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DataLyzer Spectrum Gage Management

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1. Serial Port to Test The Serial port to test area includes a pull down list for specifying which RS 232 port will be used for testing Timeout Use the Timeout field to enter the number of seconds the template will wait for an RS 232 string ne DataLyzer Spectrum Gage Management from the instrument Clear Button The CLEAR button clears the window Message The Message field allows DataLyzer Spectrum Gage Management software to report messages about the transmission being received Messages such as reading complete or time out error may display in this field Analog to Digital The Analog to Digital area allows you to high and low master the gage and set the software to do an automatic interpolation Use a large and small master gage block or other standard for this test The procedure 1 Enter the dimensional size of your high master in the high master field 2 Enter the dimensional size of your low master in the low master field 3 Position your cursor in the high gage reading field then put your high master into the gage and transmit a value to the software using the MASTER HIGH button The value will transmit from the gage in terms of a number of digital segments as discussed earlier and will display in the high gage reading field 4 Position your cursor in the low gage reading field then put your low master into the gage and transmit a value to the s
2. Save amp Exit Exit Load Logo Button To select a logo to be printed on your reports press the LOAD LOGO button A Windows explorer window will then appear where you can browse and select your logo graphic file You must then mark the Include company logo on reports checkbox for the logo to be printed The logo graphic file path is visible in the field below the buttons If a file path is visible in this field a file is loaded for use in the reports You cannot type in this field to change the path It must be unloaded and reloaded to be changed Unload Button To remove the logo that is currently loaded for use in the reports header press the UNLOAD button View Logo Button Use the VIEW LOGO button to view the logo graphic you selected This feature will only be accessible if your logo has already been loaded Include Company Logo on Reports Checkbox If you have loaded a logo graphic file you must check the Include company logo on reports checkbox to print the logo on all supported reports This feature will only be accessible if your logo has already been loaded Include Company Name on Reports Checkbox If this check box is marked the text entered in the company name field on the Identity tab will print as an additional title line at the top of each report Checking this box will apply this feature to all supported reports Logo Width mm You can resize the logo graphic
3. OK Button The OK button will close the window System Information Button The SYSTEM INFORMATION button will open the Microsoft System Information window for your computer Send Error Log Button The SEND ERROR LOG button will appear on the About DataLyzer window if an error has occurred and an error log was created by the system and exists in the Spectrum program folder Press this button to send the error log via e mail to our technical support department You must have access to the internet to use this feature but no e mail privileges are necessary 134 DataLyzer Spectrum Gage Management 9 9 1 9 2 Appendices Appendix A Computer Requirements Computer Requirements Item CPU RAM Graphics Operating System RS 232 or USB ports CD ROM Drive Mass Storage Uninterruptible power supply UPS Minimum for use with Microsoft Access Database Pentium 233 MHz 128 MB VGA 800x600 Windows 98 Required for Gage I F Required 1 GB minimum Minimum for use with Microsoft SQL Server or Oracle Databases Pentium 3 256 MB VGA 800x600 Windows 98 Required for Gage l F Required 1 GB minimum Comport gage drivers are user configurable through the software The operating system allows as many as two comports to be used simultaneously Appendix B Installation The DataLyzer Spectrum Gage Management software will operate alone or link to the DataLyzer Spect
4. Once you have set the lines per transmission correctly you may proceed defining the template with the signs see the following Reading Description fields Reading Description Fields Values for this area must be set through the CREATE TEMPLATE facility in the TEST menu Entries are visible from this screen for summary purposes only and cannot be changed using the keyboard Reading Field In some cases a gage will transmit multiple measurements at one time These fields indicate which measurement is being referenced by the measurement locator fields starting ending and sign columns These will be described later in detail Refer also to the Test Menu Create Template area for setting up a template to handle multiple readings per line Up to eight readings can be identified and used from one transmitted line no DataLyzer Spectrum Gage Management 7 12 1 Previous and Next Buttons When a multiple reading template is being used the PREVIOUS and NEXT buttons allow movement between reading locations When these buttons are used you will note the reading number of fields will change along the measurement locator fields to indicate which reading you are on and where within the string that reading is located A maximum of 64 individual measurements can be identified and used from each transmission Line Number of the Reading in the Gage Transmission The line number of the reading in the gage transmissio
5. Master Fist Master SN 112345 Tolerance 02 Nominal Bias Uncertainty Tolerance 2 001 0 0047 3 98 0 0057 0 0092 6 03 0 0007 0 0067 8 02 0 0013 0 009 9 96 0 006 0 0149 The Nominal and Bias figures are copied from the spreadsheet The Uncertainty column is a calculation of the Combined Uncertainty calculations shown above In the graphic on the right the minus and plus tolerances are shown as vertical lines For each calibration point the bias black line and Combined Uncertainty grey bar are shown If either of these are outside the tolerance limits the calibration point has status Fail Calibration Label This opens a window for printing calibration labels on A4 or similar sheets of peel off labels Select a study by clicking in its study number field in the Calibration History window The row will highlight to show it is selected Select LABEL PRINT from the FILE menu to print a calibration label for the selected study is Print calibration label fx Label Position Label Title m Fields Horizontal fi gt Calibration IV Calibration Number F Description Vertical 3 gt E V Calibration Date I Model IV Auto Increment Font IV Calibration Status I Serial Number IV Inspector TF Company Number I Gage Name IV Calibration Due Font Print Close If you have not previously printed labels using the type of label sheet click the Print Setup tab and Gage Studies
6. field Barometer Enter the barometric pressure when the study is performed in the Barometer field Notes You can use the Notes field to enter comments such as the condition or other aspects of the gage being studied 62 DataLyzer Spectrum Gage Management Instructions Button When you press the Instructions button the Measuring Instructions window will appear showing any measuring instructions and attachments that were defined on the gage s gage description window Calibration Datasets Frame This frame controls the creation and removal of Calibration Datasets A calibration dataset is a table like a spreadsheet where reference values and measurements can be entered for determining the bias throughout a measurement mode of a gage Because a cage can have more than one measurement mode e g inside diameter outside diameter depth you can have more than one calibration dataset in a calibration study When a study has one or more Calibration Datasets the study status pass fail or not set is automatically calculated from the measurements in the datasets it cannot be set manually When you add a calibration dataset the Calibration Dataset Design window opens The Dataset Table The following shows the data entry area for a typical Calibration Dataset The columns that appear are determined by the Dataset window described above Fields for user entry are white other fields show calculated results
7. for sign Once created use the TEST TEMPLATE item in the TEST menu so as not to disturb the template signs If the sign template placement is incorrect you will only get part of the measurement value through to the software during data entry A gage reading like 3 655 might come through as 655 The Up and Down Buttons The UP and DOWN buttons allow you to scroll to the transmission lines that are off the screen The Decimal Button Pressing the DECIMAL button after you take a sample string from a gage will cause each character in every line to be replaced with its ASCII decimal equivalent The ASCII values will be in square brackets This function allows you to see unprintable characters that may be in the transmission Example 1234567890 Gage transmission X 5 42mm Setup Setup Menu 113 After pressing DECIMAL 10 88 58 32 53 46 52 50 109 109 Column The columr field shows the position of the cursor within the transmission field Advanced Concept Multiple Measurement Values per Transmitted Line Some instruments transmit more than one measurement in a line To accommodate these situations without sending the same string twice overwrite each character in the measurement including the decimal point with Fs and save the template At least one space should exist between the measurements to separate them When a sign is found right in front of the measurement i e contiguous over
8. Data Menu e 5 6 enter measurements for the type of label sheet you are using After entering the measurements click the Print Label tab In the Label Position frame indicate the label on the sheet that you want to print on by clicking the Horizontal and Vertical or buttons Ifthe Auto Increment box is checked the printing position will move after a label has been printed The Label Title is printed centrally at the top of the label The Font button allows you to change the printed font for the label title The Fields frame is for selecting the information that you want to appear on the label The Font button allows you to change the printed font for this information You may need to change the font size to ensure that there is room on the label for all the selected fields Calibration Dataset Design When you add a calibration dataset the study design window opens w Calibration Study Design Calibration Points 5 Measurements for each point 2 Use Note column E Use Measurement Uncertainty column I Use Master Uncertainty column E Calibration Points Typically you will calibrate at more than one point within the gage s range to check for bias throughout its entire range called linearity Enter the desired number of calibration points typically 3 8 in the Calibration Points field Measurements for each point Enter the desired number of measurements that will be performed for each
9. How to use the Help System While you are using the DataLyzer Spectrum Gage Management System you can press F1 on the keyboard at any time to open a help screen Often this will give specific help for the area of the program you are currently using When the help screens open use the four tabs located on the left to access general areas of Help or move to individual help topics Contents offers a list of topics from which to choose Click on the topic to instantly access that section of the document You many need to click the small beside an entry to open up a list of sub topics Index allows a fast search on specific key words or phrases Search is a more general search for a word or phrase It will return all occurrences of that word or phrase in a list You can select a particular citation by double clicking an item from that list The help system will jump to that location in the help text You can broaden your search to Match similar words by checking that box below the tabs You can further refine a search by using the check box titled Search previous results Favorites allows you to save the location of a description found in the text so you can access it directly next time without searching or scrolling through the document Purpose The Purpose of the DataLyzer Spectrum Gage Management System The DataLyzer Spectrum Gage Management System was designed to assist supervisory personnel determine the credibility of measure
10. Other Supplies field User Fields 1 12 If custom user fields have been created in SETUP SYSTEM DEFINITIONS these fields will appear beneath the Other Supplies field Enter the specified information as necessary GR amp R and Calibration Menu The INSTRUCTIONS menu item opens the Instructions window in Set mode This is used to setup GR amp R and Calibration study instructions for the gage type When assigning the Gage Type to a Gage in the Gage Description window the instructions for the Gage Type can be automatically applied File Menu Save or F2 The SAVE item or pressing F2 without opening the menu saves the changes made in the Gage Type Definition window File Menu Save amp Exit or Ctrl S The SAVE amp EXIT item or pressing Ctrl S without opening the menu saves the changes made to the gage type definition and exits to the Define Gage Types catalog window File Menu Exit or Ctrl X The EXIT item or pressing Ctrl X without opening the menu closes the gage type definition window without saving changes 96 DataLyzer Spectrum Gage Management 7 5 Define Masters The DEFINE MASTERS item is provided to define master gage blocks for measuring and testing purposes When conducting accuracy or calibration studies gage measurements are compared with the known values of these standards to determine the accuracy of the gage Define Masters pel File Name ID Number MKROO
11. The Gage Suppliers setup window will then appear see here for a description of this window Once a supplier manufacturer is selected it appears in the field You can view more specific information about the supplier by clicking on the field a window containing read only information about the supplier will appear Calibration Button and Field No manual entry is allowed in the Calibration field For entry in this field use the CALIBRATION button to open the Suppliers list Note that the gage calibration option button is selected in this window allowing only predefined suppliers of that type to appear in the list for selection To select a predefined supplier s name from the list double click on it or highlight it in the list and press the SELECT Press CANCEL to exit without selecting a supplier To add a new supplier to the master list type a supplier name in the Company field and press SELECT The program will notify you that the supplier does not exist and ask if you want to create it Press YES The Gage Suppliers setup window will then appear see here for a description of this window Once a supplier is selected it appears in the field You can view more specific information about the supplier by clicking on the field a window containing read only information about the supplier will appear Recalibration Interval Enter the number of days between calibrations in the Recalibration Interval f
12. To open an existing gage type select it from the list or type its name in the Gage Type field To create a new gage enter the name of the new gage type in the gage type field OK Button Press the OK button to open the Gage Type Definition window for the new or selected gage type Delete Button To delete a gage type select it from the list or type its name in the Gage Type field and press the DELETE button Exit Button The EXIT button closes the Define Gage Types catalog and returns to the main DataLyzer Spectrum Gage Management software window Gage Type Definition Window This section describes how a Gage Type is created The Gage Type feature allows the user to o DataLyzer Spectrum Gage Management group or flag similar gages under one label or gage type There is a twofold purpose 1 It makes gage entries and studies easier to find in a large database 2 If allowed by your quality manual and auditors gage R amp R studies can be performed generalizing results from one gage to all gages in the associated gage type group To create or edit an existing gage type enter a new or existing gage type name and press OK in the Define Gage Types catalog the Gage Type Definition window will appear Any changes made in the gage type s definition window after a gage type has been selected in other areas of the program will not be applied in those areas The Gage Type
13. Trials Enter the default number of trails used when conducting a variable GR amp R study in the Trials field Parts Enter the default number of parts tested when conducting a variable GR amp R study in the Parts field Attribute Study Preferences You can set the preference configuration to match the attribute Gage R amp R study configuration you expect to use most frequently in a similar way to a variable study Re Evaluation Time Units The re evaluation period for Calibration studies and GR amp R studies can be set in days or months Set the Calibration re evaluation period for a gage in the Gage Description window Set the re evaluation 2 DataLyzer Spectrum Gage Management 7 4 period for GR amp R studies when creating a GR amp R Study Definition GR amp R calculations based on Traditionally the full spread of variation due to components measured during GR amp R studies EV AV R amp R etc was considered to be 5 15 times Sigma Standard Deviation or Estimated Standard Deviation of the component 5 15 times standard deviation represents 99 if the full spread expected assuming a normal distribution curve When 5 15 Sigma is selected in this frame deviation values calculated from the study are multiplied by 5 15 for comparison with other sigma values or tolerance When Process Variation if this is selected as the Total Variation method the standard deviation of characteristic measurements is also multiplied
14. as determined by the software Therefore when creating or editing gage supplier information it is important to remember to select all possible company types that may apply for each supplier so these suppliers can be accessed in the necessary lists The Gage Sales company type indicates the supplier being defined sells gages Gage Supplies indicates the supplier being defined is a source for gage supplies cleaners solvents tissues chemicals etc Gage Calibration indicates this company calibrates gages Gage Technical Support signifies this company supplies technical support Gage Manufacturer denotes this company manufactures gages Certifying Agency indicates the supplier does gage certifications NOTE If the supplier does certifications or calibrations their standards should be traceable to a national or international standard Use the fields in the Certification area of this window to specify the traceability information Certification Use the fields in the certification area to enter traceability information for Gage calibration and Certifying agency company types Enter the agency that certified the supplier to do its certifications in the Certifying Agency field Enter the certification number of the supplier authorizing it to do certifications in the Cert field Enter the date of the certification s expiration in the Expiration Date field The D
15. measurement values should have R or R1 in their function fields Characteristics looking for Y measurement values should have R2 in their function fields If you are only interested in one of these measurement values the whole string is processed but we overwrite only the measurement value of interest with signs In this case no R or R1 references in the characteristic function areas are not necessary The reading description area reports the line and column positions where measurements reside Zeros will appear in the fields of this area until the template has been established through the testing procedure 12 DataLyzer Spectrum Gage Management 7 12 7 Gage Template Example 3 Multiple Measurements Per Line 7 13 Example reading _ _ _X 4 379 Y 3 465 This is an example each time the gage transmits a one line ASCII string containing two measurements Elements of the transmission include three spaces transmitted at the beginning of the string shown as underlines X then a measurement value followed by another space Y and another measurement value Each space these characters occupy in the line is referred to as a column The decimal point is counted as a character So the X measurement starts in column 6 and ends in column 10 and the Y measurement starts in column 14 and ends in column 18 To get the X measurement out of
16. Fail and Not Set Certificate Scan Frame This frame provides a way to view a calibration certificate for the study Make a file of the certificate using a scanner for example a jpeg or jpg file type and store it in a known location of the computer Click the Browse button to locate the file This location will be stored in the database To view the certificate click on the Show button Advanced Mode Clicking the Advanced button reveals a tabbed section which contains more fields for the Calibration study Gage Studies Data Menu 61 File Edit Reports Calibration number 000001 Date 0770472010 Time fi 4 06 Performed by First Inspector Manufacturer Acme Calibration E FistGTFirstGaae odel Gage Type First GT Serial Number Serial No Description Desctiption 0000 Company Number Eompany No Status gt E Certificate Scan m Calibration Datasets Show Browse Add Study Details Resolution Temperature Precision VEA Humidity Range En Barometer Tee Units VE Instructions Notes Resolution Precision Range Units These fields are automatically filled in based on entries in the gage s gage description window They cannot be changed in this window Temperature Enter the ambient temperature when the study is performed in the Temperature field Humidity Enter the ambient humidity when the study is performed in the Humidity
17. This area displays characters transmitted from the gage To use this window 1 Set the com port to be used for this test using the option buttons 2 Access the READ GAGE button A countdown will begin 3 Press the transmit or print button on your gage The current template will be used and attempt to receive data from the gage Messages such as reading complete or time out error may display in the message field If the software receives anything from the gage through the template it will show up in the filtered readings area along with some additional comments supplied by the software related to the number of channels received the line number and item number in the line associated with each measurement etc lt lt lt Should have graphical eg gt gt Read Gage Button The READ GAGE button attempts to take measurements from the gage for seven seconds after which time out error will be reported in the message field Setup Setup Menu 115 OK Button The OK button saves and exits one level to the gage setup window 7 12 3 Special Menu The SPECIAL menu allows selection of several types of special gaging situations Once anything other than standard has been selected the associated window will appear for additional settings in that area Standard Unless the gage is one of the special types listed on this window the standard item should be checked in this area Single Channel A D Ana
18. Variable Group FirstCG USL foo LSL fi Study Parameters Variable Long Parameters 3 Appraisers 10 Parts 3 Trials Data Entry Method Open Sheet 7 Re evaluation required every JU Days Name The Study Definition name must be unique Gage frame If you have defined gages click the Gage button to select a gage If you have not defined any gages you can just type in the name of the gage here Ifthe gage was selected by clicking the Gage button the category of the gage will be shown variable or attribute in the frame and the Gage Type if the gage is included in a Gage Type If the gage is included in a Gage Type then GR amp R studies performed using this Study Definition can be considered as representative of all the gages in the gage type If at least one GR amp R study has Gage Details File Menu a7 been created using the Study Definition the Gage Type will become locked This means that you can only change the specified gage to another gage in the Type Characteristic frame If the program is being used in conjunction with Datalyzer Spectrum you can select a Datalyzer Part and Characteristic using the buttons in this frame Otherwise just type in Part and Characteristic names If a Datalyzer characteristic is selected the Upper and Lower specification limits will be displayed along with the category of the characteristic variable or attribute Ifthe characteristic is included in a charac
19. adjustment or repair DataLyzer Spectrum Gage Management System calibration studies support up to 20 reference points throughout the range of the gage so bias can be detected at each end of the range or the gage as well as numerous points in the middle Gage Accuracy Gage accuracy is a similar concept to calibration The graphic below shows a gage s accuracy to be the difference between the true average measurement and the gage s observed average Unlike calibration multiple measurements are required Again this study is a way of determining bias Reference Value Bias Observed Average Value Explanations Gage Stability Gage stability is the difference between a gage s observed measurement results as it measures the same standard over time Multiple measurements are taken Stability determines bias over time Stability Time 2 Time 1 Gage Linearity Gage linearity refers to accuracy of a gage throughout its measuring range Often lower end mid range and high end masters are used to test for this condition Linearity measures bias at more than one location within a measuring system s range When a gage is used heavily in one area of its measuring range it can become worn and less accurate in that range in comparison with other areas ofits range Multiple measurements are taken of the several standard sizes Reference Reference Value Value dl Bias Larger Bias Observed Observed Average A
