How does the automotive industry know that the measurement results obtained are reliable? Simply put, through “MSA.” Measurement Systems Analysis plays a key role in ensuring that the tools and methods used to evaluate automotive components are accurate, reliable, and capable of producing consistent results. In this article, we will examine MSA, drawing on the guidance provided by two key standards: the AIAG MSA Handbook and the VDA 5 Guidelines.
What is Measurement Systems Analysis?
Measurement Systems Analysis (MSA) is a statistical methodology used to evaluate the accuracy, precision, and capability of measurement systems. These systems include not just the instruments themselves, but also the procedures, personnel, and environmental factors that influence measurements. MSA aims to ensure that the data used to make decisions in the production process is trustworthy and that the measurement system is adequate for its intended purpose.
The role of Measurement Systems Analysis in the automotive industry
The automotive industry is characterized by its need for precision and zero-defect manufacturing. Whether it’s verifying the dimensions of a component, assessing material properties, or checking for defects, accurate measurements are critical. An unreliable measurement system can lead to incorrect decisions, resulting in defective products, increased costs, and even safety issues.
MSA is therefore a fundamental part of the quality management process in automotive manufacturing, providing the framework for assessing whether a measurement system is adequate for its intended use. No wonder that Measurement Systems Analysis is regarded as one of the core tools in automotive quality management.
AIAG’s approach to MSA
The Automotive Industry Action Group (AIAG) is a North American-based organization that develops standards and best practices for the automotive industry. AIAG’s MSA manual is one of the core references for implementing MSA in automotive settings.
It includes data collection, analysis and providing reliable information. Measurement Systems Analysis (MSA) is key to determining what variation is present in the product. Also it is about how much variation is due to the measurement system. Placing controls and making improvements to equipment and operators will reduce uncertainty (i.e. measurement error) and increase confidence in making firm decisions about process and product quality.
According to AIAG, the MSA process involves several key steps:
- Definition of Measurement Process Requirements: Understanding what needs to be measured and determining the requirements for the measurement system.
- Selection of Measurement Instruments: Choosing the appropriate tools and technologies based on the specific requirements of the measurement task.
- Assessment of Measurement System Variability: Analyzing the variability in the measurement system through studies such as Gauge Repeatability and Reproducibility (GR&R), bias, linearity, and stability.
- Interpretation of Results: Using statistical methods to assess the adequacy of the measurement system, ensuring that it meets the required precision and accuracy levels.
- Continuous Improvement: Based on the MSA results, making improvements to the measurement system to reduce variability and enhance accuracy.
AIAG places significant emphasis on GR&R studies, which focus on evaluating the consistency of measurements when different operators, instruments, and conditions are involved.
VDA 5’s approach to MSA
The Verband der Automobilindustrie (VDA), or the German Association of the Automotive Industry, provides an alternative approach to MSA through its VDA 5 guideline. This standard is widely used in European automotive manufacturing as the German OEMs requirement.
VDA 5 deals with the suitability of measurement and control processes. The German approach is not only about monitoring and measuring equipment. It is about all necessary resources, from spatial conditions, through appropriately trained personnel, appropriate control measures, measuring equipment including software, to the necessary aids and methods that have an impact on obtaining important and reliable monitoring and measurement results. All this must correspond to the purpose of the compliance of products and services. It must be ensured that the customer is provided only with the guaranteed quality.
We can find here, among others:
- Harmonization strategies with the AIAG Core Tool MSA (fourth edition),
- Recommendations for procurement of measurement systems (e.g., terms of reference),
- Dealing with small tolerances,
- Procedure in the case of an insufficient sample size in tests of the “measurement system” and “measurement process”,
- Handling of small series in pre-series production and production batches in development and production,
- Consideration and evaluation of the current suitability through stability measurements,
- Methods of calculating the measurement uncertainty.
AIAG vs. VDA 5: Key differences
While both AIAG and VDA 5 share the common goal of ensuring accurate and reliable measurement systems, their approaches differ in several key ways:
- Focus: AIAG focuses on repeatability and reproducibility (GR&R), while VDA 5 emphasizes measurement uncertainty and a risk-based approach.
- Methodology: AIAG’s methodology is more straightforward and prescriptive, while VDA 5 offers a more comprehensive and flexible approach, taking into account a broader range of factors affecting measurement accuracy.
- Application: VDA 5 dominates the German automotive sector, while it is safe to say that OEMs from the rest of the world use AIAG.
Measurement System Analysis and choosing the right approach
For automotive suppliers, the choice between AIAG and VDA 5 depends largely on the specific requirements of their customers. While the AIAG MSA Handbook provides a solid framework for ensuring measurement system accuracy, VDA 5 offers a more detailed approach that may be better suited to complex or high-risk applications.
Ultimately, both standards emphasize the importance of a well-implemented MSA process in achieving high-quality products in the automotive industry. Therefore, it is not possible to say that one standard is better than the other…
And finally, a few arguments why we should implement Measurement Systems Analysis MSA in an organization supplying to the automotive industry:
- MSA is considered one of the basic methods of quality assurance in the automotive industry,
- it constitutes audit criteria during audits,
- it is an important element of the competence of persons performing the functions of auditors of the quality management system, also defined in the IATF 16949 standard (this applies to both the competence of an internal auditor and a 2nd Party auditor),
- it is used throughout the product life cycle, from development to production and delivery,
- it is a basic component of the quality management system, which allows for the release of production to the customer.
Do you want to know more?
We invite you to the SPC-MSA training organized by Qualitywise, where you will learn in detail about MSA. Ask about the date.
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For people who want to know more:
MSA – Measurement Systems Analysis, 4th edition, 2010
VDA 5 – Measurement and Inspection Processes, 3rd edition, July 2021
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