure blind, in random order
Each appraiser measures all 10 parts, then again in a new order for each trial, without seeing the earlier readings.
- 4
Check the ranges
Work out each part's range for each appraiser and the average range. A range above D4 × the average range points to a misread or a damaged part: find out why and re-measure.
- 5
Work out the results
EV from the average range, AV from the difference between appraiser averages, GRR, PV from the range of part averages, then each as a % of total variation, and ndc.
- 6
Decide
Under 10% GRR is generally acceptable, 10% to 30% may be acceptable depending on the application, and over 30% means the measurement system needs fixing. Check ndc too: 5 or more is the usual requirement.
Constants
Average and range method constants
K1 depends on the number of trials, K2 on the number of appraisers, and K3 on the number of parts: 0.3146 for the 10 parts in this template. D4 sets the upper limit for the ranges.
| Constant | With 2 | With 3 |
|---|---|---|
| K1, by trials | 0.8862 | 0.5908 |
| K2, by appraisers | 0.7071 | 0.5231 |
| D4, by trials | 3.267 | 2.574 |
K1, by trials
- With 2
- 0.8862
- With 3
- 0.5908
K2, by appraisers
- With 2
- 0.7071
- With 3
- 0.5231
D4, by trials
- With 2
- 3.267
- With 3
- 2.574
A filled-in example
Illustrative, not a benchmarkAn example: flange thickness, 5.00 ± 0.15 mm, 10 parts, 3 appraisers, 3 trials each (illustrative readings). The Excel version's Example sheet has all 90 readings and gives the same results.
The example study as a share of total variation
- EV, repeatability (the gauge)10.0%
- AV, reproducibility (the appraisers)12.0%
- GRR, measurement system15.6%
- PV, part-to-part98.8%
Equipment variation 10.0 percent, appraiser variation 12.0, gauge R and R 15.6, part variation 98.8 percent of total variation. GRR is in the 10 to 30 percent band.
- Average ranges of 0.0058, 0.0074 and 0.0064 mm give an overall average range of 0.00653 mm. The range limit is 2.574 × 0.00653 = 0.0168 mm, and no range is above it.
- EV = 0.00653 × 0.5908 = 0.00386 mm. Appraiser averages are 4.96233, 4.96773 and 4.95870 mm, a difference of 0.00903 mm, so AV = √((0.00903 × 0.5231)² − 0.00386² ÷ 30) = 0.00467 mm.
- GRR = √(0.00386² + 0.00467²) = 0.00606 mm. Part averages run from 4.90767 to 5.02944 mm, a range of 0.1218, so PV = 0.1218 × 0.3146 = 0.0383 mm and TV = 0.0388 mm.
- Of total variation: EV 10.0%, AV 12.0%, GRR 15.6%, PV 98.8%. ndc = 1.41 × 0.0383 ÷ 0.00606 = 8.9, rounded down to 8. GRR is 12.1% of the 0.30 mm tolerance.
15.6% sits in the 10% to 30% band: usable for this characteristic if the customer agrees. AV is larger than EV, which points at how the appraisers measure rather than at the gauge, and appraiser B reads highest on average, so the next step was to agree one way of holding the micrometer and train all three.
Common mistakes
Parts from a narrow band
If the 10 parts are nearly the same, PV is small and %GRR of total variation looks poor even with a good gauge. Pick parts across the process spread.
Appraisers who know which part is which
They remember earlier readings. Hide the numbers and change the order every trial.
Ignoring a range above the limit
One misread inflates EV. Find the cause and re-measure before quoting the result.
Quoting %GRR without saying of what
% of total variation and % of tolerance give different numbers. Say which you report and why.
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See it in a 45-minute demoIn the lean glossary
Free tools
Guides
- Gauge R&R in Manufacturing: Repeatability and Reproducibility Studies
- Measurement System Analysis: Validating Gauge Reliability in Manufacturing
- Total Quality Management: Principles and Manufacturing Application
- Manufacturing Defects: Types, Root Causes, and Prevention
- Measurement uncertainty budget template
Train the team
FAQ
Gage R&R study sheet: common questions
By the AIAG MSA guidance, under 10% GRR is generally acceptable, 10% to 30% may be acceptable depending on how important the characteristic is, the cost of a better gauge and the risk, and over 30% is not acceptable. The number of distinct categories should usually be 5 or more. Your customer may set its own limits.
