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Kistner Metrologie Service GmbH
Tottenheimer Straße 5
97944 Boxberg-Unterschüpf
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Thomas Kistner
Phone: +49 (0)7930 9937 0
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Die Messsystemanalyse ist die Ermittlung der Fähigkeit von Mess- bzw. Prüfmitteln im Qualitätsmanagement. Sie gibt die Eignung eines Prüfprozesses für eine bestimmte Messaufgabe an. Für die Gesamtbetrachtung ist es erforderlich, verschiedene Verfahren durchzuführen.
In der Messsystemanalyse kommen ausschließlich statistische Verfahren (MSA4) zur Anwendung, es erfolgt keine systematische, metrologische Aufbereitung. Bis heute existiert keine internationale, allgemeingültige Normung mit der Folge dass unterschiedliche Vorgehens- und Betrachtungsweisen entstanden sind, Diese wurden in Richtlinien und Leitfäden von Firmen und Verbänden erstellt.
QS 9000 ist seit 2006 zurückgezogen, Dennoch bleibt die MSA im Rahmen der AIAG Core Tools als Empfehlung bestehen.
In Folgenden werden 6 Verfahren kurz beschrieben, die sich an den Leitfäden der Automobilindustrie (Leitfaden 1999; Leitfaden 2002; DaimlerChrysler 2007) orientieren. Verfahren 2, 3 und 6 beziehen sich auf Analysemethoden, die vor allem in dem „Measurement Systems Analysis. Reference Manual Fourth Edition.June 2010“ (MSA4) vorgestellt wurden.
Voraussetzung: Auswahl einer Messeinrichtung mit hinreichend kleiner Auflösung (R <= 5 % der Toleranz des zu messenden Merkmals)
• Verfahren 1: Beurteilung der systematischen Messabweichung (Genauigkeit) und der Streuung (Richtigkeit) des Prüfmittels ohne Bedienereinfluss anhand eines Prüfnormals.
• Verfahren 2:
Beurteilung des Prüfprozesses unter Berücksichtigung der Einflüsse der Bediener-, der Teileauswahl, der Wechselwirkung zwischen Bediener und Teil sowie der Umgebungsbedingungen.
Dazu werden insbesondere sowohl die Wiederholbarkeit der Messergebnisse desselben Prüfers am selben Teil als auch die Reproduzierbarkeit am selben Teil durch verschiedene Prüfer ermittelt.
• Verfahren 3: Beurteilung des Prüfprozesses wie Verfahren 2, jedoch ohne Berücksichtigung des Bedienereinflusses.
• Verfahren 4: Untersuchung der Linearität der Messergebnisse über dem gesamten Messbereich durch Analyse der systematischen Messabweichung ( Bi <= 5 % der Toleranz).
• Verfahren 5: Dokumentation der Stabilität der Messergebnisse der Messeinrichtung durch Überprüfen der Messbeständigkeit von Zeit zu Zeit.
• Verfahren 6: Attributive Messsystemanalyse für die Beurteilung von Prüflehren.
Beurteilung der systematischen Messabweichung (Genauigkeit) und der Streuung (Richtigkeit) des Prüfmittels ohne Bedienereinfluss anhand eines Prüfnormals
• Beurteilung anhand eines Prüfnormals
• 50 Messungen am Normal
• Streuung dieser 50 Messungen wird mit der Merkmalstoleranz verglichen
• Der Kennwert Cgk wird ermittelt.
Ein Cgk>1,33 bedeutet, dass die ermittelte systematische Abweichung vom Normal plus 4s der Messreihe 10% der Toleranz nicht überschreitet.
Beurteilung des Prüfprozesses unter Berücksichtigung der Einflüsse der Bediener-, der Teileauswahl, der Wechselwirkung zwischen Bediener und Teil sowie der Umgebungsbedingungen.
Dazu werden insbesondere sowohl die Wiederholbarkeit der Messergebnisse desselben Prüfers am selben Teil als auch die Reproduzierbarkeit am selben Teil durch verschiedene Prüfer ermittelt.