20. transmission This field is set from the Test Create Template area This facility is only used when the sign of the measurement is not contiguous with right next to the measurement Also it is also not necessary if the measurements to be received will always be positive File Menu New Use the NEW item from the FILE menu or CTRL N from outside the menu to create a new gage driver Open Use the OPEN item from the FILE menu or CTRL O from outside the menu to open an existing gage driver Save Use the SAVE item from the FILE menu or CTRL S from outside the menu to save the current gage driver You must always save a template before you can use it to control the computer s RS Setup Setup Menu u 232 com port s Save As Use the SAVE AS item from the FILE menu to save the selected gage driver with the name you have supplied Print Use the PRINT item from the FILE menu to print the current gage driver s settings Exit Use the EXIT item from the FILE menu to exit without saving 7 12 2 Test Menu Create Template The CREATE TEMPLATE item allows data acquisition from a com port using the baud rate parity and stop bit settings of the selected gage template driver This testing process is also used to set the reading description fields of the Gage Template template window Once communication parameters are set in the Gage Template window the interface is tested using the Create T
21. 1 since there is only one range calculation K3 is 5 15 d2 where d2 is dependent on the number of parts m and g is 1 since there is only one range calculation ld2 is obtained from Table D3 Quality Control and Industrial Statistics A J Duncan Print the report using the FILE PRINT menu item Close the report preview window by using the FILE EXIT menu item Report Header The header of the report contains information about the gage used and the characteristic defining the study Statistics from the data sheet include R double bar Average of each range calculated from each part trial all appraisers all trials X bar Diff Average from each trial all averaged for each appraiser The minimum of these averages is subtracted from the maximum of these averages Ro Part Trial average maximum Part Trial average minimum range for the entire study DataLyzer Spectrum Gage Management Measurement Unit Analysis Area Repeatability Equipment Variation EV EV RxK 5 1 R from datasheet K is associated with the number of trials in the study Reproducibility Appraiser Variation AV EV parts x trials AV Xpipp K2 i X DIFF from datasheet K is associated with the number of appraisers in the study Repeatability amp Reproducibility R amp R R amp R JEV AV Part Variation PV Rp x K3 Rp from datasheet K associated with the number of parts in the study Tota
22. 10 or 100 subgroups with subgroup size 1 X amp Mr charts Data Tab The data tab produces a data table with parts measured as rows and each appraiser trial as a column This tab applies to both long variable and ANOVA studies 42 DataLyzer Spectrum Gage Management GRER Average amp Range Method X y Average Charts Individuals Charts Range amp Error Charts Statistics i E Performance Curve Part Appr 1 Appr 1 Appr 1 Appr 2 Appr 2 Appr 2 Appr 3 Appr 3 Appr 3 Trial 1 Trial 2 Trial 3 Trial 1 Trial 2 Trial 3 Trial 1 Trial 2 Trial 3 1 56 62 64 55 52 6 64 1 62 2 57 65 61 1 1 1 65 6 64 3 83 63 65 68 57 63 62 1 54 4 61 54 1 58 56 65 68 57 5 5 58 59 51 54 6 58 1 53 56 6 62 1 52 64 61 59 58 54 58 7 67 61 57 53 61 6 52 1 57 8 7 62 72 81 57 58 54 57 61 9 56 63 6 1 1 1 64 58 62 yo 9 53 54 54 58 61 61 61 68 Print m Print Exit Average Plot Tab The average plot tab applies only to ANOVA studies The purpose of the averages plot graph is to show potential differences in reproducibility between operator averages for the same part Option buttons designate which one of three graphical analyses will be displayed They include runs chart averages chart and X Y plot 5 GREER ANOVA Method E Statistics Average Plot Appraiser 1 Appraiser 2 Appraiser 3 7 08 Appraiser Averages Sr a N o N an gt 2 36
23. Define GR amp R Characteristic Groups If you are using both the DataLyzer Spectrum Gage Management System and DataLyzer Spectrum SPC software the DEFINE GR amp R CHARACTERISTC GROUPS facility is used allows you to search the shared database for characteristics with matching engineering specifications and methods of being measured These characteristics can then be grouped together so that the results from studying one of these characteristics will be applied to all characteristics in the group This type of group application is usually only done when a quality department is relatively small so that the same study appraisers would be involved in all GR amp R studies anyway lt is not recommended where the number of appraisers involved exceeds three To use this facility your DataLyzer Spectrum Gage Management System and DataLyzer Spectrum SPC software must share a database This allows the Gage Management system to read the SPC characteristic information and search for matching characteristic criteria specifications etc The database path can be checked in both programs by going to HELP ABOUT DATALYZER After selecting the DEFINE GR amp R CHARACTERISTC GROUPS item the following window will appear Characteristic Group Te Exit Delete Name field To create a new characteristic group type the name of the new group in the Name field To open an existing characteristic group select it from the list or type its
24. Enter the name or initials of the supervisor overseeing the test in the Performed by field You can type it in directly or select from a list of previously entered names by clicking the PERFORMED BY button Part Field and Button Enter the part name or part number being studied in the Part field You can type it in directly or if sharing a DataLyzer Spectrum SPC software database you can select a part from a catalog of all existing DataLyzer Spectrum parts from the SPC system complete with data group options by pressing the PART button Using the part and characteristic entry the USL and LSL can be referenced in the associated DataLyzer SPC system to allow the calculation of bias If no DataLyzer SPC system is present then you can enter the part and characteristic information for reference but you will also need to enter the USL and LSL or process variation range for a bias value to be calculated e DataLyzer Spectrum Gage Management Characteristic Field and Button Enter the characteristic being studied in the Characteristic field You can type it in directly or if sharing a DataLyzer Spectrum SPC software database you can select it from a catalog of characteristics from the selected part by pressing the CHARACTERISTIC button If no part was specified in the Part field you will first be prompted to select a part A different characteristic can be assigned to each individual gage study LSL and USL If y
25. Gage Description x Fie GR amp R Calibration Name ID FirstGTFirstG aged Gage Type First GT y Manufacturer Model Model Description Descon Category E Variable Attribute GAR Re evaluation Interval 90 Days Precision Calibration Re evaluation Interval 30 Days Range EEN Resolution Units P Serial Number Serial No Company Company Mo Date of Purchase PO er Cost a Status First Status SS Location FirstLocation 1 Gage Supplier 2 Gage Supplier i Documentation Battery Type 1 Supplies Company 2 Supplies Company ua Other Supplies N Notes NamellD The Name ID is the name given to the individual gage It will be used to identify the gage in the gage catalog The Name ID is initially defined in the gage catalog window when creating a new gage however it can be changed here Gage Type You can assign a Gage to a Gage Type by clicking on the arrow at the right hand end of the field Gage Details File Menu 31 and selecting from the dropdown list When you select a gage type you will be offered the option to automatically fill many of the fields from the corresponding entries for the Gage Type Gage Types are created in the SETUP menu of the main program window Serial Number The Serial Number is the unique serial number assigned to the gage by the manufacturer Company This field can be used to store a serial n
26. Include Atmospheric Information checkbox the Calibration Study window will include atmospheric fields such as temperature humidity and barometer Define Gage Types The DataLyzer Spectrum Gage Management System allows gage types to be defined as a typing aid during gage creation That means when you are creating a gage and declare it to be of a particular type many fields are automatically filled in from the information stored in the common gage type area Beyond that optionally GR amp R results from one gage can be applied to all gages of the same type check with your auditor before establishing this procedure Setup Setup Menu s To create a gage type select the DEFINE GAGE TYPES item from the SETUP menu The following Define Gage Types catalog window will appear Define Gage Types Gage Type Caliper Indicator Master Micrometer Delete Exit ree This window contains a catalog of all defined gage types The Master gage type is automatically created in the software Master type gages are used as masters to calibrate other gages Masters typically do not undergo GR amp R studies Since they are highly precise they are usually more expensive than in process type gaging and therefore inventorying them more frequently is wise management Master gages are usually traceable back to an off site measuring standard i e a national or international standard unit of measurement
27. Print Performance Curve Tab The purpose of a gage performance curve is to determine the probability of a measurement system Gage Studies Data Menu 43 either accepting or rejecting parts improperly using data from Long Variable and Attribute gage studies This tab applies to long and short variable studies and long attribute studies Once the amount of gage error has been determined via a gage study it is possible to calculate the probability of accepting a part of some reference value when using the gage To accomplish this the assumption is made that repeatability and reproducibility are normally distributed with some variance s2 The gage performance curve provides a graphical method of communicating how well the measurement system is discriminating good parts from bad parts as the measurements approach the decision points at the upper and lower specs GRER Average amp Range Method Average Charts Individuals Charts Range amp Error Charts Statistics Data J Performance Curve Performance Curve GRR 6 Bias l 0 00 BERN 2 o 2 e 2 o e Gi S 5 S a 5 ce Part Measurements Probability ofAcceptance A 15 es vo B 4 5 o h o a re 5 Referen FA Print Pin Ext The graph contains x and y axes The x axis along the bottom contains values as reflected by the measurement system The y axis relates to the percent confidence Sp
28. The average of all the measurements for the calibration point Bias calculated Average minus Nominal Meas U calculated Uncertainty of measurements 2 times the standard deviation of measurements for the calibration point Master U This column is for any additional uncertainty you might know about uncertainty of Nominal value for example Status calculated Not set dark grey some values for the calibration point are missing Fail if Bias plus Total Uncertainty is greater than positive tolerance OR Bias minus Total Uncertainty is lower than negative tolerance Pass if Bias plus Total Uncertainty is less than positive tolerance AND Bias minus Total Uncertainty is greater than negative tolerance Total Uncertainty Square root of Meas U squared plus Master U squared If the Meas U or Master U column is not showing in the table the relevant value is taken as zero Note Status for the whole study is Fail if any calibration point in any calibration dataset is Fail Status for the study is Pass if all calibration points in all calibration datasets are Pass If data is incomplete and no calibration points are Fail then the status for the study is Not Set Graph Click the Graph button with the mouse and hold down the left mouse key This shows a simple graphic of the results for each calibration point e DataLyzer Spectrum Gage Management 5 5 Study Details Outside Diameter Title Outside Diameter A O o 9 02
29. When the DataLyzer Spectrum Gage Management System is run the user can be warned if a gage is due for calibration or a defined GRR study is due to be repeated This feature is enabled in the Preferences window Basic Steps for Use Basic steps for calibration studies 1 Define Gage same definition as used for GR amp R studies 2 Define master if master reference blocks are used 3 Enter calibration data 4 Print report s governed and enhanced by certain preferences and options Basic steps for gage repeatability and reproducibility GR amp R studies 1 Optional Define Gage assuming it was not already defined for calibration studies above 2 Optional Define GR amp R Study Definition and define preferences for studies 3 Create a new GRR Study choose a Study Definition or set parameters for the individual study 4 Enter gage R amp R data 5 Print reports The Setup menu allows you to define optional conveniences for use throughout the DataLyzer Spectrum Gage Management System e The DEFINE GAGE TYPES item can be used to create a prototype gage of a given type Introduction 11 Afterwards when you create a new gage and indicate that it is a specific gage type fields in the Gage Description window can be automatically completed based on the information entered for the gage type The DEFINE MASTERS item allows you to define master or known gage blocks to use as a measurement reference in calibration
30. amp Name PartOne Gage Name 0 1 caliper Study Date 5 16 2008 Characteristic varcharl Gage No 8876M09 Performed By KRE Specifications 0 10 Gage Type caliper User Field 1 From data sheet 2 0000 Ramer 0 2000 Rp 0 8889 Measurement Unit Analysis Total Variation TY Repeatability Equipment Variation EV Trias Kaf 0 00 eve EV RAxK 20000 305 2 ae 100 6 1000 6 2577 6 1000 f 4 2 50 97 32 Reproducibility Appraiser Variation AV Appraisers Ka ZAV 100 AV TV 0 0000 r Number of Trials N UR EV 2 3 65 ae 3 270 a Y 0 2000 2702 6 100027 10x3 A 20 A Repeatability amp Reproducibility R amp A Pans R amp R 100 R amp R TV R amp R Y EV AV 6 1000 0 0000 6 1000 100 6 1000 6 2677 Part Variation P 97 32 PV RpxK 0 9989x 1 62 1 4400 ZPV 100 PV TV 100 1 4400 6 2677 22 98 Y 6 10007 1 44002 6 2677 Total Variation TV TV Y R amp R Py All calculations are based upon predicting 5 15 sigma 99 0 of the area under the normal distribution curve K1 is 5 15 d2 where d2 is dependent on the number of trials m and the number of parts times the number of appraisers g which is lassumed to be greater than 15 AV If a negative value is calculated under the square root sign the appraiser variation AV defaults to zero 0 K2 is 5 15 d2 where d2 is dependent on the number of appraisers m and g is
31. and sends you back to the gage setup window Use fixed length lines Length To use the use fixed length lines option mark the check box and set the number of characters allowed in each line to be accepted from the buffer This option is only used when the strings have no discernible line terminator This setting supersedes the line terminator designation on the opening gage setup screen Accept short input lines The accept short lines option allows the program to attempt to process gage readings even when the defined template extends beyond the end of the string received If the template has signs in positions 1 through 8 and the transmission received is only 4 characters long normally this transmission would be discarded as an error However with this button selected the program will 122 DataLyzer Spectrum Gage Management attempt to evaluate the characters received Test Reading Timeout The test reading time out feature allows setting the number of seconds to accept data during use of the communication test window Seven seconds is the default Seconds before timeout The Seconds before timeout option is provided for gages that may take more than seven seconds to run a test where the gage is across the room or any scenario where it is difficult to send a sample reading in the default time Delay between lines 1 10 second When a gage sends multiple lines the program assumes that they will be sent one aft
32. any order The By Trial method can be used with long or short variable and short attribute studies Using this method all entries are made in one appraiser trial at a time column by column Data entry is organized by trial and must be entered in the order prompted by the system The Randomized method can be used with long or short variable and short attribute studies For valid results this method must be used for long variable studies using the ANOVA calculation method Data Entry Method and Data Spreadsheet All Gage R amp R studies should be done blind i e organize the samples but do not mark them so that on subsequent trials the appraiser can not keep track of previous measurements on the same samples Keep samples organized out of sight of the appraiser so a specific pattern of trials can be followed The selection of data entry method study type calculation method for attribute gages number of appraisers trials and parts will affect how the data spreadsheet will appear When using Randomized By Trial or Open sheet methods once data entry is complete data can be viewed in the data tab under ANALYZE ANALYSIS TOOLS in the Gage Repeatability amp Reproducibility Study window or data can be viewed after calculations are complete by saving and exiting the gage study and then reviewing the study by using the EDIT REVIEW STUDY button in the GR amp R History window If data needs t
33. define the study Location The Location column shows the location where the study was performed Master Value The Master Value column shows master value of the standard being measured Average The Average column shows the average value of the readings taken by the gage Bias 28 DataLyzer Spectrum Gage Management The Bias column shows the difference between the master value and the observed average New Study Button The NEW STUDY button creates a new study An empty form is displayed ready for data entry See the Bias Data Window description for more information regarding data entry into this form Edit Review Study Button The EDIT REVIEW button opens an existing study for editing or review Select a study by clicking in its study date field Its row will highlight to show it is selected Press the EDIT REVIEW button to open the selected study See the Bias Data Window description for more information regarding the study window Exit Button The EXIT button closes the study history window and retums to the main DataLyzer Gages window DataLyzer Spectrum Gage Management 4 Gage Details File Menu Select items from the File menu to create gages delete gages and edit gage details You can also create delete and edit GR amp R Study Definitions from the File Menu 4 1 Gage Description If you select New Gage or Open Gage from the File menu the Gage Description window opens
34. display when typed When using literals enclose them in quotation marks e g SEND P is a special character when used outside quotation marks that indicates a one second pause lt can be used between commands sent to the gage to allow the gage enough time to process each command Transmission to Prompt Gage for Reading The transmission to prompt gage for reading field is used only when a gage interface requires a particular set of characters to be transmitted to it before it will transmit each measurement Enter the necessary set of characters in this field When a gage driver is assigned that contains a transmission to prompt gage for reading during data entry a small button will appear in the data entry window This button will contain a label of Gage1 Gage 2 etc These labels correspond to the com port to which the associated gage driver is assigned Press the screen button to cause a measurement to be transmitted by the gage You can use ASCII characters or literals as entries for this field When using ASCII characters enter the associated ASCII number separated by commas for any characters such as carriage return and line feed e g 13 10 that do not display when typed When using literals enclose the word in quotation marks e g SEND P is a special character that when used outside quotation marks indicates a one second pause lt can be used between commands sent to the gage to allow
35. first create and set up your ODBC connections Look in the SQL Docs folder under the program folder for installation documents CreatingSpectrumDBSQLSeneer or CreatingSpectrumDBSQLServer2K SettingUpSpectrumWithSQLServer CreatingSpectrumDB Oraclev8 or CreatingSpectrumDBOraclev9 SettingUpSpectrumWithOracle or 94SettingUpSpectrumWithOracle Follow the instructions in these documents to create and set up your ODBC connections then install the Gage Management System software using the instructions below Installation Instructions Insert the DataLyzer Spectrum Gage Management CD into your CD drive The Setup program will run automatically after a few seconds if not run the setup exe program from the CD The Setup program will prompt you through the installation procedure Almost all users should use the Typical option for installation Index A Additional Reports 85 B Basic Concepts 14 Bias History 27 Bias studies 19 Bias Study 67 C Calibration 18 Calibration amp GR amp R Due 82 Calibration Certificate 81 Calibration Dataset Design 65 Calibration History 23 Calibration Label 64 Calibration Study 59 Com Port Assignments 126 D Define Gage Types 92 Define GR amp R Characteristic Groups 99 Define Masters 96 Ge Gage Catalog 22 Gage Description 30 Gage Interface Template 105 Gage Locations 104 Gage RR 18 Gage R amp R Performance Report 80 Gage Repeatability amp Reproducib
36. for all gages See the header fields description here for additional information File Menu Save or F2 SAVE or pressing F2 from outside the menu saves the changes made to the gage description form File Menu Save amp Exit or Ctrl S SAVE 8 EXIT or pressing Ctrl S from outside the menu saves the changes made to the gage description form and exits the gage description window File Menu Exit or Ctrl X EXIT or pressing Ctrl X from outside the menu exits the gage description window If you have made change to any of the fields in the window you will be asked if you want to save the changes before exiting File Menu Save as Another Gage When you choose this menu option a new gage will be created with the current values in the fields You must alter the Name ID field to a unique name or number before selecting this option GR amp R Menu Instructions Opens the Instructions Window for setting the instructions and attachments to be used for Gage R amp R studies GR amp R Menu History Opens the GR amp R History Window Calibration Menu Instructions Opens the Instructions Window for setting the instructions and attachments to be used for Calibration studies Calibration Menu History Opens the Calibration History Window a DataLyzer Spectrum Gage Management 4 2 Measuring Instructions Set The Measuring Instructions windows is in Set mode if it is opened from the Gage Description window
37. in the list To select a predefined supplier s name from the list double click on it or highlight it in the list and press the SELECT button To create a new supplier type a supplier name in the Company field and press SELECT The program will notify you that the supplier does not exist and ask if you want to create it Press YES The Gage Suppliers setup window will then appear see the description of this window Once a supplier is selected it appears in the field You can view more specific information about the supplier by clicking on the field a window containing read only information about the supplier will appear Documentation The Documentation field can be used to include the last invoice number used to purchase the gage or other documentation such as a reference to the instrument user s manuals and their location Battery Type The Battery Type field allows you to indicate what type of battery the gage requires if any 1 and 2 Supplies Company Buttons No manual entry is allowed in the 1 Supplies Company or 2 Supplies Company fields For entry in these fields use the 1 SUPPLIES COMPANY and the 2 SUPPLIES COMPANY buttons to open the Suppliers list to select or create a supplier To select a predefined suppliers name from the list double click on it or highlight it in the list and press the SELECT button Press CANCEL to exit without selecting a supplier To create a new supplier ty
38. is also available from the Reports menu Calibration History FirstGTFirstGage Serial No Study Date Performed By Calibration Due Status 000001 07 04 2010 14 06 First Inspectorzz 07 05 2010 PASS New Study Edit Review Study Exit As studies are completed results are stored in the system Summaries are displayed in spreadsheet form sorted by date time with the most recent on top Each row across in the study history window represents an individual study Each column represents key information relating to the study 24 DataLyzer Spectrum Gage Management Number Column This is a unique serial number automatically given to each study Study Date Column The Study Date column shows the date and time the study was performed Performed By The Performed By column shows the name or initials of the person who performed the study This information is taken directly from the study window as it entered the study Calibration Due This is the date when calibration must be performed again The period between calibrations is set in the Gage Description window Status The Status field shows if the study is Pass Fail or Not Set New Study Button and File Menu New Study not available from the Reports Menu The NEW STUDY button or menu item creates a new study An empty form is displayed ready for data entry See the Calibration Study Window description for more information regarding data e
39. is an example of an ASCII character string that might be transmitted from a gage or gage interface In this example there are several elements three spaces are transmitted at the beginning of the string shown as underlines X then a space a sign another space then the measurement value 4 379 Each space these characters occupy in the line is referred to as a column The decimal point is counted as a character So the X measurement starts in column 9 Setup Setup Menu 125 and ends in column 13 The sign is located in column 7 To get the X measurement out of this string automatically each time it is transmitted overwrite the X measurement value 4 379 with signs and the sign with an S This way each time the transmission is sent by the gage the software will look through this template to pick up values from these column positions Note If the sign is always transmitted right next to the measurement value with no spaces between you can use a sign to overwrite the sign making it part of the measurement value itself The reading description area reports column positions where measurement values and signs reside Zeros will appear in the fields of this area until the template has been established through the testing procedure As the signs are entered in the template the software picks up their column positions and fills in the column fields automatic
