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Case - Bloomfield Tool Co.
Bloomfield Tool Co. (BTC) is a small manufacturing company that produces precision
tools to order. One of BTC’s production processes involves producing a metal spacer
plate that has a tolerance of 0.05 to 0.100 cm in thickness. Recently, the QA manager was
receiving complaints from customers about high levels of nonconforming parts. He
suspected that there were problems in the gauges used to check outgoing parts, since they
had not been sent out for calibration in some time. However, it was expensive to do, so he
A reliability engineer pointed out that variations in the data could be traced to
three causes: repeatability problems (equipment variation or EV), reproducibility
variations (appraisal variation or AV), and process variation (part variation or PV). Thus,
total variation (TV) could be seen as made up of repeatability and reproducibility (R&R)
variation and PV. Team members had heard about EV, AV, and R&R in a training class
on measurement, but realized that the last item was an obvious, but important point that
they had not previously considered. They were given the following formulas for
computation of the PV and TV:
Table 1 Data Set for R&R Study
Table 2 Numbers of Parts and K3 Factors
No. of Parts
5
6
7
8
9
10
11
12
13
14
15
Assignment
Calculate the R&R, process, and total variation for the data. Using the TV as the
divisor, calculate the percentage of total variation that the EV, AV, R&R, and PV
encompass. (Note: these variations are not directly related to one another, so the