Die Anzahl der Prüfer und der Teile für das Experiment ist abhängig von der Forderung (z.B. 2 Prüfer, 10 Teile, 2 Messreihen je Prüfer oder 3 Prüfer, 10 Teile und 3 Messreihen)
Die Kennwerte:
• EV = Wiederholstreubreite (Messmittel)
• AV = Vergleichstreubreite (Prüfer)
• PV = Teilestreuung
• IA = Streubreite der Wechselwirkung
werden ermittelt und letztlich zum Fähigkeitskennwert GRR verarbeitet.
Die Forderung für fähige Prozess ist %GRR < 10 %
Für bedingt fähige Prozesse gilt 10 % <= %GRR <= 30 %
Beurteilung des Prüfprozesses wie Verfahren 2, jedoch ohne Berücksichtigung des Bedienereinflusses.
• Empirische Ermittlung des Einflusses der zu messenden Produkte (Oberfläche, Verschmutzung, Temperatur etc.)
⃘ Gemessen werden 25 Teile, die möglichst über die Toleranz verteilt sein sollen. Diese Messung wird nochmals wiederholt. Dann wird die Streuung der Messergebnisse derselben Teile ermittelt, die 20% der Toleranz nicht überschreiten sollte.
• Für automatische Messeinrichtungen (z.B. mechanisierte Messeinrichtungen, Prüfautomaten, automatisches Handling usw.), bei denen der Bedienereinfluss entfällt oder klein ist, bestimmt.
⃘ Berechnet wird der vereinfachte Kennwert GRR = EV.
Die Forderung für fähige Prozess ist%GRR < 10 %
Für bedingt fähige Prozesse gilt 10 % <= %GRR <= 30 %
Untersuchung der Linearität der Messergebnisse über dem gesamten Messbereich durch Analyse der systematischen Messabweichung
(Bi <= 5 % der Toleranz)
• Die Linearitätsuntersuchung ist dann erforderlich, wenn der Messbereich des Messgerätes bei den anfallenden Messaufgaben ausgenutzt werden soll.
⃘ Mit dieser ermittelt man die systematische Messabweichung an mehreren Stellen innerhalb des Messbereichs
• Erforderlich sind mehrere – minimal drei, besser fünf oder sieben – Normale mit bekanntem Referenzwert
⃘ Referenzwerte sollten so gewählt werden, dass diese in dem zu untersuchenden Messbereich gleichmäßig verteilt liegen
• Jedes Normal wird 10 Mal unter Wiederholbedingungen gemessen
• Das Produkt aus der Anzahl der Normale und der Anzahl der Wiederholungen sollte mindestens 30 ergeben
• Aus den zehn Messungen je Normal sind die Mittelwerte zu berechnen
Für jede Messwertreihe ist die systematische Messabweichung Bi zu berechnen:
Die an jedem Normal ermittelte bekannte systematische Messabweichung Bii sollte z. B. dem Betrag nach kleiner gleich 5 % der Toleranz sein.
In diesem Fall lautet die allgemeine Forderung für Bii:
Dokumentation der Stabilität der Messergebnisse der Messeinrichtung durch Überprüfender Messbeständigkeit von Zeit zu Zeit
• Überwachung der Messbeständigkeit mit einem Normal bzw. Referenzteil
• Ergebnisse werden festgehalten und ausgewertet
• Bei Abweichungen von den Sollvorgaben müssen Verbesserungsmaßnahmen eingeleitet werden
Zu Beginn der Messbeständigkeitsüberwachung wird eine Vorlaufuntersuchung durchgeführt.
Für die Untersuchung kann das im Verfahren 1 verwendete Normal mit dem richtigen Wert xm eingesetzt werden. Dazu wird eine
Qualitätsregelkarte mit folgenden Eingriffsgrenzen angelegt:
Nach Möglichkeit werden an einem Tag 25 Messungen in gleichen Zeitabständen eingeplant. Die ermittelten 25 Messwerte werden in die Qualitätsregelkarte eingetragen. Anhand des Werteverlaufs in der Qualitätsregelkarte können folgende Fälle unterschieden werden:
• Fall 1: Liegen die Werte innerhalb der Eingriffsgrenzen, genügt für Verfahren 5 eine Überwachungshäufigkeit von einmal pro Schicht zu Arbeitsbeginn
• Fall 2: Bei trendbedingten Über- und Unterschreitungen muss das Überwachungsintervall für Verfahren 5 so verkürzt werden, dass eine Überschreitung der Eingriffsgrenzen verhindert wird.