40. line terminator use the ASCII character 44 for the comma character Using a line terminator is the most commonly used technique however there is an alternative that can be used in certain situations which is using fixed line length described later Lines Per Transmission Received from The Gage The lines per transmission received from the gage field is used to enter the number of lines the gage will send each time it transmits See the gage s operating manual for this information This feature relates to the previously described line terminator item Remember that the default line termination character is carriage return If it is not clear exactly how many lines are transmitted it may be necessary to use the CREATE TEMPLATE item in the TEST menu to take test transmission s that displays the number of lines being transmitted To do this set the number of lines to a large number such as 8 or 10 and read the gage You ll be able to see five lines at a time By taking a test string and waiting for timeout the software will report how many lines were received from the gage the maximum being the number of lines set in this field A field will appear next to the word transmission that will report how many actual lines were received from the gage then you can go back and adjust the number of lines per transmission accordingly Save the template and then enter the actual number of lines received in the gage template window
41. menu saves the changes made or data entered to the study File Menu Save Exit or Ctrl S The SAVE amp EXIT item or pressing Ctrl S without opening the menu saves the changes made or data entered to the study and closes the study window File Menu Exit The EXIT item closes the study window without saving any entered data or changes Analyze Menu Preview or F5 The PREVIEW item or pressing F5 without opening the menu will open a report preview window for the current study A full description of the report can be found in Reports Menu You can PRINT or EXIT the report from the FILE menu in this window s DataLyzer Spectrum Gage Management Analyze Menu Analysis Tools or F6 This opens the Analysis Tools window 5 3 GR amp R Report Definition This window appears if you attempt to print from the GR amp R Analysis Tools window and none of the tabs have the Print checkbox checked Gage R amp amp R Report Definition Data Table Graphics Average Plot Charts Individuals Charts Range amp Error Charts Performance Curve Print Select All Exit Select the aspects of the report you wish to print You will build a report by checking all items to be included in the report Each check box will cause an associated set of information up to 1 2 page in size to be included in the printed report Therefore if all the sections are selected the report will be about three pages
42. of Trials and Number of Parts fields The following list contains recommended values for the fields for each type of GR amp R study Some values are set and locked by the software as indicated to force the study to conform to generally accepted rules 38 DataLyzer Spectrum Gage Management a Variable Gage Study Attribute Gage Study Copas Tae Fans sopas Trae rm Number of Appraisers Enter the number of operators to be included in the study in the Number of Appraisers field In certain study types the number of appraisers is set and locked by the software See the table above for the number of appraisers recommended or allowed for the different study types Study validity depends on these appraisers being the same individuals who ordinarily measure production parts Number of Parts Enter the number of sample parts to be measured in the Number of Parts field In certain study types the number of parts is set and locked by the software See the table above for the number of parts recommended or allowed for the different study types Number of Trials Enter the number of trials to be included in the study in the Number of Trials field Trial refers to the number of times a set of samples are measured In certain study types the number of trials is set and locked by the software See the table above for the number of trials recommended or allowed for the different study types Stu
43. on initialization If a gage sends initialization information on start up it will need to be cleared from the buffer or it will be treated as a reading transmission and erroneous readings will be displayed on the screen Select this option to clear this information before starting normal gage entries Clear buffer after each reading This facility was originally developed for Microvu optical comparators It allows one reading or part of a string to be accepted and processed then the buffer is cleared and another string can be accepted without portions of the previous string remaining in the buffer Turn debug mode on This mode intercepts gage transmissions and reports back the trigger that caused the transmission and the contents of the buffer See also RS 232 options window and Appendix K for event codes that may be returned Setup Setup Menu 123 Special Modes The GagePort TM Computer mode check box allows the DataLyzer Spectrum Gage Management software to send special codes to the GagePort to pull data from it on demand This mode causes a gage button to appear on the data entry window The button will be numbered corresponding to the computer s com port number where it is connected This GagePort Computer Mode is usually used in combination with the multichannel mode This allows the gage button to access each channel of the GagePort independently E g for GP channel A you set the multi channel prompt to send the GP
44. or mask mentioned earlier 4 Once the driver is created you must assign it permanently to the com port where the instrument is connected Com port assignments during template tests are temporary DataLyzer International Inc always recommends purchasing the RS 232 connecting cable directly from the gage or interface manufacturer to eliminate any cable problems The RS 232 cable between the gage and the computer must be pinned correctly If the individual conductors inside the RS 232cable are not connected to the correct pins at each end communication will be impossible and valuable time will be wasted during system implementation Note about USB communication support The DataLyzer system supports RS 232 communication for up to four com ports com 1 and 2 along with two virtual com ports for extended serial communication The virtual com ports are often used for supporting USB to RS 232 conversion cable systems where separate software is installed to make a USB port emulate a com port or for metaframe serial communication under systems like Citrix or Microsoft s Terminal Services Gage interfaces that are already completely USB compatible require no RS 232 conversion and therefore do not require the use of the gage template system e g Mitutoyo 264 012 USB single gage interface In cases of USB compatible interfaces the gage assignments for the two virtual comports should be set to no gage because communication is automatically built int
45. results or the gage can be re evaluated using a more rigorous long form attribute study or the gage should be repaired or replaced Gage Studies Data Menu 53 Number of Appraisers Enter the number of operators to be included in the study in the Number of Appraisers field In certain study types the number of appraisers is set and locked by the software See the table above for the number of appraisers recommended or allowed for the different study types Study validity depends on these appraisers being the same individuals who ordinarily measure production parts Number of Parts Enter the number of sample parts to be measured in the Number of Parts field In certain study types the number of parts is set and locked by the software See the table above for the number of parts recommended or allowed for the different study types Number of Trials Enter the number of trials to be included in the study in the Number of Trials field Trial refers to the number of times a set of samples are measured In certain study types the number of trials is set and locked by the software See the table above for the number of trials recommended or allowed for the different study types Study validity depends on these trials being conducted blindly so that appraisers do not know results from previous associated trials Data Entry Method The Open Sheet method can be used with all studies The user can enter study data in
46. the changes made or data entered to the study File Menu Save amp Exit or Ctrl S The SAVE amp EXIT item or pressing Ctrl S without opening the menu saves the changes made or data entered to the study and closes the study window File Menu Exit The EXIT item closes the study window without saving any entered data or changes Reports Menu Print or F6 The PRINT item or pressing F6 without opening the menu will print the report DataLyzer Spectrum Gage Management 6 Reports Reports Menu The following procedure is used for printing Gage R amp R study Gage Calibration certificate of calibration and Performance reports Select the type of report to be printed GAGE R amp R STUDY GAGE CALIBRATION PERFORMANCE from the REPORTS menu The Gage catalog window will then appear select the desired gage from the gage catalog After you have selected a gage a history window will appear containing all studies performed for the report type selected The studies will be sorted by date and time with the most recent on top If no studies exist in the list no studies have been performed for this gage The history window that appears for printing GR amp R studies and performance reports looks like this GRER History 0 1 caliper File Study Date Type Performed By Part Characteristic Ev Ay TV Method 5 29 2008 13 22 Ecua Gage TOL PartOne varcharl 1 0 94 71 ANOVA 5 28 2008 15 41 Actu
47. 0 57 0 72 0 60 Average 0 61 0 61 0 70 0 72 0 56 0 71 0 62 0 68 0 60 Range 0 08 0 08 0 20 0 46 0 08 0 48 0 10 0 10 0 07 Appraiser 2 Trial 1 0 55 1 00 0 68 0 58 0 54 0 64 0 53 0 81 1 00 Trial 2 0 52 1 00 0 57 0 56 0 60 0 61 0 61 0 57 1 00 Trial 3 0 60 1 00 0 63 0 65 0 58 0 59 0 60 0 58 1 00 Average 0 56 1 00 0 63 0 60 0 57 0 61 0 58 0 65 1 00 Range 0 08 0 00 0 11 0 09 0 06 0 05 0 08 0 24 0 00 Appraiser 3 4 The data table can be printed using the PRINT option in the FILE menu Close the window by using the FILE EXIT menu item To copy from this window highlight the desired cells and press Ctrl C on the keyboard and then press Ctrl V to paste into a spreadsheet or other document DataLyzer Spectrum Gage Management 6 2 Gage R amp R Long Variables ANOVA The average plot tab applies only to ANOVA studies The purpose of the averages plot graph is to show potential differences in reproducibility between operator averages for the same part Option buttons designate which one of three graphical analyses will be displayed They include runs chart averages chart and X Y plot 5 GREER ANOVA Method Average Plot Statistics a a a Appraiser 1 Appraiser 2 Appraiser 3 7 08 Appraiser Averages f Ea a N N w a J Print Reports Reports Menu 77 6 3 Gage R amp R Short Variables The preview window for short variable GR amp R studies don
48. 0 8 0 7 0 6 2 0 5 0 4 0 3 0 2 0 1 0 0 0 427 0 434 0 455 0 462 0 469 0 441 0 448 oO Lo N D o 2 e P in DQ D 2 oa a mm ise tiz m mm o o o o o ao g mim Eight parts must be selected each with a unique size The largest and smallest can pass 100 and fail 100 but the other parts must not pass the gage system 100 The gage must sometimes accept and other times reject these parts during the 20 trials The probability of accepting each size is calculated a number of accepted parts from the 20 measured m number of parts measured of that size m a 5 m Probability of acceptance if a m lt 5 a 0 These are the values in the P column Probability of acceptance if a m gt 5 a 20 These are the values in the P column 5 Probability of acceptance if a m 5 These are the values in the P column Reports Reports Menu 6 5 X atP 995 X at P 005 Bias Bias Lower Limit X at P 5 Repeatability To calculate whether the bias is significantly different than zero _ 31 3 x Bias Repeatability Compare this result with the critical value in t distribution table for 025 or 975 and number of samples you are testing minus 1 degrees of freedom Ifthe calculated t value for this study is greater than the critical t value found in the table then bias in this study is significant Gage R amp R Short Attribute The previe
49. 20001 length ref Serial Number 25mm 2mm Manufacturer Mitutoyo Belgium NY Calibration Eaim s S Recalibration Interval fasso Days Date of Purchase 11 09 1992 Cost 280 00 Status Location Documentation Supplies Company Other Supplies Notes Set bestaat uit volgende lengtes 2 5mm 890791 5 1mm 890204 7 7mm 900051 Last Calibration Date 27 09 2005 09 curent Name ID Number The Name ID field is automatically filled in with the name entered in the previous Gage Catalog window The name can be edited or changed Serial Number In the Serial Number field enter the serial number of the master if it exists for traceability purposes Manufacturer Button and Field No manual entry is allowed in the Manufacturer field For entry in this field use the Setup Setup Menu er MANUFACTURER button to open the Suppliers list to select or create a manufacturer Note that the manufacturer option button is selected in this window allowing predefined suppliers to be selected from a list To select a manufacturer from the list double click it or highlight it in the list and press the SELECT button Press CANCEL to exit without selecting a supplier To add a new manufacturer to the master list type a supplier name in the Company field and press SELECT The program will notify you that the supplier does not exist and ask if you want to create it Press YES
50. A A in this command represents the channel number on the GagePort Checking the GagePort Computer Mode box causes the program to send the other command required in the GagePort s sequence automatically You do not need to enter the As anywhere RS 232 Options 5 RS 232 Options Handshaking geonsnnsnnsunennennnunenn M ATS CTS MW DSR DTR XON XOFF Communication Events Reject all hardware triggers C Ignore all hardware triggers C Allow all hardware triggers Framing Errors Reject all framing errors Ignore all framing errors C Allow all framing errors Save Cancel The SAVE button stores the data and sends you back to the gage setup window The CANCEL button cancels any changes made and sends you back to the gage setup window Handshaking The standard handshaking uses RTS CTS and DSR DTR If the owners manual of your instrument indicates XON XOFF protocol that can be used by checking the XON XOFF box and unchecking the others Refer to the owner s manual for your gage for the specific communication handshake Communication Events The Communication Events are typically related to conditions with cabling 124 DataLyzer Spectrum Gage Management 7 12 5 Reject all hardware triggers default The Reject all hardware triggers option away all data in the com buffer if other than trigger 2 com event is received Trigger 2 com event means the acceptable number of cha
51. Definition window looks like this Gage Type Definition BAX Fie GR amp R Calibration Category ts G GAR Re evaluation Interval Days Precision Calibration Re evaluation Interval Days Range Manufacturer 1 Gage Supplier 2 Gage Supplier Documentation Battery Type 1 Supplies Company 2 Supplies Company Other Supplies Category Use the Variable or Attribute option buttons to select whether the gage type is for variable or attribute go no go gages GRR Re evaluation Interval Days Enter the number of days between GR amp R studies in the GRR Re evaluation Interval field This is often dictated by the organization s quality manual or procedures Calibration Re evaluation Interval Days Enter the number of days between calibration studies in the Calibration Re evaluation Interval field This is often dictated by the organization s quality manual or procedures Precision Enter the smallest interval the gage can measure in the Precision field Range Enter the range between the smallest and the largest sizes measurable by the gage in the Range field Manufacturer 1 Gage Supplier 2 Gage Supplier 1 Supplies Company 2 Supplies Company Buttons and Fields No manual entry is allowed in the Manufacturer 1 Gage Supplier 2 Gage Supplier 1 Setup Setup Menu as Suppli
52. EV Equipment Variation field represent the variation in the measurement process associated with the gaging equipment itself presented as a percentage of Total Variation TV AV Appraiser Variation Appraiser variation AV gage reproducibility The values in the AV Appraiser Variation field represent the variation in the measurements between personnel using the gaging system presented as a percentage of Total Variation TV RR Repeatability and Reproducibility Repeatability and Reproducibility is the combined variation due to EV and AV presented as a percentage of Total Variation TV The RR field will turn green for pass or red for fail after the study is completed Set the pass level in the Preferences window The total variation TV method used in the above calculation is set in the GR amp R Study Method The method column displays the method used for the study e g long variable short attribute etc New Study Button and File Menu New Study The NEW STUDY button or menu item creates a new study You are first prompted to select a Study Definition If you want to start a GR amp R study that is not based on a Study Definition select none An empty form then is displayed ready for data entry See Gage R amp R Study section for more information regarding data entry into this form Edit Button and File Menu The EDIT button or menu item opens an existing study for editing or review Sel
53. FILE PRINT menu item Close the history window by using the EXIT button or FILE EXIT menu item To copy from this preview window highlight the desired cells and press Ctrl C on the keyboard and then press Ctrl V to paste into a spreadsheet or other document 6 10 Supplier Summary A supplier summary report is a list of all suppliers in the database along with attending information The following procedure is used for printing a supplier summary report Select the SUPPLIER SUMMARY item from the REPORTS menu A scrollable preview report will be displayed It will look similar to this amp Supplier Summary Report Jog File Company Name 1234 Gage Company Type Gage Supplies Address 999 Main Street Contact 1 Tina Thompson Title Sales Phone 555 888 4848 Contact 2 Title Phone Company Name ABC Gage Company Type Gage Sales Supplies Technical Support Address 1111 2nd Street Contact 1 Bob Smith Title Sales Phone 555 555 0002 Contact 2 Julie Miller Title Support Phone 555 555 0001 4 N om The suppliers will be sorted alphanumerically Print or exit the report using the options in the FILE menu Reports Reports Menu s 6 11 Additional Reports Several additional reports are available via the analyze menu in the Gage R amp R Study windows under the main program window s data menu Most of these graphical tools relate to long variable and ANOVA studies with the exception of the perform
54. Study Definition can be considered as representative of all the characteristics in the group If one or more GR amp R studies has been stored using the Study Definition the characteristic group will become locked This means that you can only change the specified characteristic to another characteristic in the group Ifthe program is not being used in conjunction with Datalyzer Spectrum just type in Part and Characteristic names You can enter USL and LSL manually Tolerance USL LSL is one of the Total Variation TV methods Specification limits are not necessary in short attribute studies and only one specification limit is needed for long attribute studies Saved Calculations This frame is for specifying the type of calculations ANOVA or Average and Range and total variation method that will be used for displaying results in the GR amp R History screen and reports after it is saved However you can always view analysis based on ANOVA or Average and Range with any available total variation method by selecting items in the Analyze menu Average amp Range Method Long and Short Variable Studies The Average amp Range method is the simple method used by AIAG in its SPC manual It provides results for equipment variation repeatability and appraiser variation reproducibility only It does not express interactions between appraiser variation and equipment variation ANOVA Long Variable Studies The ANOVA analys
55. Study Details Outside Diameter Title Outside Diameter Master First Master Tolerance 02 Tolerance 02 Nominal Meas1 Meas2 Meas3 Average Bias MeasU MasterU Status Ela 2 001 2 005 2 01 2 002 2 0057 0 0047 0 0081 001 Br 3 98 3 99 3 981 3 986 3 9857 0 0057 0 009 002 Eva 6 03 6 028 6 033 6 027 6 0293 0 0007 0 0064 002 _4 8 02 8 025 8 017 8 022 8 0213 0 0013 0 0081 004 5 9 96 9 97 9 965 9 963 9 966 0 006 0 0072 0 013 Title Enter a title for the dataset This title will also appear on the tab Tolerance and Enter the permitted positive and negative tolerances for the measurement mode Calculated fields in the data entry spreadsheet are displayed to two more decimal places than the number of decimal places shown in the tolerance fields For example if you set a tolerance to 0 20 calculated fields will display to four decimal points Gage Studies Data Menu e Master Button and Fields To enter a master block set in the Master Set field press the MASTER button and select a master from the list that appears The masters in this list are defined under SETUP DEFINE MASTER in the main program window Text included in the Notes field for the master will be printed on the calibration certificate Table columns Nominal The reference or known value ofthe master block or characteristic used for the calibration point Meas The gage measurement s Average calculated
56. Suppliers setup window without saving select EXIT from the FILE menu or press Ctrl X without opening the menu Gage Locations The GAGE LOCATIONS item allows you to set up a list of locations that you can expect gages to be found Setting a location for a gage is done in the Gage Description window The gage locations in the list are only suggested locations it is not it is not compulsory to choose a location from the list When you select the GAGE LOCATIONS item the following window will appear Gage Locations Ea Location Name mee ooo Blow Molding Cycle amp Barst Domestic Post Molding Domestic Winding OK Engineering Everpure Industrial Filtration Delete Industrial Post Molding Industrial Winding Lamineer Department Maintenance EM Pomp Assembly Pool Post Molding Poolfilter Assembly Preforming 04 Office Quality lab El The OK button opens the selected gage location description window The DELETE button deletes the selected gage location The EXIT button closes the Gage Locations catalog window Location Name Type the name of a new or existing storage location in the Location Name field or select an existing location name from the list to open Setup Setup Menu os 7 10 Gage Statuses and Inspectors Choosing Gage Status or Inspectors from the Setup menu opens a window like this With this window you can create a new Gage Status or Inspector or delete an existin
57. _ DATALYZER Ahnternati G Partners in Continuous Improvement DataLyzer Spectrum Gage Management 2010 Datalyzer International Inc Cotes 3 Table of Contents Foreword Part I Introduction 8 PUrPose u eu keller eher 8 Special Fe t reS 2 2 ns a A ii 9 Basie Steps for Use iii IR 10 Part Il Explanations 14 1 Basic CO DIS aa 14 LOCURA 18 A A O 18 4 Bias StUqICS ici a ia 19 Part Ill General Windows 22 tT Gage Catalonia 22 2 Calibration History iia 23 3 GR amp R HISOLY id 25 amp Bias ISON in ode iaa nd 27 Part IV Gage Details File Menu 30 T Gage Description sararan AE E aan ads 30 2 Measuring Instructions Set cioininrnccnonnccci rica 34 3 GREER Study Definitions sssini 36 Part V Gage Studies Data Menu 40 1T OGR amp R Analysis TOO Sii aa en in an is 40 2 Gage R amp R Study ii ar HE are Erna NARESE 48 3 GR amp R Report Definition 4u4unsnnnnnnnnnannnnnnnnnnnnnnnannnnnnnnnnnnnnnanennnnnnn nenn nenn nenn 58 A Calibration Study idas 59 5 Calibration Label seien 64 6 Calibration Dataset Design uusssnssnnsnnnennnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnsnnnnnnnsnnnnnnnsnnnnnnn nenn 65 7 Measuring Instructions Read z 44sns4s4nn0n nenn nnn nn en nnnnnn sure nenn snnenn nen snnnnsnnennnnen nenn 66 8 Bias MUAY n 67 Part VI Reports Reports Menu 72 4 DataLyzer Spectrum Gage Management 1 Gage R amp R Long Variables Average am
58. aders User Field 1 poo User Field 2 User Field 3 User Field 4 AAA User Field 5 User Field 6 User Field 7 poo User Field 8 po User Field 9 User Field 10 User Field 11 User Field 12 Save amp Exit Exit In the User Fields 1 12 enter a field label Examples of field names may include such items as line operation or manager in charge You can create user fields 1 12 depending on your company s specific needs Reports Tab The Reports tab is used to set report preferences You can add a logo change report titles and include your company name to report titles Setup Setup Menu ss System definitions Identity Reports Logo Options Logo width mm 25 4 View Logo Load Logo Unload Header Fields Report Options Include company logo on reports EASCSLOGO BMP Reports IV Include Company Name Instructions Due Date Signature line Report User Name GRASA AVERAGE amp RANGE REPORT GR amp R ANOVA REPORT GR amp R ANOVA REPORT GRR ATTRIBUTE REPORT GR amp R ATTRIBUTE REPORT GR amp R BIAS REPORT GR amp R BIAS REPORT CALIBRATION HISTORY REPORT CALIBRATION HISTORY REPORT Certificate Of Calibration Certificate Of Calibration M Include I Include I Include F Include M Include TF Include I Include F Include V Include I Include I Include I Include I Include X F Include E Include
