Imagine this: you regularly measure the thickness of a product in your production process. Sometimes the value appears to be just within specification, while the same measurement a few minutes later shows a slightly different result. In such situations, you want to know whether the variation is caused by the product itself or by the measurement system. This is where Measurement System Analysis can help. In this blog, we explain what Measurement System Analysis is, its benefits, and how to carry out the analysis.
What is the MSA method?
MSA (Measurement System Analysis) is a method used to assess the quality of a measurement system. The purpose of this analysis is to determine the reliability of measurements and whether they are accurate enough to base decisions on – such as decisions related to quality and processes.
An MSA does not only involve the measuring instrument itself, but also the operator performing the measurement, the measurement method, the measurement environment, and the measurement software or systems. With a Measurement System Analysis, you examine how much variation exists within the measurement system by looking at factors such as:
- Repeatability
- Reproducibility
- Bias
- Stability
Measurement System Analysis is often applied within methodologies such as Lean Six Sigma. MSA within Lean, for example, is typically carried out before analysing process improvements. After all, if your measurement system is not reliable, you cannot draw reliable conclusions about your process.
What are the benefits of a Measurement System Analysis?
Conducting a Measurement System Analysis offers several advantages for organisations looking to improve their processes. For example, it shows whether your measurement data is reliable, ensuring that decisions are not based on inaccurate measurements. In addition, you can design and analyse process improvements more effectively when you know the data is accurate. By using a Measurement System Analysis to identify where variation in measurements originates, you also reduce discussions between operators and departments that obtain different measurement results. Reliable measurements make it easier to quickly detect and correct deviations in the process. In many quality standards, including ISO standards, demonstrating reliable measurement systems is an important requirement. This means that Measurement System Analysis can be highly valuable in supporting audits.
How do you set up an MSA?
Carrying out an MSA within a Lean framework follows a number of structured steps. These steps help you clearly map variation within the measurement system:
- Define the objective of the analysis
Start by determining which measurement system you want to analyse and why – for example, measuring product length, temperature, or weight.
- Select measurement samples
Choose multiple products or samples that represent the normal range of your process. This ensures the analysis is realistic.
- Select operators
Have multiple operators perform the same measurements. This allows you to analyse differences between users.
- Perform repeated measurements
Ask each operator to measure the same products multiple times. This helps assess the repeatability of the system.
- Analyse the results
Use statistical analyses (such as a Gage R&R study) to determine how much variation comes from the measurement system.
- Draw conclusions and improve where necessary
If the variation in the measurement system is too high, you can take corrective actions, such as:
- Improving measurement instructions
- Calibrating instruments
- Training operators
- Adjusting the measurement system
For a successful MSA, having a clear structure in your measurements is essential. It is therefore advisable to create a solid measurement plan in advance, outlining what will be measured, when, and how.
Example of a Measurement System Analysis
To give a clear picture of how MSA within Lean Six Sigma supports practice, here is an example:
Suppose a company produces metal components where the diameter of a shaft must remain within approximately 0.02 mm. The company conducts a measurement system analysis using ten different parts, three operators, and three measurements per part per operator. Each operator measures all parts multiple times using the same calliper. The measurement results are then analysed. The analysis shows that 85% of the variation comes from the product itself, 10% originates from the measurement system, and 5% is caused by the operators. This means the measurement system is reliable enough to base process decisions on.
MSA in the EZ-GO app
Carrying out a Measurement System Analysis can be time-consuming when measurements are recorded and analysed manually. Digital tools can significantly simplify this process. With the EZ-GO app from EZ Factory, operators can record measurement data directly on the shop floor. This ensures that measurements are automatically recorded and centrally stored, enabling fast and error-free data collection and real-time insight into measurement results. It also allows for easy analysis of measurement data and improved collaboration between operators and quality departments. Would you like to see how this works in practice? Then take a look at the EZ-GO app demo.
Questions about Measurement System Analysis? Get in touch!
Would you like to learn more about performing an MSA or improving your measurement systems? The specialists at EZ Factory are happy to help. Feel free to contact us for advice or to discover how digital tools can support your quality measurements and process improvement efforts.