• Fall 3: Bei fortwährenden Über- oder Unterschreitungen - trotz Optimierung des Überwachungsintervalls - muss die Messeinrichtung verbessert werden.
• Fall 4: Kleinste Toleranzen können eine Prüfung des Messprozesses grundsätzlich vor jeder Messung erfordern. Die Messbeständigkeitsprüfung entfällt dann.
Attributive Messsystemanalyse für die Beurteilung von Prüflehren:
• Zur Überprüfung von Lehren werden nach dem „Measurement Systems Analysis. Reference Manual. Fourth Edition. June 2010“ (MSA4) eine ausreichend große Anzahl von Teilen zufällig dem Prozess entnommen
• Teile sollten so gewählt werden, dass die ganze Merkmalstoleranz überdeckt und überschritten wird
• Teile, die in der Zone II liegen, sind bei der Prüfung attributiver Messsysteme von besonderem Interesse. Zone II wird mit zunehmender Prozessfähigkeit schmaler.
• Stichprobe wird in Abhängigkeit der Prozessfähigkeit bestimmt. Dabei sollte „Ein möglichst großer Teil der Stichprobe nahe der Spezifikationsgrenzen liegen“.
Methoden der Datenanalyse:
• Hypothesentest(Kreuztabellen-Methode)
• Signalerkennung
• Leistungskurve des Messsystems (gage performance curve)
Vorteile der Messsystemanalyse MSA:
• Für alle Prüfprozesse anwendbar
• Keine speziellen messtechnischen Kenntnisse notwendig
• Auswertungen sind überschaubar komplex. Sie lassen sich relativ leicht mit Rechenhilfen wie Excel oder Statistiksoftware abbilden.
• Es entsteht ein großer Aufwand für die Durchführung der Experimente.
• Jede getroffene Aussage gilt nur für die Bedingungen, die bei der Durchführung der Experimente geherrscht haben.
• Im Fall der Nichtfähigkeit, erhält der Anwender keine gute Unterstützung, da die Streuungen einzelnen Einflussgrößen nicht zweifelsfrei zugeordnet werden können.
• Die Verfahren haben keinen Zugang in die metrologische Normung gefunden, sie bleiben somit eine Branchenlösung Automotive.
MSA 4 ist eine Software zur Durchführung der Messsystemanalyse (MSA) bzw. Messmittel-Fähigkeitsanalyse oder Prüfmittel-Fähigkeitsanalyse bezeichnet die Analyse der Fähigkeit von Messmitteln und kompletten Messsystemen.
Ziel ist es, die richtige Aussage über die Eignung des untersuchten Messsystems zu treffen. Unsere Prüfverfahren sowie die Berechnungen unserer Anwendung basieren auf "Measurement Systems Analysis - Reference Manual – Fourth Edition" herausgegeben 2010 von der Automotive Industry Action Group (AIAG), (Chrysler Group LLC, Ford Motor Company und General Motors Corporation.
Anders als andere Lösungsansätze, wie z.B.. Excel Arbeitsblätter, setzen wir auf eine kostenlose Web-basierte Anwendung, die mit einfacher, intuitiver Handhabung Ihnen ein effektives Werkzeug sein will.
Seit 1982 entwickeln wir Software in den Bereichen Qualtiätsmanagement und Messtechnik. Durch die Konzentration auf (mess-)technische Nischen sind wir heute Spezialisten für eine Reihe von Softwareanwendungen, die dem Anwender die Umsetzung spezieller Aufgaben ermöglichen oder erleichtern.
Wir nutzen leistungsfähige Datenbanken, modernste Entwicklungswerkzeuge und sind seit Jahren auch mit Internet-Anwendungen am Markt, die dem Anwender in bestimmten Bereichen erhebliche Vorteile bieten.
MSA4 - A Service by Kistner Metrologie Service GmbH
Kistner Metrologie Service GmbH
Tottenheimerstraße 5
D-97944 Boxberg-Unterschüpf
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