59. age Type Serial Number Active Location Storage Location Due Date LastDate Active 1 Presioe2 cae 836787 Lab1 Storage2 6 20 2008 5 6 2008 Yes 2 attgage caliper 53334 Lab Storage 6 27 2008 5 28 2008 Yes 3 0 1 caliper caliper 8876M09 Lab Storage 7 10 2008 6 10 2008 Yes 4 gage Unknown Type 988547 Labl Storage2 New Gage NewGage Yes 5 gagel Unknown Type 0977MT7 Lab Storagel NewGage NewGage Yes 6 1 2caliper Unknown Type 14443222 Lab Storagel NewGage NewGage Yes The gages in the list will appear in descending order based on the due date Each gage listed will include the number name type serial number active and storage locations and active status as defined in the gage description window The last date column shows the date a study was last performed for the gage The number of days entered in the re evaluation intervals fields in the gage description window are added to the last date to determine the due date for the next study Print the list by using the PRINT option in the FILE menu To copy from this preview window highlight the desired cells and press Ctrl C on the keyboard and then press Ctrl V to paste into a spreadsheet or other document GR amp R and Calibration Histories The following procedure is used for printing GR amp R and Calibration History reports Select the desired report type GR amp R HISTORY CALIBRATION HISTORY from the REPORTS menu The Gage catalog wind
60. age transmission 1 Starting column of reading in line Ending column of reading in line iil Sign column of reading in line 108 DataLyzer Spectrum Gage Management Port Settings Refer to the user s manual of your RS 232 gage or multiplexing interface for information regarding its baud rate parity data bits and stop bits Set the port settings fields to match Defaults are 9600 baud no parity eight data bits one stop bit Ordinarily gage communication works on a push system where a transmit button is pressed and the gage sends a measurement however as DataLyzer products have matured features have been developed to handle certain specific situations Transmission to Initialize Gage The transmission to initialize gage field is only used when a gage interface requires a particular set of characters to wake it up or when the gage must receive a specific command to set it into a mode for sending data This transmission from the computer to the gage is typically only required once per session Refer to the gage manufacturer s operating manual and enter the necessary set of characters in this field Ifthe gage requires no initialization message leave this field blank You can use ASCII characters or literals as entries for this field When using ASCII characters enter the associated ASCII number separated by commas for any characters such as carriage return and line feed e g 13 10 that do not
61. al Gage 1 0 95 73 Long 5 28 2008 15 13 Actual Gage widget2000 weight 1 0 81 64 Long 5 16 2008 11 54 Actual Gage KRE PartOne varcharl 1 D 97 30 Long 5 16 2008 10 59 Actual Gage TOL 1 0 1213 Long 5 16 2008 10 31 Actual Gage PYM widget thickness 0 970 0 000 96 84 Long 5 14 2008 15 09 Actual Gage KRE widget2 length 0 000 0 350 34 89 Short 5 14 2008 14 53 Actual Gage KRE widget2 length 0 9500 0 0000 95 07 ANOVA 5 6 2008 11 21 Actual Gage MTL widget width 092 000 91 71 Long Preview Print The history window that appears for printing calibration reports looks like this g Calibration History 0 1 caliper File Study Date Performed By Master Set Status ey 5 16 2008 13 34 Pass Preview Print The spreadsheet areas of these windows are described in Chapter 4 Data Select the desired study by clicking on it You can then print the study using the PRINT button or FILE PRINT menu item You can preview the study using the PREVIEW button or FILE PREVIEW menu item Close the history window by using the EXIT button or FILE EXIT menu item Reports Reports Menu 73 6 1 Gage R amp R Long Variables Average amp Range The preview window for long variable GR amp R studies done using the average amp range calculation method looks like this GRER Report File Variables Stephen Computer Services Inc GR amp R AVERAGE amp RANGE REPORT Part No
62. ally You must use the TEST CREATE TEMPLATE area to cause the column fields to be filled in 7 12 6 Gage Template Example 2 Multi Line Example reading _ _ _X 4 379 _ _Y 3 465 In this example each time the gage transmits it sends an ASCII character string with two lines Elements of the transmission include three spaces at the beginning of the string shown as underlines X then a measurement value An invisible carriage return line feed also exists at the end of the first line The second line includes three spaces Y and another measurement value Each space these characters occupy in their respective lines is referred to as a column The decimal point is counted as a character So the X measurement starts in column 6 and ends in column 10 of line 1 and the Y measurement starts in column 6 and ends in column 10 of line 2 To get the X measurement out of this string automatically each time it is transmitted overwrite the X measurement value 4 379 with signs Similarly the Y measurement should be overwritten with signs This way each time the transmission is sent by the gage the software will use this template to look in these line and column positions for input values When templates of this type are used the reading number of the transmission must be referenced in the FUNCTION area of each characteristic Characteristics looking for X
63. ance curve which also applies to long attribute studies These facilities are not available from the reports menu but are informational reporting type resources so we have referenced them here These analyses are intended to provide different views of data and calculations to reveal measurement problems more clearly The following graphic example shows one of the analyses available along with the tabs to access others The print checkbox on each tab allows you to select that analysis for inclusion on the report GRER Average amp Range Method Statistics 1 Data Ri Pestormence Curve Average Charts 1 Individuals Charts Y Range amp Eno Charts Chart Type C Run Chart C XY Plot Averages Chart za Appraiser 3 DataLyzer Spectrum Gage Management 7 7 1 Setup Setup Menu System Definitions The SYSTEM DEFINITIONS item brings up a window that contains three different tabs All three tabs use the following buttons Save 8 Exit Button The SAVE amp EXIT button saves the information and closes the System Definitions window Exit Button The EXIT button closes the System Definitions window Header Fields Tab The Header Fields tab allows you to define up to 12 custom fields for use elsewhere in the program They appear when creating gages gage types masters and in certain reports System definitions xi Identity Reports i File Viewers Gage Description He
64. and accuracy studies The DEFINE GR amp R CHARACTERISTIC GROUPS item links the DataLyzer Spectrum Gage Management System with the DataLyzer Spectrum SPC program and allows you to create groups of characteristics with similar specifications for easy measuring characteristic selection Using SYSTEM DEFINITIONS you can create custom fields that will be included in the Gage Description window and on reports These fields may be used to store and display additional information that is not already defined in the DataLyzer Spectrum Gage Management System You can also use this item to modify report titles add a logo and or your company name to reports e Use PREFERENCES to set default settings for GR amp R studies The SUPPLIER items allow you to manage the gage supplier entries Create edit or delete various types of gage supply companies Maintain information such as shipping address costs service records etc for several categories of supplier These records allow quick reference in case the measurement instrument needs service or replacement The GAGE LOCATIONS item allows you to define and catalog locations for gages e The GAGE STATUSES item allows you to define statuses to apply to your gages The Inspectors item allows you to list the inspectors that will supervise GR amp R and calibration studies The GAGE INTERFACE TEMPLATE item is used to create and test gage templates for your specific gages Use the COM PORT ASSIGNMENTS item to e
65. as the difference between the master value and the observed average The percent bias is defined as 100 bias au process variation Bias studies do not draw conclusions regarding pass fail like calibration studies Because bias studies use an average of observed measurements rather than the one observed measurement at each calibration point they may be considered more thorough than calibration studies Bias studies also consider only one master one calibration point while calibration studies often use multiple masters at multiple calibration points So if a calibration fails at one calibration point the bias at that point it can be studied more thoroughly using a bias study Bias studies can only be done on variable type gages The bias value from the most recent bias study is used in calculations for the Performance Curve of the gage 22 DataLyzer Spectrum Gage Management 3 3 1 General Windows The Gage Catalog and Study History windows are used in many places in the DataLyzer Spectrum Gage Management System Gage Catalog When you create a new gage need to select a gage or delete one the Gage Catalog window appears Gage Catalog x Gage m Filter Gage List Serial Number FirstGTFirstGage FirstGTSecondGage Gage Type SecondGTFirstG age mM ThirdGTFirstGage First GT C Master C Second GT C Third GT Status falL E Location faLL bd Gage Field Enter the name o
66. ation of a process Gage Repeatability Does a measuring system report the same result when the same master is blindly measured several times by the same person Can one operator be consistent in measuring the same part characteristic using the same gage Repeatability is also referred to as equipment variation because it often reflects on equipment design or condition Repeatability Explanations 15 Gage Reproducibility Does a measuring system report the same results when two or three operators measure the same part characteristic blindly several times Between operator reproducibility is the other dimension of variation in a measuring process Gage reproducibility is also referred to as appraiser variation because it most significantly reflects on operators consistency in using the measurement system Solutions to problems of reproducibility often involve operator training Operator B AN Operator C Operator A Reproducibility Gage R amp R studies are usually made up oftwo components equipment variation and appraiser variation These components serve to focus any remedial attention on repairing or improving the gage itself EV equipment variation or training operators to use the gage correctly or more consistently AV appraiser variation See report examples in the Reports descriptions for more information about appraiser and equipment variation Either total tolerance USL LSL or total process varia
67. by 5 15 When the Total Variation TV method is Tolerance the study sigma values after multiplication by 5 15 are compared with the total tolerance USL LSL 6 times sigma represents 99 7 of the full spread of a normal curve When 6 Sigma is selected in this frame deviation values based on ANOVA calculations are multiplied by 6 before comparison with other sigma values No multiplication factor is applied to values calculated from Average and Range Because no multiplication factor is applied when Tolerance is selected as the Total Variation method the Tolerance value is divided by 6 USL LSL 6 Note that the AIAG MSA Manual shows calculations based on 5 15 Sigma in the first two editions The Third Edition used 6 times Sigma for ANOVA and 1 times Sigma for Average and Range Alert if calibration or GR amp R study is due in days Ifthis box is checked a message will appear when the program starts to warn if a calibration study or GR amp R study is overdue or is due within the specified number of days Passing Error Limit Enter the passing percent error limit for Gage R amp R studies in the Passing Error Limit field Use Appraiser Names When you mark the Use Appraiser Name as Labels checkbox the DataLyzer Spectrum Gage Management software will use appraiser names rather than appr in the labels for the data entry tables as well as on the reports Include Atmospheric Information When you check the
68. calibration point If this number is greater than one they will be averaged to determine the gage s bias for the calibration point Use Note column Ifyou check this box a column in the spreadsheet will be added for miscellaneous notes about the calibration point for example the master blocks stacked to create the reference value Use Measurement Uncertainty column If the number of measurements for each calibration point is greater than 1 the Use Measurement e DataLyzer Spectrum Gage Management Uncertainty column checkbox appears If it is checked a column appears in the spreadsheet showing the measurement uncertainty This is a calculated column based on the variation of the individual measurements This uncertainty is taken into account when determining the status of the calibration point If there is no uncertainty column then pass or fail is calculated from a simple average Use Master Uncertainty column If this checkbox is checked a Master Uncertainty column appears in the spreadsheet The value in this column is input by the user representing uncertainty of the reference value This uncertainty is taken into account when determining the status of the calibration point If there is a Measurement Uncertainty column and a Master Uncertainty column in the spreadsheet then the values are combined together to make a Total Uncertainty figure 5 7 Measuring Instructions Read The Measuring Instructions windows is in Read mode if it i
69. can be considered as representative of all the characteristics in the group This mode is widely employed but should only be used with the approval of management and your auditors This method assumes that all gages of a particular type Mitutoyo 0 1 micrometer for example are identical and all characteristics in a characteristic group are identical If the premise is acceptable you can study a specific gage and assume the study applies to all gages of that type and all characteristics in the group It is more cost effective because it requires much less extensive record keeping than dealing with all gages and characteristics individually However this method is based on certain assumptions that may not always be true and may not be acceptable to specific management and or auditing teams In any event this method of generalizing results by gage type only applies to gage R amp R studies Calibrations continue to be done individually so bias and inaccuracy can be caught during calibration for individual gages DataLyzer Spectrum Gage Management System Consolidation with DataLyzer Spectrum SPC System The DataLyzer Spectrum Gage Management System will operate alone or link to the DataLyzer Spectrum SPC module By default both programs are installed in the same folder and will use a single database therefore accessing common setup information so characteristic specifications and gage R amp R results are shared between the applications Study due
70. cnnnncnnnnnnnerennnanerennnnnarennnanens 105 11 Gage Interface Template iii nn been 105 12 Gage Template Window ooccconnccnnncccnnncnonnnennnnnnnnnnnnnnnnnnrrnnnnnrnnrrrnnnernnnrrnnernnnnrrnnernnnnens 107 File 2a es ee here Heer p senken Test Menu Special Menu Options Menu Gage Template Example 1 Single Line Single Measurement nnusussunnnsannnnnnnnnnnnnnnnnnnnnnnnnnnnnnn 124 Gage Template Example 2 Multi Line u z0us444044400nnn00nnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn 125 Gage Template Example 3 Multiple Measurements Per Line usuusrss0nnnsannnnnnnnnnnnnnnnnnnnnnnnnnnnnn 126 13 Com Port Assignime ts i 4 1 uc0 men a naar nee 126 14 Select Database u 220 0 200 aa i 127 Part VIII Help Help Menu 130 1 Help Documentation n 2 u canada iaa andanada nenne neu nn nenne 130 2 DataLyzer Application Notes ccccceece cece cece nese ee ee ee ee nese eee eeea nese essa eeae esse es nun nun ann ann 130 3 About GR amp R Spectrum u r24u04404 RR 130 Contents 5 Part IX Appendices 134 1 Appendix A Computer Requirement oocoonccconnccconnconnncnonnncnnnrnnnnnnnnnnnnnnernnnncrnnarenanennns 134 2 Appendix B Installation ooococnconocnnononnnononnnoronnnoaronnnaronnnoronnnoronnnaronnraronnrarennnarenananes 134 137 Index 8 DataLyzer Spectrum Gage Management 1 1 1 Introduction
71. dy Definitions can be set up where a gage and DataLyzer characteristic are specified along with certain parameters of the study If the specified gage in a GR amp R Study Definition is part of a Gage Type and the Characteristic is part of a Characteristic Group the results can be considered as applying to all gages in the Type and all characteristics in the Group This will reduce the number of GR amp R studies required Individual Gage History This is the most thorough method It involves creating a gage entry for each gage to be tracked and for GR amp R studies associating that gage with one or more product characteristics it measures This method provides maximum traceability and the most accurate and specific information about gage performance for each job While this method offers the highest level of traceability it is time consuming and expensive to maintain GR amp R using Study Definition A GR amp R Study definition is a way to specify details for repeating Repeatability amp Reproducibility tests of a gage and characteristic part combination on a regular baisi If the gage in a Study Definition is included in a gage type then GR amp R studies performed using the Study Definition can 1 DataLyzer Spectrum Gage Management 1 3 be considered as representative of all the gages in the gage type If the characteristic in a Study Definition is part of a characteristic group then GR amp R studies performed using the Study Definition
72. dy validity depends on these trials being conducted blindly so that appraisers do not know results from previous associated trials Data Entry Method The Open Sheet method can be used with all studies Appraisers user can enter study data in any order The By Trial method can be used with long or short variable and short attribute studies Using this method all entries are made in one appraiser trial at a time column by column Data entry is organized by trial and must be entered in the order prompted by the system The Randomized method can be used with long or short variable and short attribute studies For valid results this method must be used for long variable studies using the ANOVA calculation method 40 DataLyzer Spectrum Gage Management 5 5 1 Gage Studies Data Menu Selecting items in the Data menu allows you to create delete or edit Calibration GR amp R and Bias studies GR amp R Analysis Tools Note Most ofthe Analyze graphical tools relate to Long variable and ANOVA studies with the exception ofthe Performance Curve which also applies to Long Attribute Studies When you select the ANALYSIS TOOLS item or press F5 without opening the menu a window will appear containing a set oftabs These tabs contain different statistical or graphical analyses ofthe Gage R amp R Study You can preview information in these tabs and click the Print check box to include them in a report Som
73. e fields for each type of GR amp R study Some values are set and locked by the software as indicated to force the study to conform to generally accepted rules Short Form Variable The Short Variable study is the shortest and easiest variable GR amp R study however it only provides an abbreviated picture of the measurement variability It analyzes only appraiser variation reproducibility because the appraisers measure only one set of parts one trial then those results are compared against each other This study requires two appraisers to make one measurement 52 DataLyzer Spectrum Gage Management each on the same characteristic for five parts To begin the study select five production parts at random or of sizes ranging through the specifications and any two operator appraisers whose regular job it is to measure the parts from the process Each appraiser should measure each part independently so neither appraiser knows the results of the other s test i e a blind test The measurements are arranged in two columns so the results from each part are side by side Short Variable studies are often preferred because they are quicker and easier than long variable studies They save time for the operator and manager while still providing an indicator of the gage s reproducibility Short variable studies always use the average 8 range calculation method Short variable studies will only show appraiser variation When th
74. e high and low values measured in the trials The average is represented by a dot on this whisker line It is similar to the normalized chart except the dot is located on the average and the connective line whisker emanates from there to the extreme values high and low for each appraiser s samples GRER Average amp Range Method E Statistics Data Performance Curve Average Charts Individuals Charts Range amp Error Charts Chart Type C Normalized G C Scatter Plot Part Averages Whisker Appraiser 1 Appraiser 2 Appraiser 3 Print Print Exit Scatter Plot Using the scatter plot option values of all readings for each part are plotted minus the grand average One might expect as many as three dots for each appraiser for each part However when measurements are the same for a given appraiser on a given part two or three measurements may Gage Studies Data Menu ar appear as one dot This is a desirable condition showing repeatability of the appraiser GRER Average amp Range Method X Statistics Data Performance Curve Average Charts Individuals Charts Range amp Error Charts Chart Type C Normalized Whisker Individuals Charts Scatter Plot Appraiser 1 Appraiser 2 Appraiser 3 Print Print Exit Range amp Error Charts Tab Option buttons include range chart and error chart This tab only applies to long variable stud
75. e ofthese analysis tools are available in other forms in the reports menu but this is the only place where you can select your own report components For ANOVA variable studies the following tabbed sections are included Statistics Data and Average Plot For Average and Range variable studies the following tabbed sections are included Statistics Data Performance Curve Average Charts with run chart averages chart X Y Plot options Individuals Charts with normalized whisker scatter plot options Range amp Error Charts with range chart error chart options Each tab in the preview window is described below On each of the tabbed sections you will find these common items Exit Button The EXIT button closes the window and returns to the GR amp R study window Print Checkbox Mark the print checkbox to include the graph or information on the current tab in a report generated by pressing the PRINT button Print Button Use the PRINT button to print a report If you have marked the print checkbox on any of the tabbed sections any graphs and information on those marked tabs will be included on the report If you press the PRINT button without any checkboxes marked the GR amp R Report Definition window will appear which allows you to quickly select which report components you would like to include This unique area offers print options not available from the REPORTS menu in the main program window Statistics Tab T
76. e using the average amp range calculation method looks like this GRAR Report Stephen Computer Services Inc GR amp R AVERAGE amp RANGE REPORT Part No amp Name wdget2 Gage Name 0 1 caliper Date 5 14 2008 Characteristic length Gage No 3376M03 Performed By KRE Specifications 5 000 0 100 Gage Type caliper Measurement Unit Analysis Parts Appraiser A Appraiser B Range A B 1 2 354 3 6857 1 332 2 3 654 4 974 1 32 3 1 688 3 7111 2 023 4 2 697 2 499 0 198 5 4 414 1 784 2 63 Average Range 1 501 GR amp R 6 49419 Equipment variation repeatability is not allowed because only one trial per operator is involved ANOVA analysis is not supported on short variables studies Average Range DR 2 GRER Rid WORER 100x GR amp R process standard deviation DataLyzer Spectrum Gage Management 6 4 Gage R amp R Long Attribute The preview window for long attribute GR amp R studies looks like this Gage Repeatability and Reproducibility Report X File Part No amp Name PartOne Gage Name alt gage Date 7722 2008 Characteristic attcharl Gage No 53334 Performed by JUL Specifications 400 Infinite Gage Type Appraiser 1 Status Pass Part Size Accepts P 1 4 0 0 025 2 405 6 0 325 3 41 5 0 275 4 45 7 0 375 5 1 42 3 0 475 e 425 9 0 475 7 1 4 8 0 425 g 435 20 0 975 Performance Curve Bias 0 022 GRR Val 0 053 1 0 0 9
77. easurement system whether total process variation can absorb significant measurement variation or whether measurement variation must be reduced and thereby reduce total process variation to an acceptable level By performing careful R amp R studies the user can draw conclusions about whether the measurement system can be used as is whether it must be replaced or can be improved sufficiently through a combination of operator training and equipment repair The program also offers an alternative graphical view relating GR amp R study results to a part s specification limits in the form of a performance curve From the cur the confidence interval for a gage system can be determined i e the measurement range within which one may be 99 confident that a measurement system will be accepting or rejecting parts properly The difference between the confidence interval and the engineering specification limits should be applied as a reduction in tolerance due to measurement error Gage Inventory and Management Tools Surveillance The program stores hundreds of gages and provides several listing facilities to aid in inventory and scheduling of regular measurement system evaluations Supplier information containing shipping address product costs service record etc can be stored and referenced later at the point of gage replacement or purchase of supplies or parts Special Features For GR amp R analyses gages can be studied individually or GR amp R Stu