Repeatability (EV) is the variation when the same appraiser measures the same part with the same gauge several times. Reproducibility (AV) is the variation between the averages of different appraisers. High EV points at the gauge or the fixture; high AV points at method or training.
The usual average and range study is 10 parts, 3 appraisers and 2 or 3 trials, 60 or 90 readings. This template takes 10 parts with 2 or 3 appraisers and 2 or 3 trials. Fewer parts or trials make the estimates less reliable.
With total variation when the gauge is used to control or improve the process, because it shows whether the gauge can see the process moving. With the tolerance, 100 × GRR ÷ (tolerance ÷ 6), when the gauge is used to sort good parts from bad. Report which one you used.
The number of distinct categories: how many groups of parts the measurement system can tell apart across the process spread. It is 1.41 × PV ÷ GRR, rounded down. Below 5, the gauge cannot separate the parts well enough to control the process.
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- Daily kaizen routine boardA team's 10 to 15 minute daily routine at the board: one problem from each person, small fixes with one owner, counted every week.
- Weekly maintenance schedule templateNext week's maintenance jobs, scheduled only when ready, loaded against each craft's hours by day, with schedule compliance and break-ins at week end.
- Operational excellence assessment templateThe ten principles of operational excellence as 30 behaviors and practices you can see, scored 1 to 5 by several people, with the spread, the three lowest principles and an action plan.
- Scrum meeting agenda templateTimed agendas for the five scrum meetings, a sprint planning sheet, a retrospective sheet, and an Excel sprint backlog with a burndown.
- Toyota Production System (TPS) house templateThe TPS house for one plant or value stream: roof, two pillars and foundation, with what you do today, the evidence, a status and the next step for each element.
- EPEI and batch size calculatorHow often each part can come round on a shared machine (EPEI) and how big each batch must be, from demand, cycle times and changeovers, now and after SMED.
- Process capacity sheet templateEach machine in a part's routing with manual, auto and tool change time, its capacity per shift, and the step that limits the cell against demand.
- Team charter templateA one-page charter for a standing team: purpose, scope, roles, the KPIs it owns, which decisions it makes itself, norms and cadence.
- Chaku-chaku line plannerPlan a load-load cell: time each machine, load and walk, check that every machine is ready when the operator comes back, compare the cell cycle with takt and size the crew.
- Standard operating procedure (SOP) templateA full SOP in the hierarchical step format, from purpose and scope to the steps, records, revision history and approvals, with review checks and an SOP register.
- Process improvement method selectorEight questions about one problem, an example rule that suggests a method and a matrix of nine methods: when each fits, the usual team and time, and the template to start with.
- Safety pillar 90-day model area planThirteen weeks from the incident pyramid to safety standards on one model area, a KPI board, the day-90 gate and expansion waves.
- Autonomous maintenance 90-day model area planAM steps 0 to 3 on one model machine in 13 weeks, a KPI board, the day-90 gate and expansion waves for months 4 to 12.
- Professional maintenance (PM) 90-day model area planThirteen weeks from breakdown analysis to a running PM calendar on one model machine, a KPI board, the day-90 gate and expansion waves.
- Environment and energy pillar 90-day model area planThirteen weeks from waste and energy maps to area standards on one model area, a KPI board, the day-90 gate and expansion waves.
- Focused improvement 90-day model area planThirteen weeks from the loss Pareto to standardized fixes on one model line, a KPI board, the day-90 gate and expansion waves.
- Logistics and customer service pillar 90-day model area planThirteen weeks from the current-state map to pull on one model value stream, a KPI board, the day-90 gate and expansion waves.
- People development pillar 90-day model area planThirteen weeks from the skills matrix to trained cover on critical tasks in one model area, a KPI board, the day-90 gate and expansion waves.
- Cost deployment pillar 90-day model area planThirteen weeks from the loss map to costed, ranked projects in one model area, a KPI board, the day-90 gate and expansion waves.
- Moving from Excel to one system checklistA 34-point checklist and a file inventory for moving trackers from spreadsheets to one system: keep, move, connect or retire, clean, pilot, run both, retire.