78. easuring system s result at that size For instance in the case above the gage being used needs to be replaced because at the lower specification limit 0 00 we can only be about 45 confident about making the right decision to accept or reject product worse than simply flipping a coin Reports Reports Menu a 6 7 Discrimination required from the gaging system is a function of cost of the gage itself ofthe products being measured and improperly scrapped and of the personnel time required to do the inspection Calibration Certificate There is no preview for the Calibration Certificate Calculations used in the Calibration Certificate are Bias Average minus Nominal Meas U Uncertainty of measurements 2 times the standard deviation of measurements for the calibration point Status Nothing some values for the calibration point are missing Fail if Bias plus Total Uncertainty is greater than positive tolerance OR Bias minus Total Uncertainty is lower than negative tolerance Pass if Bias plus Total Uncertainty is less than positive tolerance AND Bias minus Total Uncertainty is greater than negative tolerance Total Uncertainty Square root of Meas U squared plus Master U squared If the Meas U or Master U column is not showing in the table the relevant value is taken as zero Note Status for the whole study is Fail if any calibration point in any calibration dataset is Fail Status for the study is Pass if all cal
79. ecification limits are shown as vertical lines intersecting the x axis Normal curve tails intersect these specs and represent confidence indicators At the intersection of either spec you can read the corresponding left or right scale to see the confidence one has in the measuring system s result at that size For instance in the case above the gage being used needs to be replaced because at the lower specification limit 0 00 we can only be about 45 confident about making the right decision to accept or reject product worse than simply flipping a coin Discrimination required from the gaging system is a function of cost of the gage itself ofthe products being measured and improperly scrapped and of the personnel time required to do the inspection The bias value from the most recent bias study is used in calculations for the performance curve Average Charts Tab The purpose of the averages charts analyses is to show potential differences in reproducibility between operator averages for the same part Option buttons designate which one of three graphical analyses will be displayed printed They include runs chart averages chart and X Y plot Run Chart The run chart option displays data points that represent the average of each appraiser s trials for DataLyzer Spectrum Gage Management each part Each appraiser s data points are displayed in a different color and shape Lines of the associated color connect each a
80. ect a study by clicking in its study date field Its row will highlight to show it is selected Press the Edit button to open the selected study You can also select a study by double clicking it 3 4 General Windows Exit Button and File Menu Exit The EXIT button closes the study history window and returns to the main program window File Menu Delete The DELETE item will delete the selected study Select a study by clicking in its study date field Its row will highlight to show it is selected Select DELETE from the FILE menu to delete the selected study A window will appear to confirm that you want to delete the selected study Bias History The Bias History window looks like this Bias History 0 1 caliper Study Date Performed By Location Master Value Average Bias 6 10 2008 10 44 MTL 0 50 a amp CC EdivReview Study Ext As studies are completed results are stored in the system Bias study summaries will be displayed in spreadsheet form sorted by date time with the most recent on top Each row represents an individual study Each column represents a key statistic or label relating to the study Study Date Column The Study Date column shows the date and time the study was performed Performed By The Performed By column shows the name or initials of the person who performed the study This information is taken directly from the study window as it was entered to
81. ed measurement and press OK For attribute gages short form enter G for Go or Accept and N for No Go or Not accept The corresponding cell will turn green and the actual value will be internally stored in the database The value will be hidden so it will not cause bias in later measurements Open Sheet The Open Sheet method can be used with long or short variable and short attribute studies The Open Sheet entry spreadsheet looks something like this s DataLyzer Spectrum Gage Management Gage Repeatability amp Reproducibility Study x File Edit Analyze Instructions Performed By Date 26 07 2010 Time 11 52 Dero o oo r Characteristic Part LSL ae USL p Characteristic r Saved calculations Calculation Method Average amp Range y Total Variation Method Study Variation y Study Parameters Variable Long 3 Appraisers 10 Parts 3 Trials Data Entry Method Open Sheet Appr 1 Appr 2 Appr 3 Trial 3 Trial 1 Tral 2 Trial 3 Appr 1 Appr 1 Appr 1 Aen 2 Appr 2 Appr 2 Appr 3 Appr 3 Appr 3 Trial 1 Trial 2 Trial 3 Trial 1 Trial 2 To use this method enter values in the spreadsheet in any order until the form is complete For variable gages enter the value for the specified measurement For attribute gages short form enter G for Go or Accept and N for No Go or Not accept Open
82. eld Cancel Button 102 DataLyzer Spectrum Gage Management The CANCEL button closes the Suppliers catalog and returns to the main DataLyzer Spectrum Gage Management software window 7 8 Supplier Details The following Gage Suppliers window is used to enter the details for a new supplier or edit existing supplier information Gage Suppliers File Company Information Company Type Name Gage Sales eins Gage Supplies Address Gage Calibration IT Gage Technical Support City SY Gage Manufacturer State nn Certifying Agency oe l Certification Country OoOo O O Certifying Agency Contact 1 IT Title Cert A y Phone PA Espiration Date ln e Mail A Document o Contact 2 no Title IT Phone e Mail CY Fax fC Website r Notes Save Exit Company Information Use the fields in the Company Information portion of the supplier window to enter general contact information for the supplier Company Type If you selected a company type option button other than all in the previous Suppliers catalog when creating a new supplier this company type will be selected here However you can select as many types that apply to the supplier being currently defined Setup Setup Menu 103 In certain areas of the program where the system accesses the Suppliers catalog the catalog may contain only suppliers of a particular company type
83. emplate window Ifthe parameters are set correctly and if the RS 232 cable pinouts are correct you should be able to receive a string of characters from the instrument When you click READ GAGE a seven second countdown starts giving you time to press the button on your instrument send or print or transmit that causes it to transmit a string of characters to the computer This string appears in the transmission line 1 field You will be asked to overwrite the measurement number in the string with pound signs to make a mask or template for future transmissions from this instrument Save the template and exit The Create Template window looks like this 7 amp Read sample data Message Serial port to test dr Timeout 7 Clear Transmission Up Dem De Column H HHEH Read Gage Save Cancel Serial Port to Test Use the serial port to test area to temporarily designate a com port to use for the current test This selection will not be stored permanently because the com port selection for ongoing use is made from the COM PORT ASSIGNMENTS item in the SETUP menu 112 DataLyzer Spectrum Gage Management Timeout Use the Timeout field to enter the number of seconds the template will wait for an RS 232 string from the instrument Clear Button The CLEAR button clears all transmission lines of previously set Ps and extraneous characters that may exist from p
84. emplate The TEST TEMPLATE item allows you to test the template filter s created in the Create Template window If you test a template in the Create Template window the test will overwrite the template Ps and S signs and you will have to replace them after each test The Test Template window not only confirms communications but also displays other information like the mode reading and channel identifiers as well as any analog to digital A D conversions that are taking place The Test Template window looks like this 114 DataLyzer Spectrum Gage Management a Read sample data x NER l Serial port to test a Timeout E Clear Transmission Up Doan Deena Column BE H HHHHHHH Read Gage Save Cancel Serial Port Use the serial port to test area to temporarily designate a com port to use for the current test This selection will not be stored permanently because the com port selection for ongoing use is made from the COM PORT ASSIGNMENTS item in the SETUP menu Timeout Use the Timeout field to enter the number of seconds the template will wait for an RS 232 string from the instrument Clear Button The CLEAR button clears the test reading window Message The Message field will display operational comments that the software reports about the transmission Messages include opening com port send data now communication timeout etc Filtered Readings
85. er another immediately However some gages do some calculations between lines or have intermediate steps that cause additional delays If the program does not receive the complete transmission in a prompt fashion it discards the entire transmission By setting the delay higher the program will wait the specified time between lines before giving up Regardless of the delay specified when the reading is received the program will display it immediately With a large value in this field the program will appear to be locked up once a transmission has started until either the transmission is completed or until the specified delay has elapsed The value entered is in tenths of seconds not seconds When using BAUD rates below 2400 it may be necessary to specify a small delay of up to 5 10 of a second to account for the slow transfer rate Another instance where this delay should be increased from the default is when a whole report that is ordinarily printed is being redirected to the com port for data acquisition Buffer Size The buffer size option boxes must also be set to control the size of each com port character buffer Specific options are selectable as character buffer sizes The default 1024 should be adequate for almost all situations Use larger buffer options only when pages of ASCII information are being transferred through the com port with each transmission If the buffer size is not large enough data will be lost Special clear buffer
86. ers i e TAL Fowler software wedge MicroRidge GageWay Il and direct USB interfaces set the com port s to No Gage Experience has proven that a high percentage of communication problems result from the use of an incorrect RS 232 cable We advise you to always buy RS 232 cables directly from the manufacturer of the gage or interface Advanced Concept IRQ Windows by default reserves two processor interrupts IRQs IRQ4 for com 1 and IRQ3 for com 2 With the advent of virtual com ports different numbered com ports become available usually com5 and above Separate software must usually be employed to establish the existence of these additional com ports in the operating system This allows the simultaneous use of more than two RS 232 ports at a time Select Database This option is available only for the Microsoft Access database platform Use the windows browser to locate and select the location of the desired database and press the Open button You will be prompted to restart the program so the different database can be accessed 130 DataLyzer Spectrum Gage Management 8 8 1 8 2 8 3 Help Help Menu Help Documentation The HELP DOCUMENTATION item accesses the DataLyzer Gage Management help system Use the search facility to find all references to a topic you enter or move to the beginning of a general topic by selecting it from the list of topics Press F1 on the keyboard at any time to show t
87. ers do two things they define the RS 232 communication environment in terms of baud rate parity stop bits etc and they tell the DataLyzer Spectrum Gage Management package the actual location of the measurement within the gage s transmission The transmitted string may contain information such as a measurement value sign units of measure serial number of device date and time stamp etc The order and contents of the transmitted string is different for each instrument or interface The purpose of the template is to define a mask to lay over the transmitted string of characters so that each time a string is received the mask can pick out only a specific set of characters the measurement from the string Maybe the measurement number is located in the 5th through the 12th space in the string of transmitted characters That is where this gage driver s template should be set to pick up valid values for data entry Steps for gage driver creation and use 1 Configure the communication parameters to match the gage transmissions This means the software s baud rate parity data bits and stop bits must all match the gage s settings Refer to the instrument s user s manual for this information 2 Enter any necessary commands that prompt the gage for readings define line termination characters and the number of lines to be transmitted in the string 3 Take a test transmission from the gage to verify communication and define the string template
88. es Company or 2 Supplies Company fields For entry in these fields use the associated buttons to open the Suppliers list to select or create a gage supplier Note that the applicable option button e g manufacturer gage supplies is selected in this window allowing only predefined suppliers of that type to appear for selection however if you create a new supplier you can specify it to be any of the supplier types available in the system To select a predefined suppliers name from the list double click it or highlight it in the list and press the SELECT button Press CANCEL to exit without selecting a supplier To create a new supplier type a supplier name in the Company field and press SELECT The program will notify you that the supplier does not exist and ask if you want to create it Press YES The Gage Suppliers setup window will then appear see here for a description of this window Once a supplier is selected it appears in the field You can view more specific information about the supplier by clicking on the field a window containing read only information about the supplier will appear Documentation The Documentation 4 field can be used to locate the manual or instructions for the gage Battery Type Enter the SKU or model number of the battery required by the gage if any in the Battery Type field Other Supplies Enter any other supplies required to maintain or use the gage in the
89. es a one line per transmission gage setup with signs in the gage template The multi channel facility is then accessed to tie a channel 1 D to an individual part characteristic The window for setting up multi channel translation looks like this Multi channel description Channel information 64 Prompt Identifier Reading ft Column lt lt Previous Save Cancel Nexb gt Channel Information The Channel information area displays the current channel description number Prompt Use the Prompt field to enter a message to be sent to the gage to request a reading from the current channel This field should not be used to request a reading from all channels Any global requests should be entered at the main gage setup screen Identifier Enter a set of characters in the Identifier field that uniquely identify the line containing the reading for the current channel This may be a label like X axis or radius or a channel number such as 01 or A It is important that you enter the characters in the exact column positions that they occur in the gage transmission Reading Number The Reading number field allows for multiple readings per line to be handled If only one measurement is transmitted per line then enter 1 in this field Column The Column field does not allow input It merely displays the cursor s position for the identifier fie
90. f the gage in the Gage field or select a gage from the list below If you are creating a new gage use a name that has not been used before You cannot create a new gage with the name of an existing gage Filter Gage List frame The frame on the right is for filtering the list of gages on the left When creating a new gage this list is for information only Gage Type Selecting a gage type in this catalog window will cause the window to refresh showing only gages of the specified type to appear Marking the ALL check box causes the screen to refresh to display all existing gages Gage types are defined under SETUP in the main program window General Windows 23 3 2 Status If you select a status from the dropdown list mouse click on the small arrow to reveal the list only gages with this status will show Statuses are defined under SETUP in the main program window A gage is assigned a status in the Gage Description window under the FILE menu To remove the filter and show gages with all statuses select ALL at the top of the list Location This filters the gage list in a similar way to Status OK Button Pressing the OK button selects the gage currently in the Gage field Cancel Button The CANCEL button exits to the DataLyzer Spectrum Gage Management main program window without saving any changes Calibration History Select Enter Edit Calibration from the Data menu to show the Calibration History window This window
91. for printing on the report by using the logo width field Enter the desired width in millimeters 100 mm max Report Titles Table The report titles table contains two columns Report column default title and User Name column Use this area to re title any of the available reports To rename a report click or double click on the name you want to change in the User Name column and enter the desired title Identity Tab 90 DataLyzer Spectrum Gage Management 7 2 Company Name Originally the Company Name field will contain the name of the company to which DataLyzer International Inc registered the software The name in this field can be changed Any changes made to the company name will flow backward to change the official registration software s owner of record The entry in this field is the one used for printing in the reports if desired see Reports tab Note In the event you wish to change the software s official assignment that appears in the HELP ABOUT DATALYZER window please contact DataLyzer International Inc File Viewers Tab Identity Reports Header Fields afi File Viewers Path to Microsoft Word Viewer Change Folder Path to Microsoft Excel Viewer Change Folder Path to Microsoft PowerPoint Viewer Change Folder Exit Change Folder Use the buttons to locate the executable exe files to use for viewing Microsoft Word documents Excel spreadsheets and Powe
92. from the instrument Message The Message field allows DataLyzer Spectrum Gage Management software to report messages about the transmission being received Messages such as reading complete or time out error may display in this field Analog to Digital The Analog to Digital area allows you to high and low master the gage and set the software to do an automatic interpolation The procedure 1 Enter the size measurement of your high master in the high master field 2 Enter the size measurement of your low master in the low master field 3 Position your cursor in the high gage reading field then put your high master into the gage Press the MASTER HIGH button If you are not using a gage prompt you will need to press the footswitch or send button on the gage The value will transmit from the gage in terms of a number of digital segments as discussed earlier and will display in the high gage reading field 4 Position your cursor in the low gage reading field then put your low master into the gage Press the MASTER LOW button If you are not using a gage prompt you will need to press the footswitch or send button on the gage The value will transmit from the gage in terms of a number of digital segments as discussed earlier and will display in the low gage reading field 5 Save the gage file template by using the SAVE button This sets up an automatic interpolation relationship The software does the f
93. g one Create and Delete Gage Statuses Ed Active Calibration externally Exit Maintenance New Gage Rejected E To create a new status or inspector type in the name of the new status or inspector and click the OK button To delete a Status or Inspector click on the name in the list then click the DELETE button The EXIT button closes the window 7 11 Gage Interface Template Gage interface templates or gage drivers are created to allow direct communication between the gage or gage interface and the DataLyzer Spectrum Gage Management software They provide specific information about the gage to ensure proper communication with DataLyzer Spectrum Gage Management software The template supports RS 232 communication for up to four com ports com 1 and 2 along with two virtual com ports for extended serial communication Gage interface templates for the most commonly used gages and interfaces are provided with the DataLyzer Spectrum Gage Management software Other gage drivers can be created allowing the DataLyzer Spectrum Gage Management software to operate with your specific gages Once a gage driver is setup it can be used in the Com Port Assignment window The information in this section describes the process of defining a gage driver that can then be used by the DataLyzer Spectrum Gage Management software to control any ofthe computer s four com ports 106 DataLyzer Spectrum Gage Management Gage driv
94. he statistics tab contains a detailed listing of key statistics in the GR amp R study This tab applies to both Average Range and ANOVA studies ij GR amp amp R ANOYA Method Statistics SSS Average Plot ANOVA Supporting Calculations Source DF s MS Appraiser 2 jr fs Parts B fess fasieo ApprxPart fig foso fomss fosa Error fo 27589 0 0460 Total fs faen m Total Variation Study C Tolerance Process when saved Process current 6 5364 6 Std Dev Results Lower 90 CL 6Std Dev Upper 90 CL of Variation Contribution Repeatability Equipment Variation EV jf 1 2865 0 19 Reproducibility Appraiser Variation AV 5 4695 1 3698 fiseso9 Part x Appraiser Interaction foot ooo ooo Repeatability te Reproducibility R amp R 1 1997 fazas Jans Part Variation PY faszo9 so Ja F Print You can see the effects of different Total Variation methods by clicking on the options in the Total Variation frame The Process options are only available if a Datalyzer Characteristic was selected for the study With the Process when saved option a calculation of the Standard Deviation of the last one hundred data points was made when the GRR study was saved Process current will recalculate process variation with the most recent one hundred data points One hundred data points is irrespective of the subgroup size for example 10 subgroups with subgroup size is
95. he help screen If you have a window or dialogue box open specific help for that window will be shown DataLyzer Application Notes Selecting this menu item takes you to the DataLyzer International website About GR amp R Spectrum ABOUT GR amp R SPECTRUM item provides some general information about the software and installation Information like version number database type ACC MS Access SQL MS Sequel Server and ORCL Oracle program path and database path information is also included The following window offers an example of what the About DataLyzer Spectrum window looks like Help Help Menu 131 About Datal yzer Spectrum Gaging Analysis xi Datal yzer Gage Version 0 30 12 DB Version 93 GRA DB Version 12 ACC Copyright 92001 by DataLyzer International Inc This program is licensed for Serial Demo Licensed copies 1 Program Path TSCLIENTSD Work D atalyzer sS ource D atalyzerG age a Database Path Tsclient d Work D atalyzer S ource D atalyzerG ages MarcD ata4ndLang22May Warning this computer program is protected by copyright law and international treaties Unauthorized reproduction or distribution of this program or any portion of it may result in severe civil and criminal penalties and will be prosecuted to the maximum extent possible under the law System Infol Technical support Phone 248 960 3535 Fax 248 960 3539 Email support D atal yzer com
96. her than the date and whether the study is Pass or Fail Performed By Field and Button Enter the name or initials of the supervisor overseeing the test in the Performed by field You can type it in directly or select from a list by clicking the PERFORMED BY button Gage Name The Gage Name field displays the gage name The contents of this field cannot be changed Gage Type The Gage Type field displays the gage type as specified in the gage s gage description window It cannot be changed here Date Enter the date the study was initiated in the Date field The current system date is automatically entered into this field but another date can be entered if desired Time e DataLyzer Spectrum Gage Management Enter the time the study was initiated in the Time field The current system time is automatically entered into this field but another time can be entered if desired Serial Number The Serial Number field is automatically filled in based on the serial number entered in the gage s gage description window lt cannot be changed in this window Company Number The Company Number field is automatically filled in based on the company number entered in the gage s gage description window lt cannot be changed in this window Status Field and Set button In simple mode the status Set button is available to manually set the status Three statuses are available Pass
97. ibration points in all calibration datasets are Pass If data is incomplete and no calibration points are Fail then the status for the study is Not Set 82 DataLyzer Spectrum Gage Management 6 8 Calibration 8 GR amp R Due Select the desired report type GAGE LISTS CALIBRATION DUE GR amp R DUE MASTER DUE from the REPORTS menu The Due List Setup window will appear Due List Setup Reports Gage Type v ALL Calipers C Due Next 7 Days indicators Master C Due Next 15 Days MASTER C Due Next 30 Days None Complete Chronological List Status C All Active C Inactive OK Cancel Reports In the Reports section select a time frame for the report list Gage Status In the Status section select the status for gages to be included in the report Status values are originally set or edited in the gage description window Gage Type In the Gage Type list select a gage type if applicable Gage Types are defined in setup and selected in the gage description window Cancel Button Press the CANCEL button to close the Due List Setup window OK Button After pressing the OK button a list of gages due will appear If no gages appear none were found to be due under the conditions specified The list of gages due will look similar to this Reports Reports Menu s 6 9 TI GRER GRER Due ListComplete Sorted Chronologically Jon Fie Gage Number_G
98. ibute gages short form enter G for Go or Accept and N for No Go or Not accept The corresponding cell will turn green and the actual value will be internally stored in the database The value will be hidden so it will not cause bias in later measurements By Trial Method The By Trial method can be used with long or short variable and short attribute studies Using this method all entries are made in one appraiser trial at a time column by column Data entry is organized by trial and must be entered in the order prompted by the system The By Trial entry spreadsheet looks something like this Gage Studies Data Menu 55 ij Gage Repeatability amp Reproducibility Study xi File Edit Analyze Instructions Performed By Date 26 07 2010 Time 11 52 E Gage A r Characteristic Part LSL USL Characteristic Saved calculations Calculation Method Average Range gt Total Variation Method Study Variation Variable Long 3 Appraisers 10 Parts 3 Trials Data Entry Method By Trial Appr 1 Appr 1 Appr 2 Appr 2 Appr 3 Trial 1 Trial 2 Trial H2 Trial 3 Trial 1 Trial 2 Trial 3 To begin click the green ENTER button at the top of the first column The system will display a data entry window with an indicator as to which appraiser trial and part to measure For variable gages enter the value for the specifi
99. ield This is often dictated by the organization s quality manual or procedures Date of Purchase Enter the date the master was purchased in the Date of Purchase field Cost Enter the cost of the master in the Cost field Status Set the current status of the master by clicking on the Status button and selecting from the list No manual entry is allowed you must pick from the list Location Set the current status of the master by clicking on the Location button and selecting from the list You can also type in a location that is not in the list Documentation Enter for the location of the documentation or the documentation ID for the master in the Documentation field 8 DataLyzer Spectrum Gage Management Supplies Company Button No manual entry is allowed in the Supplies Company field For entry in this field use the SUPPLIES COMPANY button to open the Suppliers list to select or create a supplier Note that the gage supplies option button is selected in this window allowing only predefined suppliers of that type to appear in the list for selection however if you create a new supplier you can specify them to be any of the supplier types available in the system To add a new manufacturer to the master list type a supplier name in the Company field and press SELECT The program will notify you that the supplier does not exist and ask if you want to create it Press YES The Gage S
100. ies Range Chart The range chart option shows the range of each operator s readings for each sample measured In addition a control limit is calculated and displayed Note the control Llimit calculation in Appendix A GRER Average amp Range Method E Statistics Data Performance Curve Average Charts Individuals Charts Range 4 Chart Type Range Chart C Eror Chart Range Chart Appraiser 1 Appraiser 2 Appraiser 3 J Print Print Exit Error Chart s DataLyzer Spectrum Gage Management On the error chart individual deviation error for each part is plotted Error in this case is calculated as observed value minus average measurement of the part This analysis offers several good applications One appraiser s averages are higher than another An appraiser s second reading is consistently lower than the others A particular part is difficult to measure consistently by all appraisers GRER Average amp Range Method X Statistics Data Performance Curve Average Charts Individuals Charts Range amp Error Charts Chart Type Range Chart Error Chart 2 0 16 1 2 0 8 0 4 0 0 0 4 0 8 1 2 16 2 0 m a Appraiser 1 Appraiser 2 Appraiser 3 J Print m Print Exit 5 2 Gage R amp R Study Once a new GR amp R or GR amp R by type study is created or an existing study is opened a Gage Repeatability amp Reproducibility St
101. iety of RS 232 devices The COM PORT ASSIGNMENTS and GAGE INTERFACE TEMPLATE menu items work together to define this communication Each computer com port 1 2 and 2 virtual ports can be controlled by a driver that defines how that com port will communicate The COM PORT ASSIGNMENTS menu item displays which drivers are invoked on which com ports The GAGE INTERFACE TEMPLATE menu item allows definition editing and testing of the gage drivers themselves 7 14 Setup Setup Menu 127 Com 2 Unavailable No Gage v Com v No Gage Com No Gage OK Cancel The DataLyzer Spectrum Gage Management package provides predefined drivers for most popular interfaces and serial gages You can assign these drivers to each com port field by selecting an available gage driver You can assign one gage driver to each com port The sole purpose of the com ports window is to assign existing gage drivers to control particular communication ports on your computer If no RS 232 communication will be required the no gage option should be used No gage is the default for all com ports at installation To activate a com port s drop down menu use Alt the respective number For example Alt 1 activates the com port 1 menu and Alt 2 activates the com port 2 menu The program will show which com ports are available or unavailable for communication When using external non DataLyzer software TSR gage driv
102. ility Study Gage Statuses 105 Index Gage Template Window 107 GR amp R Analysis Tools 40 GR amp R and Calibration Histories 83 GR amp R History 25 l Inspectors 105 L Language 90 Measuring Instructions 34 66 P Preferences 91 R Reports Reports Menu 72 ere Supplier 102 Supplier Summary Suppliers 101 System Definitions 84 88
103. in length Text Area Statistics Checkbox Marking the statistics checkbox will list all statistics and show calculations associated with the study on the report Data Table Checkbox Marking the data table checkbox will include a complete data table in the report Graphics Area Use the checkboxes in the graphics area to select the items you would like to include in the report The average plot charts individuals charts range error charts and performance curve checkboxes apply to long variable studies The average plot charts item applies to ANOVA studies 5 4 Gage Studies Data Menu NOS Print Button Press the PRINT button to print the report Exit Button The EXIT button closes the window without printing Calibration Study Use the ENTER EDIT CALIBRATION item in the DATA menu to define and enter review or edit gage calibration study information for an individual gage Simple Mode File Edit Reports Calibration number 000007 Date 07 04 2010 Time has Performed by First Inspector SCS Manufacturer Acme Calibration Gage Name Model Model Gage Type Frer Serial Number E Description Desctiption Company Number Comman Status DAA se Certificate Scan Browse Advanced When a calibration study is started the Calibration Study displays simple mode Simple mode is for situations where there is no need to record calibration data ot
104. is of variance method is a more accurate more flexible method than the Average 8 Range method with no additional data entry requirements ANOVA shows equipment variation repeatability and appraiser variation reproducibility and adds discrimination for the interactions between appraiser variation and equipment variation The ANOVA method is similar to the long variable study average amp range method and is the preferred method of GR amp R analysis because it can handle any experimental setup number or samples operators and trials and it can estimate variances with higher bias but the computation handled by DataLyzer Spectrum Gage Management and analyses are more complicated When conducting an ANOVA study data entry must be randomized to be valid Use the randomized data entry method Operators will be prompted for measurements of pieces in a random order to ensure independent measurements The draw back to this is that all operators must be present at the time of the study where as you can enter data for one operator at time for Average 8 Range type studies Total Variation Method Variable Gages Only The selection of the Total Variation Method is used along with the globally set passing error Gage Studies Data Menu 51 limit located in SETUP PREFERENCES to determine if a gage passes or fails the R amp R study There are three options for this item Study Variation Study variation is gage er
105. is study type is selected the Number of Appraisers Number of Trials and Number of Parts fields will be set and locked by the software Long Form Variable The long study has flexible parameters for number of operators number of parts measured and number of trials per part We suggest using two or three appraisers operators each making two or three trial measurements on eight to ten sample products characteristics The sample products are chosen randomly from production parts or organized by size ranging through the specifications Appraisers are asked to make the desired number of measurements using their normal measuring techniques Appraisers should take measurements independent of each other so results between appraisers have no influence on each other The studies require significantly more sampling than the short studies but they provide more detailed information regarding the type and amount of repeatability and reproducibility variation present in the measurement system Two types of calculation methods are available for long variable studies average amp range and ANOVA see the Calculation Method item for a description of these Long Form Attribute The long attribute gage study is the most in depth study and requires a substantial amount of time The study consists of one operator making twenty measurements on 8 10 samples Samples must be selected carefully This study may be used on both single a
106. l Gage Name 0 1 caliper Performed By KRE Gage No 8876M09 Date 5 16 2008 Gage Type caliper Serial Number 8876M09 100 confidence range 3 30 to 6 10 Probability of Acceptance at LSL 0 53 USL 0 53 The purpose of a gage performance curve is to determine the probability of a measurement system either accepting or rejecting parts improperly using data from Long Variable and Attribute gage studies This tab applies to long and short variable studies and long attribute studies Once the amount of gage error has been determined via a gage study it is possible to calculate the probability of accepting a part of some reference value when using the gage To accomplish this the assumption is made that repeatability and reproducibility are normally distributed with some variance s2 The gage performance curve provides a graphical method of communicating how well the measurement system is discriminating good parts from bad parts as the measurements approach the decision points at the upper and lower specs The graph contains x and y axes The x axis along the bottom contains values as reflected by the measurement system The y axis relates to the percent confidence Specification limits are shown as vertical lines intersecting the x axis Normal curve tails intersect these specs and represent confidence indicators At the intersection of either spec you can read the corresponding left or right scale to see the confidence one has in the m
107. l Variation TV Total variation can be based on one of three different statistics Study Variation Ty VR amp R PV Process Variation TV VR amp R PV 60 of the manufacturing process Tolerance Reports Reports Menu 75 TV USL LSL Total Variations TV Area EV 100 EV TV or 100 EV SV or 100 EV TOL depending on which was selected in study setup EV 100 EV TV where TV could be variation found in this R amp R Study or 3sigma of the most recent SPC data or Percent of Tolerance depending on which one was selected when the study was setup AV 100 AV TV or 100 AV SV or 100 AV TOL depending on which was selected in study setup AV 100 AV TV where TV could be Study variation 3sigma of the most recent SPC data or of Tolerance depending on which one was selected when the study was setup R amp R 100 R amp R TV or 100 R amp R SV or 100 R amp R TOL depending on which was selected in study setup Variables Menu Item When you access the VARIABLES menu item from the report preview window a window will appear containing a spreadsheet of the data used in the study It looks like this 2 51 xi File Variables for GR amp R Average Appraisers JPart 1 Part 2 Part 3 Part 4 Part 5 Part 6 Part 7 Part 8 Part 9 Appraiser 1 Trial 1 0 56 0 57 0 83 0 61 0 58 0 62 0 67 0 70 0 56 Trial 2 0 62 0 65 0 63 0 54 0 59 1 00 0 61 0 62 0 63 Trial 3 0 64 0 61 0 65 1 00 0 51 0 52
108. ld so you can locate the specific channel identifier in the exact position of the line s transmission string For example ifthe gage interface transmits 02 as the channel identifier in position 10 and 11 you must put 0 in position 10 and 2 in position 11 of the identifier field The column field shows you where you are as you move the cursor ns DataLyzer Spectrum Gage Management Previous and Next Buttons The PREVIOUS and NEXT buttons allow you to scan and set up to 64 channel descriptions Save Button The SAVE button saves the template Cancel Button The CANCEL button exits without saving Special Menu Multi Channel A D The Multi channel A D window is a combination of the two previously described windows lt is used in situations where you need to communicate with an analog to digital interface that has more than one channel Multi channel description Channel information 1 64 Prompt Identifier Reading hr Column Serial port to test 1 Timeout 7 Message Analog to Digital High Master DD Low Master fo High Gage Reading fo Master High Low Gage Reading fo Master Low lt lt Previous Save Cancel Next gt gt Channel Information The Channel information area displays the current channel description number Prompt Use the Prompt field to enter a message to be sent to the gage to request a reading from the current chan
109. led locally on drive C for graphics and framing objects support Microsoft PowerPoint Viewer must be installed locally on drive C to view PowerPoint files Adobe Reader must be installed locally on drive C to view Acrobat pdf files To detach a file press the desired SET button When the Open browser window appears press the CANCEL button The program will ask if you would like to remove the file press YES Specify Web Addresses To enter or edit a web address as an attachment mark the specify web addresses checkbox before pressing the SET button A dialog box window will appear where you can enter the web address path required To attach another file type unmark the specify web addresses checkbox before pressing another SET button Attachment Buttons After setting a file or website click the Attachment to check that the link is working DataLyzer Spectrum Gage Management 4 3 GR amp R Study Definition A GR amp R Study definition is a way to specify details for Repeatability amp Reproducibility tests of a gage and characteristic part combination that will be regularly repeated If you select New GR amp R Study Definition or Open GR amp R Study Definition the Study Definition window opens ig GR amp R Study Definition Name G1VarChart DK Gage G age nn E xit Category Variable Type Typel Characteristic Part Pa Characteristic Varchan Category
110. log to Digital This facility is used to master analog to digital transmissions Typically A D converters break an analog DC voltage range into digital segments An example would be a 12 bit A D converter breaking a given DC voltage range into 4096 digital segments If the analog range is 2 volts DC to 2 volts DC this 4 volt range will be divided into 4096 segments or approximately 1000th of a volt per segment A D interfaces typically transmit a measurement in terms of the number of segments the measurement represents out of the total voltage range Therefore if the gage can measure 010 inches to 010 inches this range will be cut into 4096 segments with each segment approximately equal to 000005 of an inch This means that each 1000th of a DC volt increment is represented by 000005 of an inch travel in the gage Therefore when the gage measures 005 inches it will transmit the representative number of segments or 3000 This value is then converted into inches with the result reported to the software as the measurement from the gage in this case 005 inches This process of interpolation can be setup automatically using the SINGLE CHANNEL A D facility It is sometimes referred to as mastering The window looks like this a Sa amp Analog Gage Message Serial port to test dr Timeout 7 Clear Analog to Digital High Master 0 Low Master 0 zava High Gage Reading 0 Master High _ I Cancel Low Gage Reading 0 Master Low
111. ments to be used in any statistical quality control effort and follows the AIAG Gage Repeatability Reproducibility study procedures The DataLyzer Spectrum Gage Management System provides analytical tools for measurement assurance as well as gage inventory and management Measurement Assurance Tools The DataLyzer Spectrum Gage Management System provides two basic types of measurement system analysis The first is a calibration analysis based on the accuracy of a measurement system i e the extent to which bias exists in the system The second is a set of statistical techniques gage repeatability and reproducibility studies that quantifies the variation a measurement system introduces into the total process variation when gages are put in the hands of actual human appraisers Gage Calibration Accuracy and Extent of Bias Introduction 9 1 2 Gage calibration allows you to find the difference between the observed average of measurements and the reference or true value Is this bias within an acceptable range The DataLyzer Spectrum Gage Management System further maintains a history of these accuracy analyses Gage Repeatability and Reproducibility Studies Measurement System Variation The DataLyzer Spectrum Gage Management System determines repeatability equipment variation and reproducibility appraiser variation for both variable and attribute gaging systems These results can then be used to evaluate the adequacy of a complete m
112. n field is set from the Test Create Template area When multiple lines are transmitted from the gage this feature allows you to tell the software which line will contain the measurement you want After setting this information in the Test Create Template window it will flow through to be set in the gage template window as well Starting Column of Reading in the Line The starting column of reading in the line field is set from the Test Create Template area lts purpose is to locate the position of the first character in the transmission s actual measurement value No measuring units channel identifiers or other textual information in the transmission should be confused with the location of the first character in the measurement This first character of a measurement is often a or sign and these should be included in the set of when creating the template in the test area Ending Column of Reading in the Line The ending column of the reading in the line field is set from the Test Create Template area Its purpose is to locate the position of the last character of the transmission s actual measurement value No measuring units channel identifiers or other miscellaneous information in the transmission should be confused with the location of the last character in the measurement Sign Column of Reading in Line The sign column of reading in line is the location of the measurement s sign in the
113. n you press the Instructions button the Instructions window will appear providing any measuring instructions and attachments that are defined on the gage s gage description window Process Variation In the Process Variation field enter the value for either 6sigma of the process or tolerance whichever you want to measure the bias against Gage Studies Data Menu e Observed Average After the study is saved the Observed Average field will display the average of the 10 samples entered Bias After the study is saved the Bias field will display the difference between the master value and the observed average The bias value from the most recent bias study is used in calculations for the Performance Curve of the gage Bias After the study is saved the Bias field will display the percent of the process being used by gage bias bias process variation 100 Data Entry Spreadsheet To enter data in the Master cell enter the value of the master being measured The master is often a part of known dimension but can be a standard like a gage block that is similar in size to a production part such that it is reasonable to assume similar results from measuring the standard or a production part Measure the master 10 times and enter the results into cells 1 10 Blind studies are the best way to avoid bias File Menu Save or F2 The SAVE item or pressing F2 without opening the menu saves
114. name in the Name field OK button The OK opens the Characteristic Group window for the new or selected characteristic group Exit Button 100 DataLyzer Spectrum Gage Management The EXIT button closes the window Delete Button To delete an existing characteristic group select a name from the list or type its name in the Name field and press the DELETE button Characteristic Group Window 5 Characteristic Group OD Jog Part Select Characteristic 30 clip v30 clip b 40 clip 30 clip bi Save Cancel Find Similar Statistics Show Selected Part List The Part list located in the left hand side of the window lists all parts in the shared DataLyzer database Select the part or parts whose characteristics you wish to group by double clicking on the part or highlighting it and pressing enter Select Characteristic Once a part is selected all of its characteristics appear in the Select Characteristic list on the right hand side of the screen Select the characteristics you wish to group together by marking their checkboxes Save Button The SAVE button saves the characteristic group Cancel Button The CANCEL button closes the Characteristic Group window without saving changes Find Similar Characteristics Button The FIND SIMILAR CHARACTERISTICS button will search all parts in the database for characteristics similar to the selected characteristics at lea
115. nd double limit gages however in both cases only one limit must be examined at a time so their actual sizes are distributed symmetrically around the reference or true value The smallest sample must have O accepts and at least six other parts must have 1 19 accepts At least one sample with 20 accepts is also required The long attribute study analyzes around one spec limit The software will not allow data to be stored unless it meets the criteria of the study If you try to store data that does not comply with what is required by the long attribute study definition the software displays a window containing directions about how the sampling needs to be corrected The long attribute study shows equipment variation only It provides the following results on reports gage performance curve plot R probability for repeatability at a given reference value B bias Short Form Attribute The short attribute gage study evaluates go no go measurement systems lt involves two appraisers each taking two measurements on 20 sample parts Some passing and some failing parts should be included in the samples Both appraisers should measure all the parts once and then repeat to measure all 20 parts again If all four results for any sample do not match the gage is not acceptable Conversely the gage is acceptable if all four trials agree for every sample Ifthe gage is judged to be unacceptable it can be re evaluated using this method if there is doubt about the
116. nel This field should not be used to request a reading from all channels Any global requests should be entered at the main gage setup screen Identifier Setup Setup Menu 119 Enter a set of characters in the Identifier field that uniquely identify the line containing the reading for the current channel This may be a label like X axis or radius or a channel number such as 01 or A It is important that you enter the characters in the exact column positions that they occur in the gage transmission Reading Number The Reading number field allows for multiple readings per line to be handled If only one measurement is transmitted per line then enter 1 in this field Column The Column field does not allow input It merely displays the cursor s position for the Identifier field so you can locate the specific channel identifier in the exact position of the line s transmission string For example ifthe gage interface transmits 02 as the channel identifier in position 10 and 11 you must put 0 in position 10 and 2 in position 11 of the Identifier field The column field shows you where you are as you move the cursor Serial Port to Test The Serial port to test area includes a pull down list for specifying which RS 232 port will be used for testing Timeout Use the Timeout field to enter the number of seconds the template will wait for an RS 232 string