- Prioritization matrix templateScore up to 20 improvement ideas on weighted criteria, rank them, test the ranking with equal weights and place each one on an effort and benefit grid.
- Cost per unit worksheet (manufacturing cost per good unit)One product's cost per good unit by materials, labor, machine and overhead, the gap to target, and which cost lever is worth most a year.
- Manufacturing KPI dashboard templateWeekly plant numbers in, 14 KPIs out: OEE and its parts, first pass yield, scrap, on-time delivery, recordable rate, cost and absence, each against a target.
- Training matrix template with expiry datesPeople by required trainings with expiry dates, OK, due, expired and missing flags, compliance by person and area, cover per training and a renewal list.
- Downtime reason codes template26 starter codes mapped to the six big losses, a log with drop-downs, a Pareto by code and by loss, and a code card for the line.
- Kaizen event preparation checklistEverything that has to be ready before a kaizen event and done after it: 44 items with owners and due dates from 6 weeks before day 1 to 30 days after, five go or no-go gates and a day-by-day agenda.
- Critical spare parts list and stocking levelsAssets ranked by consequence, each part classed and given a stocking policy, and min and max worked out from usage and lead time, with the downtime each stock-out would cost.
- Tier 2 meeting agenda and escalation sheetA 15-minute tier 2 agenda in ten timed blocks, fixed roles and rules, escalation triggers with time limits, and a log that ages every escalation and sends the answer back down.
- Forklift operator training and evaluation recordPer-operator training and evaluation record, a register with three-year due dates and refresher triggers, and a weighted practical evaluation scoresheet.
- REBA worksheet (Rapid Entire Body Assessment)Score up to six postures with REBA: body-part drop-downs, Tables A, B and C as lookups, final score and action level, and a before and after comparison.
- ISO 45001 internal audit checklist44 audit questions for the plant floor in 16 safety topics, each with its ISO 45001:2018 clause, the evidence to look for and the sample to take, plus 12 worker interview prompts, a findings log and a summary by clause.
- Plan for every part (PFEP) templateOne row per part: supplier, pack, container, usage, lead time and locations, with ABC classes, market and line kanban counts and a lineside space check.
- Changeover matrix templateA from-to matrix of changeover minutes with the clean each transition needs (allergen, colour, format), and a weekly planner that totals the order and suggests a shorter one.
- Overhead crane inspection checklist: frequent and periodic34 crane checks tied to OSHA 1910.179: an operator's pre-shift card, frequent and periodic inspections with signed records, a deficiency and tag-out log, and a register of next due dates.
- Maintenance job plan templateOne job planned on one sheet: steps and craft hours, parts checked against stock, tools, lockout and permits, documents, a ready check for the schedule, and technician feedback.
- Reorder point and safety stock sheet (many parts)Safety stock, reorder point, order quantity and an order list for up to 500 parts, worked out from each part's own demand and lead time history.
- OSHA compliance calendar (general industry)37 recurring federal OSHA duties with the paragraph, interval, owner, next due date and an overdue flag, plus a 12-month view and counts by owner.
- TRIR and DART rate trackerMonthly hours, OSHA 300 case counts and near misses in; rolling 12-month TRIR and DART rate, a case budget against your target and a trend chart out.
- Energy use and EnPI trackerMonthly electricity, gas and fuel in one unit, a 12-month regression baseline, expected against actual energy for each month, an EnPI ratio, the running saving and the tests that say whether the model can be trusted.
- FIFO lane sizing sheetThe maximum for a FIFO lane from the stop it must cover, in whole containers, with length, refill and wait checks for up to eight lanes.
- Machine guarding inspection sheetA machine register with due dates and a status per machine, 21 checks tied to OSHA 1910.212, .219 and .147, a guard opening check against Table O-10, and an action log.
- Condition monitoring route sheetA route of measuring points with baselines, alert and alarm limits, a check interval from the P-F interval, readings with rising and overdue flags, and an exceptions list worst first.
- Fire extinguisher inspection logOne row for every portable extinguisher: hydro test interval from OSHA Table L-1, annual and 6-year due dates, a 12-month check grid and open issues.
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A shift handover sheet, a red tag log, a changeover checklist for one machine: if your team uses it on the floor, ask.