117. nstructions window Clicking the attachment buttons at that point will cause the system to follow the link you are establishing now and result in the instantaneous display of the attached file linked to it It may be a picture file like a jpg or tif It may be an MS Word or Excel file or it might even be a movie about how to do sampling for the study These attachments can be a powerful addition to assist in performing a study Supported attachment file types include Document Files Movie Files Text Files txt AVI Move avi wmv Rich Text Format Files rtf Audio File wav aif au snd wma aiff Word Document Files doc t MPEG Move mpg mp2 mpeg m1v mpe mpv Acrobat Files pdf t Quick Time 2 qt mov Hypertext files htm html Windows Media File asf wm wma wmv Image Files Other AutoCAD dwg dxf Excel Files xls xlw t CADKey prt PowerPoint Files ppt t BMP Images bmp Web addresses GIF Images gif JPEG Images jpg jpeg PCX Images pcx PNG Images png TIFF Images tif tiff WMF Images wmf t Note The DataLyzer Spectrum Gage Management software provides an internal utility for viewing doc and xls files however Microsoft Excel Viewer must be installed locally on drive C for embedded graphic and multiple worksheet support otherwise only the cell contents of the first worksheet are visible Microsoft Word Viewer must be instal
118. ntry into this form Edit Review Study Button and File Menu Edit Review Study not available from the Reports Menu The EDIT REVIEW button or menu item opens an existing study for editing or review Select a study by clicking in its study date field lts row will highlight to show it is selected Only the latest calibration study of the selected gage is available for editing other studies are read only Press the EDIT REVIEW button to open the selected study See the Calibration Study Window description for more information regarding the study window Exit Button and File Menu Exit The EXIT button closes the study history window and retums to the main DataLyzer Gages window File Menu Delete The DELETE item will delete the selected study Select a study by clicking in its study number field Its row will highlight to show it is selected Select DELETE from the FILE menu to delete the selected study A window will appear to confirm that you want to delete the selected study File Menu Print Certificate Select Select this menu item to print a calibration certificate for the currently selected calibration study Select a study by clicking in its study number field File Menu Print Label This opens a window for printing calibration labels on A4 or similar sheets of peel off labels Select a study by clicking in its study number field General Windows 25 3 3 File Menu Print History This prints the list of calibrati
119. o be edited because of user error or gage malfunction save the study and open the study using the EDIT REVIEW STUDY button in the GR amp R History window an open sheet is then available to edit all entries Randomized Method The Randomized method can be used with long or short variable and short attribute studies For valid results this method must be used for long variable studies using the ANOVA calculation s DataLyzer Spectrum Gage Management method The Randomized entry spreadsheet looks something like this ij Gage Repeatability amp Reproducibility Study xi Fie Edit Analyze Instructions Performed By Date 26 07 2010 Time 1 52 Gage Gage r Characteristic Part LSL USL Characteristic Saved calculations pe Method Average amp Range y Total Variation Method Study Variation X Variable Long 3 Appraisers 10 Parts 3 Trials Data Entry Method Randomized Appr 1 Appr 2 Appr 3 Appr 1 Appr 1 Appr 1 Appr 2 Appr 2 Appr 2 Appr 3 Appr 3 Appr 3 Trial 1 Tral 2 Trial 3 Trial 1 Trial 2 Trial 3 Trial 1 Tral 2 Trial 3 _ To begin data entry click the green START button in top left of the spreadsheet The system will display a data entry window with an indicator as to which appraiser trial and part to measure For variable gages enter the value for the specified measurement and press OK For attr
120. o the operating system and these interfaces should begin working as soon as they are plugged in From the SETUP menu select the GAGE INTERFACE TEMPLATE item The following window will appear 7 12 Setup Setup Menu 107 5 Open Create a Gage Interface Template File Y Gage Name Import Templates Enter a new gage name in the Gage Name field or select a gage file name from the list Press OK to open the Gage Template window The CANCEL button closes the Open Create a Gage Interface Template File window To delete a gage template select the desired name from the list and click the DELETE button When you are sharing a database with the DataLyzer Spectrum SPC package an IMPORT TEMPLATES button is available Use it to import existing gage driver files that exist in the database Gage Template Window The Gage Template window looks like this amp Gage Template C Program Files DataLyzer Spectrum gages GAGEPORT File Test Special Options Port Settings Baud rate 9600 y Parity None v Data bits le y Stop bits 1 z Transmission to initialize gage DOO O Transmission to prompt gage for reading A Secondary gage prompt y Reading Acknowledgement y Line terminator for lines received from gage E Lines per transmission received from gage ET Reading Description Reading fr of E lt lt Previous lt lt gt gt Next gt gt Line number of reading in g
121. o this field but another date can be entered if desired Time Enter the time the study was initiated in the Time field The current system time is automatically entered into this field but another time can be entered if desired Gage frame In the Gage frame click the Gage button to select a gage The category of the gage will be shown variable or attribute in the frame and the Gage Type ifthe gage is included in a Type If you have not defined any gages you can just type in the name of the gage here If Study is based on a Study Definition and the gage is included in a Gage Type then this study can be considered as representative of all the gages in the gage type Ifone or more GR amp R studies has been stored using the Study Definition the Gage Type will become locked This means that you can only change the specified gage to another gage in the Type s DataLyzer Spectrum Gage Management Characteristic frame Ifthe program is being used in conjunction with Datalyzer Spectrum you can select a Datalyzer Part and Characteristic by clicking on the buttons The Upper and Lower specification limits will be displayed along with the category of the characteristic variable or attribute Ifthe characteristic is included in a characteristic group the group will be also be shown If Study is based on a Study Definition and the selected characteristic is part of a characteristic group then GR amp R studies performed using this
122. ocument field allows you to add intemal traceability information Notes Use the Notes field for any extra comments you wish to add about the supplier Save Button The SAVE button saves the changes made to the supplier s information and exits the window The SAVE button only appears when using the NEW SUPPLIER or OPEN SUPPLIER options Delete Button The DELETE button will delete the currently displayed supplier The DELETE button will only appear when using the DELETE SUPPLIER option Exit Button The EXIT button closes the supplier window without saving changes or without deleting File Menu Save or F2 To save the information in the Gage Suppliers setup window select SAVE from the FILE menu or press F2 without opening the menu File Menu Save amp Exit or Ctrl S When using the NEW SUPPLIER or OPEN SUPPLIER options select FILE SAVE amp EXIT or press 104 DataLyzer Spectrum Gage Management 7 9 Ctrl S without opening the menu to save the information and close the Gage Suppliers setup window When using the DELETE SUPPLIER option select FILE SAVE amp EXIT or press Ctrl S without opening the menu to delete the currently displayed supplier File Menu Print or Ctrl P To print the information in the Gage Suppliers setup window select PRINT from the FILE menu or press Ctrl P without opening the menu File Menu Exit or Ctrl X To close the Gage
123. oftware using the MASTER LOW button The value will transmit from the gage in terms of a number of digital segments as discussed earlier and will display in the low gage reading field 5 Save the gage file template by using the SAVE button This sets up an automatic interpolation relationship The software does the following calculation automatically High master size Low master size High segments received Low segment received This defines the measurement size corresponding to each digital segment received The multiplication of the number of segments by the measurement increment per segment is then done automatically in the background so the actual measurement value is entered in the input window as the current measurement value Save Button The SAVE button saves the template Cancel Button The CANCEL button exits without saving Special Menu Multi Channel Setup Setup Menu 17 Some gages transmit multiple measurements in a transmission in random order When this is the case these measurements are typically labeled with a measurement identifier in the transmission The purpose of the multi channel facility is to key on these identifying labels for input rather than on the line number where it was transmitted These multi channel gage files typically must be created for each part file because of the specific nature of the ordered characteristics involved Multi channel gage operation typically utiliz
124. ollowing calculation 12 DataLyzer Spectrum Gage Management automatically High master size Low master size High segments received Low segment received This defines the measurement size corresponding to each digital segment received The multiplication of the number of segments by the measurement increment per segment is then done automatically in the background so the actual measurement value is entered in the input window as the current measurement value Previous and Next Buttons The PREVIOUS and NEXT buttons allow you to scan and set up to 64 channel descriptions Save Button The SAVE button saves the template Cancel Button CANCEL exits without saving 7 12 4 Options Menu Communications Options The communications options feature defines the RS 232 communication environment and sets some general rules for communication Setup Setup Menu 121 amp Communication Options Line length Length f0 ru Accept short input lines Test reading timeout Seconds before timeout 7 Delay between lines 1 10 second 3 Buffer size e 1024 2048 4096 8192 Buffer usage Special Clear Buffer on initialization Clear buffer after each reading Debug mode Turn debug mode on Special modes Gageport TM computer mode Save Cancel The SAVE button stores the data and sends you back to the gage setup window The CANCEL button cancels any changes made
125. on studies GR amp R History The window will be empty if no studies have been performed The NEW STUDY button will allow you to create a new GR amp R study File Show Study Definition an y Gage Al All Study Date Study Definition Characteristic av AR Method 11 07 2010 12 38 i Long 03 07 2010 20 13 10Daysb VarCharl UA Sor 02 07 2010 20 09 10D ays VarCharl Long 01 07 2010 20 09 10Days VarCharl Long 07 07 2010 14 30 Long 07 07 2010 14 28 WarCharl Long 07 07 2010 14 27 VarCharl Long 07 07 201013 42 VarCharl Long 07 07 2010 10 34 VarCharl 20 0 BE 06 07 2010 17 26 VarCharl 20 1 Long 06 07 2010 17 19 21 0 ANOVA 06 07 2010 17 14 21 0 ANOVA 06 07 2010 17 05 20 1 ANOVA 06 07 2010 16 52 20 1 Long New Study Edit Exit As studies are completed results are stored in the system Summaries are displayed in spreadsheet form sorted by date time with the most recent on top Each row represents an individual study Each column represents a key statistic or label relating to the study Each study type has different statistics in the study history window To delete a study click anywhere on the study s row and press the delete key It is important to note that certain studies do not provide all these statistics and so certain fields will be blank for example long attribute studies only provide equipment variation EV since they involve just one appraiser Short attribute studies offer no AV EV or RR
126. or Gage Type window Example calibration gage GR amp R Attachments xi GRR Measuring Instructions GRR Control Plan Reference ee aaa Attachment 1 Set Attachment 2 Set Attachment 3 Set Attachment 4 Set Attachment 5 Set I Specify web addresses Measuring Instructions Field Enter instructions for how to run the GR amp R or Calibration study in the Measuring Instructions field 3000 characters max This field can be left blank but it is not recommended Different instructions and attachments are stored for Calibration and GR amp R studies Control Plan Reference The Control Plan Reference field allows you to cite the applicable page or paragraph in your control plan describing how Gage R amp R studies for this gage should be conducted It can also be left blank Set Buttons By clicking any of the five SET buttons you can browse your computer and network resources to select files such as images documents videos or spreadsheets that will then be attached to the selected button Web addresses can also be attached see specify web address below These Gage Details File Menu 35 attachments are intended to augment measuring instructions for the gage at the time when it is being studied Up to five attachments of the types listed below can be selected one per button At the point when you or your staffis actually performing the studies attachment buttons will be available in a measuring i
127. ou are sharing an SPC DataLyzer database and have assigned a specific characteristic to the study both the lower and upper specifications will be filled in automatically from the characteristic you selected Otherwise type in the upper and lower specification limits for the characteristic into the LSL and USL fields Once data is saved in the study or a characteristic is assigned to the study the specification limits are locked and cannot be changed Date Enter the date the study was initiated in the Date field The current system date is automatically entered into this field but another date can be entered if desired Time Enter the time the study was initiated in the Time field The current system time is automatically entered into this field but another time can be entered if desired Location Enter where the bias study is performed in the Location field Gage Name The Gage Name field displays the gage name The contents of this field cannot be changed Gage Type The Gage Type field displays the gage type as specified in the gage s gage description window lt cannot be changed here Serial Number The Serial Number field displays the serial number as specified in the gage s gage description window It cannot be changed here Notes You can use the Notes field to enter comments such as the condition or other aspects of the gage being studied Instructions Button Whe
128. ow will then appear select the desired gage from the gage catalog After you select a gage the study history window will appear containing all studies performed for the report type selected The studies will be sorted by date and time with the most recent on top If no studies exist in the list no studies have been performed for this gage The history window will look similar to one of these GRER History File Study Date Type Performed By Part Characteristic EV AY TV Method 5 29 2008 13 22 Estua Gage TOL PartOne varcharl 1 0 94 71 ANOVA 5 28 2008 15 41 Actual Gage 1 0 95 73 Long 5 28 2008 15 13 Actual Gage widget2000 weight 1 0 81 64 Long 5 16 2008 11 54 Actual Gage KRE PartOne varcharl 1 0 97 30 Long 5 16 2008 10 59 ActualGage TOL 1 0 1213 Long 5 16 2008 10 31 ActualGage PVM widget thickness 0 970 0 000 96 84 Long 5 14 2008 15 09 Actual Gage KRE widget2 length 0 000 0 350 34 89 Short 5 14 2008 14 53 Actual Gage KRE widget2 length 0 3500 0 0000 95 07 ANOVA 5 6 2008 11 21 Actual Gage MTL widget width 092 000 91 71 Long Print s DataLyzer Spectrum Gage Management J a T Calibration History 0 1 indicator 12342134 File Study Date Performed By Master Set Status Location 12 13 2005 14 16 Pass cib 2 Print The spreadsheet areas of these windows are described in Chapter 4 Data Print the history report using the PRINT button or
129. p Range unzzunsnnnennnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn nn 73 2 Gage R amp R Long Variables ANOVA uuenenssnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnsnnnnnnn nennen 76 3 Gage R amp R Short Variables nee nenne 77 4 Gage R amp R Long Attribute 2222er anna 78 5 Gage R amp R Short Attribute see nein 79 6 Gage R amp R Performance Report uuussseennnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnsnnnnnnnsnnnnnnn nn 80 7 Galibration Certificate 2 2 ann oia danna da 81 8 Calibration amp GR amp R D e vicio ee 82 9 GR amp R and Calibration Histories 440 44400nnnnnnnnnnnnnnnnnnnnannnnnnnnnnnnnnnannnnnnnnn nenn 83 10 Supplier SUMMARY ciencia aaa a aan anne nenn EHRE nennen 84 11 Additional Reports 2 2 ar ii ie ea 85 Part VII Setup Setup Menu 88 T System DEMOS di 88 EE A A A OO TO 90 3 Preferences icon ne einen 91 4 Define Gage Types ia 92 5 Define Masle S eea re ii i Ain ti cascadas 96 6 Define GR amp R Characteristic Groups ccconccconccnconccnnnnccnnnnnnnncnnnnnonnnernnnnnnnnrrnnnncrnnnrenanenes 99 7 Suppliers New Open 8 Delete cccoonccoonccocnceconnconnnccnnnennnnnnnnnnnnnnnnnonarennnennnnnrnnenennns 101 8 Supplier Details sinirinin iinne iaa a akaa aeaaea aa a raaa aaia diia 102 9 Gage Locations zeuai ineeie detec cee di ia ii 104 10 Gage Statuses and Inspectors ccoooncccccononcccnonancnnnnnncncnnnnnrnn
130. p R The measuring process often contributes a significant amount of variation to the total variation of a manufacturing process There are several standardized ways to study this variation Selecting one over another depends on which type of measuring system is being used variable or attribute gages along with how much discrimination and precision is required vs the amount of time available to do the study GR amp R studies can be entered for a specific gage or you can study one gage and designate results to apply for all gages of a specified gage type After conducting a study a high repeatability value also known as equipment variation or EV can point to the need for gage maintenance repair or redesign or the addition of fixturing etc A high reproducibility value also known as appraiser variation or AV points to the need to increase measurement consistency between operators possibly better measuring procedures or additional appraiser training to develop uniform measuring techniques between operators Repeatability and reproducibility values are compared to total variation TV to determine a percent R amp R i e the percent of total variation being consumed by gage error Total variation can be defined three ways 1 Total tolerance USL LSL 2 Total study variation 3 Total process variation which uses a larger sample from the manufacturing data usually collected in an associated SPC system Sometime
131. pe a supplier name in the Company field and press SELECT The program will notify you that the supplier does not exist and ask if you want to create it Press YES The Gage Suppliers setup window will then appear see the description of this window Once a supplier is selected it appears in the field You can view more specific information about the supplier by clicking on the field a window containing read only information about the supplier will appear Other Supplies The Other Supplies field is an optional field used for noting external gage supplies like batteries cables chemicals attachments printer paper or other miscellaneous items consumed while using the gage Gage Details File Menu 33 Notes Use the Notes field to enter miscellaneous user notes about the gage A maximum of 3000 characters are allowed in this field Full calibration procedures graphical attachments and work instruction documents are available in the INSTRUCTIONS items under the GR amp R and CALIBRATION menus User Defined Fields 1 12 The user fields only appear if they have been previously setup in the headers fields tab under SETUP SYSTEM DEFINTIONS These fields will appear at the bottom of the window beneath the Notes area not only in the in the Gage Definition window but also in the reports They are available for entering any information you wish up to 24 characters per field 12 fields max they are global
132. ppraiser s trial avg points In a perfect situation all points would be in identical locations on the graph GRER Average amp Range Method X Statistics Data Performance Curve Average Charts Individuals Charts Range amp Error Charts Chart Type oR C Averages Chart C XY Plot Run Chart N m An m o a 10 Appraiser 1 Appraiser 2 Appraiser 3 Print LJ Print Exit Averages Chart The averages chart option adds control limits that are calculated by using the average appraiser trial points for each part as subgroups GR amp R Average tt Range Method E Statistics Data Performance Curve Average Charts Individuals Charts Range amp Error Charts Chart Type C Run Chart C XY Plot Averages Chart r N Ly E Ll e amp p pP a Appraiser 1 Appraiser 2 Appraiser 3 Print m Print Exit X Y Plot The X Y Plot option ranks the parts in the study smallest to largest using a calculated grand Gage Studies Data Menu 45 average for each part This ranking becomes the x axis and represents the order the part trial averages are plotted left to right Measured average is the y axis A linear regression is plotted on each operators points Dramatic differences between operator performances can be addressed by training or other remedial measures GRER Average amp Range Method E Statistics Data Performance Curve Average Chart
133. r Point presentations Language Use the LANGUAGE item to select the desired operating language for the program The default language is English The user defined language item can be used to enter your own localized language Contact DataLyzer International Inc for instructions regarding use of this option Setup Setup Menu a 7 3 Preferences The PREFERENCES item is used to set preferences for the various studies in the program m Variable Study Preferences Attribute Study Preferences Appraisers 3 2to4 Type Appraisers fi L Parts fo 5to10 oe Parts fo 8to10 Trials 3 2to4 Lo Trials 20 r Re Evaluation Time Units GR amp A calculations based on Days Month C 5 15 Sigma 6 Sigma IV Alert if calibration or GARA is due in le Days I Use Appraiser Name Passing Error Limit fo Include Atmospheric Information Save amp Exit Exit Variable Study Preferences You can set the preference configuration to match the variable Gage R amp R study configuration you expect to use most frequently These will come up as defaults when doing a new study or creating a GR amp R Study Definition They can also be changed at that time as necessary Type Using the Type selection choose whether the default GR amp R variable study will be long or short Appraisers Enter the default number of appraisers used when conducting a variable GR amp R study in the Appraisers field
134. racteristics was received by the com buffer Ignore all hardware triggers The Ignore all hardware triggers option leaves data in the com buffer time after time Allow all hardware triggers The Allow all hardware triggers option attempts to process data in the com buffer no matter what garbage characters may exist Framing Errors These errors typically arise from software errors like incorrect baud rate or parity Reject all framing errors default The Reject all framing errors option throws away all data with framing errors Ignore all framing errors The Ignore all framing errors option attempts to process data in the com buffer no matter what garbage characters may exist Allow all framing errors The Allow all framing errors option attempts to process data in the com buffer no matter what garbage characters may exist Hexadecimal In rare cases instruments will transmit in Hexadecimal code This option converts the hexadecimal code into readable ASCII text before displaying the string This item works like a toggle switch When it is set the message HEX appears next to the Reading Description heading Select the menu option again and HEX disappears Clear The CLEAR item resets all gage template fields to their default settings This includes fields in the SPECIAL and OPTIONS menus Gage Template Example 1 Single Line Single Measurement Example string _ _ _X 4 379 This
135. results since only a pass or fail conclusion is drawn Short variable studies require only one trial from 2 operators so only AV can be measured Show Menu Over time the number of studies stored can get very long which can slow down the loading of the list As you are likely to be most interested in the most recent studies the Show Menu allows you to improve performance by limiting the number of studies listed Study Definition drop down list The drop down list under the menu bar allows you to filter the table to show only studies which used particular Study Definition Click the small down arrow at the right hand end of the box to show the list of Study Definitions Select All to show all Study Definitions 26 DataLyzer Spectrum Gage Management Gage Button Click the button to select a Gage from the Gage Catalog The table will then only show studies which used the selected gage Click the All button to remove the filter Study Date The Study Date field displays the date and time the study was performed Study Definition If the study was based on a Study Definition the name will be shown in this column Part The Part field displays the name of the part being measured in the study Characteristic The Characteristic field displays the name of the characteristic being measured in the study EV Equipment Variation Equipment variation EV gage repeatability The values in the
136. revious tests Message The Message field will display operational comments that the software reports about the transmission Messages include opening com port send data now communication timeout etc Transmission Field s The number of transmission fields displayed in the Transmission area is determined by the number entered in the lines per transmission received from gage field in the Gage Template window These fields are used to define the template that is used to mask and pull out measurement values from the string When a gage transmits one or more strings of information during testing they will appear in these fields Use the arrow keys to access only the lines and columns that have characters received from the gage including spaces Then overwrite the desired measurement number including the decimal point in each line with pound signs and save the template Thereafter during standard use each time the gage transmits a string of characters the software will pick up values located under the positions designated by s in the template they form and use these values as numeric input for data entry A maximum of 130 characters can be accommodated on each transmission line When the sign of the measurement value in the transmitted string is right in front of the measurement i e they are contiguous overwrite the sign with a also When they are not contiguous overwrite the sign with an S
137. ror expressed as a percent of total variation where total variation is estimated by the part variation found in the parts used in the study Total study variation TV is similar to total process variation except that it uses part to part variation of parts used in the study to estimate variation of the manufacturing process Process Variation Process variation refers to total variation in the manufacturing process This is the Standard Deviation of the most recent one hundred measurements Tolerance Tolerance is gage error expressed as a percentage of engineering tolerance for the selected characteristic i e percentage of the spec range being used by error in the gaging system The engineering tolerance will be taken from values entered into the USL and LSL fields If using a shared DataLyzer Spectrum SPC software these values will be filled in automatically Study Parameters Clicking the Study Parameters button brings up the Study Parameters screen Study Parameters x Study Variation GAR Attribute Study Long Form C Short Form Number of Appraisers 3 2to4 Number of Parts fi 0 5to 10 Number of Trials E 2t04 r Data Entry Method Open Sheet By Trial C Randomized OK Cancel The study category variable or attribute and long or short form dictate what entries are acceptable in the Number of Appraisers Number of Trials and Number of Parts fields The following list contains recommended values for th
138. rum SPC module Using the Gage Management System with the DataLyzer Spectrum SPC Package with Microsoft Access Microsoft SQL Server and Oracle Databases If you are using both the DataLyzer Spectrum Gage Management System and the DataLyzer Spectrum SPC packages you should install the SPC packages first if they are not already installed follow the instructions in the DataLyzer Spectrum SPC user s manual After the DataLyzer Spectrum SPC package s has been installed install the Gage Management System software By default both programs are installed in the same folder C Program Files DataLyzer Spectrum and will use a single database in order to allow results to be shared by both programs Note When using a Microsoft Access database ifthe SPC and Gage Management programs have not been installed in the same folder or the dsdbase mdb database file has been installed to a Appendices 135 location other than the default such as a server you will need to select the desired database using SETUP SELECT DATABASE in either package You can see the path of the database currently being used by the program by going to HELP ABOUT DATALYZER Using the Gage Management System Only When using a Microsoft Access database install the Gage Management System software following the installation instructions below The program is then ready to run with no additional steps required When using Microsoft SQL Server or Oracle databases you must
139. s Individuals Charts Range amp Error Charts Chart Type Run Chart C Averages Chart X Y Plot 3 a 6 3 5 Pat 4 8 1 2 10 Appraiser 1 Appraiser 2 Appraiser 3 Print Print Exit Individuals Charts Tab On the individuals charts tab part size is on the Y axis and parts measured follow the X axis Option buttons include normalized whisker and scatter plot This tab only applies to long variable studies Normalized Using the normalized option scale is converted showing the grand average of all readings at 0 The high and low measurements for each appraiser and each part are plotted as a deviation from the grand average The points for each operator are plotted in a different color and shape and connected by a line One might expect as many as two dots at the extremes high and low of each operator for each part except when all measurements are the same for a given appraiser on a given part In this desirable case only one dot will be plotted 45 DataLyzer Spectrum Gage Management GRER Average amp Range Method E Statistics Data Performance Curve Average Charts Individuals Charts Range amp Error Charts Chart Type oh ed C Whisker Scatter Plot Data Values Grand Average Normalized Appraiser 1 Appraiser 2 Appraiser 3 Print Print Exit Whisker Using the whisker option for each part a line whisker connects th
140. s customers set which TV criteria to use but most often the practitioner is left to decide To compare variation values calculated during the study to total tolerance the sigma values standard deviation or estimated standard deviation have traditionally been multiplied by 5 15 This represent 99 of the expected full spread assuming a normal distribution curve More recently a multiplication factor of 6 has been used this represents 99 7 of the full spread DataLyzer Spectrum Gage Management System can use either choose the multiplication factor in the Preferences screen Guidelines for acceptance of gage repeatability and reproducibility R amp R Explanations 2 4 e Under 10 error measurement is acceptable e 10 to 30 error measurement system may be acceptable depending on application importance cost of the gage cost of repairs or improvement and existing process capability e Over 30 error measurement system needs improvement depending on process capability make every effort to identify problems and correct them Source AIG MSA Manual Bias studies Gage bias studies determine the difference between a measured value and a known value To determine bias in a gage there must be known values to compare with readings taken by the gage When the study is conducted one operator measures one known standard or part ten times and the measured values are compared to the known value The bias is defined
141. s opened during a Calibration or R amp R study Example calibration gage GR amp R Attachments Ea GRR Measuring Instructions GRA Control Plan Reference lee a i Attachment 1 Attachment 2 Attachment 3 Attachment 4 Attachment 5 Gage Studies Data Menu er 5 8 Measuring Instructions Field The Measuring Instructions field shows instructions or procedures about conducting studies Different instructions are stored for Calibration and GR amp R studies Control Plan Reference The Control Plan Reference field offers control plan cross reference File Attachment Buttons If attachments were included when the gage was defined each of the five ATTACHMENT buttons may link to a file or website to help describe procedures or work instructions for doing a study Buttons with attachments will display the name of the linked file or website inside the label of the button clicking on the button will cause the system to follow the link and display the attached file or website that is linked to it Bias Study The Bias Study window looks like this Bias Data File R E Rd Gage Name D 1 caliper Part Gage Type caliper y Characteristic Serial Number LSL USL Notes Date 6 10 2008 Time 11 18 Location Instructions Process Variation bserved Average Bias Bias Master 1 2 3 4 5 6 2 8 9 10 Reading Performed By Field and Button
142. sheet is the most flexible data entry method Long Attribute The long attribute study uses a special spreadsheet for data entry It looks like this is Gage Repeatability amp Reproducibility Study File Edit Analyze Instructions Performed By Date 26 07 2010 Time fiz07 Gage Gage r Characteristic Part LSL USL Characteristic GRA Attribute Study Long 1 Appraisers 10 Parts 20 Trials Data Entry Method Open Sheet Appr 1 l Sort Accepts Run each sample through the attribute gage 20 times and record the dimension size and enter the number of accepts for each size in the corresponding Accepts field The whole study should have at least one sample within the gage s limit with a result of Go for all 20 samples and the study should include at least one sample outside the gage s limits resulting in 20 No Go entries Results between the two extremes should have a variable number of acceptances It is required that at least six samples be measured where the number of acceptances is between 1 and 19 If the originally selected pieces do not yield 6 samples with 1 19 acceptances choose more samples from the process with different measurements taken by the variable gage The P column is used to show the estimated probability of acceptance and is calculated after data entry File Menu Save or F2 The SAVE item or pressing F2 without opening the
143. smallest interval the gage can measure in the Precision field Range of the Gage Enter the range between the smallest and the largest sizes measurable by the gage in the Range field 32 DataLyzer Spectrum Gage Management Manufacturer Button No manual entry is allowed in the Manufacturer field For entry in this field use the MANUFACTURER button to open the Suppliers list to select or create a manufacturer To select a predefined supplier s name from the list double click on it or highlight it in the list and press the SELECT button To create a new supplier enter a supplier name in the Company field and press SELECT The program will notify you that the supplier does not exist and ask if you want to create it Press YES The Gage Suppliers setup window will then appear see the description of this window Once a supplier is selected it appears in the field You can view more specific information about the supplier by clicking on the field a window containing read only information about the supplier will appear 1 and 2 Gage Supplier Button No manual entry is allowed in the 1 Gage Supplier or 2 Gage Supplier fields For entry in these fields use the 1 GAGE SUPPLIER and the 2 GAGE SUPPLIER buttons to open the Suppliers list to select or create a supplier Note that the gage sales option button is selected in this window allowing only predefined suppliers of that type to appear
144. st one characteristic must be selected checked for this button to work All applicable characteristics will appear in the Select Characteristic list Show Selected Pressing the SHOW SELECTED button hides all characteristics that are not selected as part of the Setup Setup Menu or characteristic group 7 7 Suppliers New Open amp Delete The NEW SUPPLIER OPEN SUPPLIER and DELETE SUPPLIER items use nearly identical windows to operate After selecting one of these options from the SETUP menu the following window will appear amp Suppliers Company Type all C Gage Sales Gage Technical Support C Gage Supplies C Gage Manufacturer Gage Calibration Certifying Agency Company OK Cancel Company Type Use the Company Type option buttons to select a supplier type If you select a type other than all when creating a new supplier this will carry through to the Gage Suppliers setup window The option buttons determine what types of existing suppliers are contained in the list below the Company field Company Enter the new or existing supplier name in the Company field Existing suppliers will appear in a list below this field To open or delete an existing supplier you can type in the name or select it from the list OK Button Press the OK button to open the Gage Suppliers setup window for the supplier name entered in the Company fi
145. stablish direct communication with electronic gages via RS 232 protocol Other program functions e Scheduling for gage calibration This facility requires the calibration interval to be entered for each gage in its gage definition then reports interpret and organize gages by calibration due dates e Scheduling for GR amp R study This facility requires the re evaluation interval to be entered in a GR amp R Study Definition pa DataLyzer Spectrum Gage Management 2 2 1 Explanations Basic Concepts Gage R amp R Calibration Basic Concepts SPC analysis is largely affected by measurement system error Measuring instruments inspection techniques of technicians and fixturing all make up a measuring system Any of these components can introduce variation in the measuring system This variation in the measuring system is then reflected as part of total process variation in the SPC analysis and negatively affects key quality statistics like Cp Ppl Cpk Ppk Ppm etc The DataLyzer Spectrum Gage Management System helps to quantify this measurement system variation so steps can be taken to reduce it NX Total Variation Every process contains inherent variation The sources of variation can be related to any of the inputs from the mechanics of the process itself to raw material or personnel consistency However it is often true that the variation in the measurement process is the most significant contributor to the overall vari
146. teristic group the group will be shown You can enter USL and LSL manually if the program is not being used in conjunction with Datalyzer Tolerance USL LSL is one of the Total Variation TV methods If the selected characteristic is part of a characteristic group then GR amp R studies performed using this Study Definition can be considered as representative of all the characteristics in the group If at least one GR amp R study has been created using this Study Definition the characteristic group will become locked This means that you can only change the specified characteristic to another characteristic in the group Re evaluation required every days Ifthis box is checked a new GR amp R study with the Study Definition will be due after a specified time Studies coming up for re evaluation can be seen in the Gage Lists GRR Due report The user can also be alerted when the program is started if the time for a re evaluation is approaching Parameters Button Clicking the Parameters button brings up the Study Parameters screen Study Parameters xi Study Variation GAR Attribute Study Long Form C Short Form Number of Appraisers 3 2to4 Number of Parts fi 0 5to 10 Number of Trials 3 2to4 r Data Entry Method Open Sheet C By Trial C Randomized OK Cancel The category of the study variable or attribute and long or short form dictate what entries are acceptable in the Number of Appraisers Number
147. the gage enough time to process each command Secondary Gage Prompt Sometimes instruments require a prompt to be sent causing them to take readings into their memory then another prompt to transmit those measurements from memory to the computer As one example the GagePort s computer mode works in this manner Enter into this field the secondary prompt required by the gage for it to send from memory As in previous cases ASCII characters and literals are supported Reading Acknowledgment Setup Setup Menu 109 Sometimes instruments require the computer to return a got it message confirming its measurement was received before additional data can be collected When this is true put the string expected by the instrument in the acknowledgment field As in previous cases ASCII characters and literals are supported Line Terminator for Lines Received by the Gage The software must be told what character or set of characters will be at the end of each line sent by the gage The line terminator for lines received by the gage field is used to enter the line terminator character s In most cases entries for this field will not be visible when typed such as carriage return and line feed The default is carriage return ASCII character 13 When more than one entry is made in this field thereby establishing more than one character for line termination commas should be used between the characters If the comma itself is a
148. this string automatically each time it is transmitted overwrite the X measurement value 4 379 with signs Since the Y measurement is in the same line its measurement should be overwritten with signs This way each time the transmission is sent by the gage the software will use this template to look in these column positions for input values When templates of this type are used the reading number of the transmission must be referenced in the FUNCTION area of each characteristic Characteristics looking for X measurement values should have R or R1 in their function fields Characteristics looking for Y measurement values should have R2 in their function fields The reading description area reports column positions where measurements reside Zeros will appear in the fields of this area until the template has been established through the testing procedure Com Port Assignments The purpose of the com ports window is to assign existing gage interface template files gage drivers to control particular communication ports on the computer One gage driver can be assigned to each com port Data can then be sent directly from the gage to DataLyzer Spectrum Gage Management software Com port assignments can be changed at any time If no gage is necessary fields can be left at No Gage The DataLyzer Spectrum Gage Management software allows you to communicate directly with a wide var
149. tion 6 sigma from long range SPC data or total study variation 6 sigma of data collected in the gage study only can be used for calculating the proportion used in measurement error Customer requirements typically mandate which method to use Guidelines for acceptance of gage repeatability and reproducibility R amp R e Under 10 error measurement is acceptable e 10 to 30 error measurement system may be acceptable depending on application importance cost of the cage cost of repairs or improvement and existing process capability e Over 30 error measurement system needs improvement depending on process capability make every effort to identify problems and correct them Source AIG MSA Manual Gage Calibration Bias This is the difference between the true reference value that the gage should be reporting and the actual measurement the gage is reporting 16 DataLyzer Spectrum Gage Management Reference Value Bias Observed Average Value Calibration Calibration is a one time look at a gage or measuring system under ideal conditions temperature controlled and clean environment A trained and experienced technician carefully tests the measuring system By measuring a known standard once the amount of bias for that standard size is determined Bias is the difference between the observed measurement of the gage and the known standard being measured by the gage Bias can often be reduced through gage
150. udy window similar to the one below opens the appearance of the window may vary depending on whether it is a variable or attribute gage or due to other items such as the study type If you created a new study based on a Study Definition some of the fields will already be filled in Gage Studies Data Menu IO is Gage Repeatability amp Reproducibility Study Study Definition 10Days lyze Instructions H Date 23 07 2010 Time 17 45 Gage G 6111 Serial 12345 age Category Variable Type Typel Locked Characteristic Par Parti is fi ust fico Hin Kain e Category Variable _ Characteristics VarCharl Group FirstCG Locked Saved calculations Cata o Method Average amp Range y Total Variation Method Study Variation y Study Parameters Variable Long 3 Appraisers 10 Parts 3 Trials Data Entry Method Open Sheet Appr 1 Appr 2 Appr 3 Appr 1 Appr 1 Appr 1 Appr 2 Appr 2 Appr 2 Appr 3 Appr 3 Appr 3 Trial 1 Trial 2 Trial 3 Trial 1 Trial 2 Trial 3 Trial 1 Trial 2 Trial 3 Performed By Field and Button Enter the name or initials of the supervisor overseeing the test in the Performed by field You can type it in directly or select from a list by clicking the PERFORMED BY button Date Enter the date the study was initiated in the Date field The current system date is automatically entered int
151. umber assigned to the gage by the company if this is different from the entry in the Name ID field Date of Purchase Enter the date the gage was invoiced by the supplier in the Date of Purchase field so in the future you will know how old the gage is PO Enter the purchase order number used by your organization to purchase the gage in the PO field Cost Enter the price paid for this gage in the cost field Status Set the current status of the master by clicking on the Status button and selecting from the list No manual entry is allowed you must pick from the list Location Set the current status of the master by clicking on the Location button and selecting from the list You can also type in a location that is not in the list Variable Attribute The Variable or Attribute items are used to further identify the gage type and the type of studies to be performed Variable gages enter numeric measurements attribute gages give measurements such as defect information or go no go information Calibration Re evaluation Interval Enter the interval between gage calibration analyses Refer to your quality manual for this interval Enter 0 zero for gages that are only used for reference and do not need to be regularly studied The re evaluation period can be set in Days or Months this is chosen using the in Preferences item in the SETUP menu of the main program window Precision of the Gage Enter the
152. uppliers setup window will then appear see here for a description of this window Once a supplier is selected it appears in the field You can view more specific information about the supplier by clicking on the field a window containing read only information about the supplier will appear Other Supplies Enter information about other supplies required that are specific to this master or master set in the Other Supplies field Notes Enter any further notes documenting this master or master set in the Notes field Last Calibration Date Enter the last calibration date for the master in the Last Calibration Date field User Fields 1 12 If custom user fields have been created in SETUP SYSTEM DEFINITIONS these fields will appear beneath the Last Calibration Date field Enter the specified information as necessary File Menu Save or F2 The SAVE item or pressing F2 without opening the menu saves the changes made to the master File Menu Save amp Exit or Ctrl S The SAVE 4 EXIT item or pressing Ctrl S without opening the menu saves the changes made to the master and returns to the main DataLyzer Spectrum Gage Management software window File Menu Exit or Ctrl X The EXIT item or pressing Ctrl X without opening the menu closes the Define Masters window and exits to the main DataLyzer Spectrum Gage Management software window without saving Setup Setup Menu ss 7 6
153. verage Value Value lower part of range higher part of range DataLyzer Spectrum Gage Management System calibration studies support up to 20 reference points throughout the range ofthe gage so bias can be detected at each end ofthe range or the gage as well as numerous points in the middle 18 DataLyzer Spectrum Gage Management 2 2 2 3 Calibration Calibration is the comparison of measurement and test equipment or measurement standard of unknown bias in order to detect report or eliminate by adjustment any variation in the bias of the instrument being studied The process involves measuring several known standards up and down the gage s range of measurement then verifying any differences and average differences between the gage s measurements and the true standard If the difference is smaller than the allowed tolerance for all calibration points the gage passes the calibration study Ifthe difference is larger than the allowed tolerance for any calibration point the gage fails the calibration study and must be adjusted sent for repair replaced or relegated to reference use only Some gages have more than one measurement mode for example a calliper gage may have different jaws to measure outside diameter inside diameter and depth The bias of each measurement mode will have to be determined separately Required bias is dependent on the application along with the number of points to be measured throughout its range Gage R am
154. w window for short attribute GR amp R studies looks like this Gage Repeatability and Reproducibility Report E File Part No amp Name Gage Name alt gage Date 772272008 Characteristic Gage No 53334 Performed by ALG Specifications Gage Type User Field 1 Appraiser 1 Appraiser 2 Status Fail Appr 1 Appr 1 Appr 2 Appr 2 Part Trial 1 Trial 2 Trial 1 Trial 2 D D D o a zzooonoooooooo zzonononm 05000000000000272000002z2z D oon2oooooooooooo DooDoo D 20 050000000000900027200000 In this short attribute study example 20 samples are measured by two appraisers in two trials each Samples are selected in order to include examples of passing samples and failing products Passing products are represented on the report by G and failing samples in the list are represented by NG For the gage to pass all trials must be the same across each row In the example above you can see entries on rows 1 2 7 8 19 and 20 are not the same so this gage fails the R amp R study If all trials for each sample match then the gage is deemed acceptable s DataLyzer Spectrum Gage Management 6 6 Gage R amp R Performance Report The preview window for a performance report looks like this Performance Report E File Performance Curve GRR 6 1 Bins 0 gt gt Probability of Acceptance gt Reference Part Measurements Serial Number Part ne Serial Number varchar
155. write the sign with a When the sign is not contiguous overwrite the sign with and add enough s to the string to connect it with the measurement Once created use the TEST TEMPLATE item in the TEST menu so as not to disturb the template signs If the sign template placement is incorrect you will only get part of the measurement value through to the software during data entry A gage reading like 3 655 might come through as 655 There is a maximum of eight unique measurement values that the software can process per line There is also a maximum of 64 values that can be processed for all lines of a full transmission So an eight line transmission could have a total of eight accessible measurements per line Most of the standard interfaces used transmit only one measurement per line The Read Gage Button The READ GAGE button is used to set the software to receive a transmitted string It will open the designated com port and continue trying to receive a string from the gage for seven seconds by default after which a time out error will be reported in the message field This waiting interval can be changed through the COMMUNICATION item in the OPTIONS menu Save Button The SAVE button stores all the template information If no further changes are made to the main gage template window saving at the outer level would be redundant Cancel Button The CANCEL button exits without storing anything Test T

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