Real-World MSA Case Studies

Learn from practical examples across different industries

Automotive
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Medical Device
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Aerospace
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Electronics
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Automotive Industry Case Studies

Case 1: Engine Block Bore Measurement
Automotive Tier 1 Supplier - Machining Operation
Background
  • Part: Aluminum engine block
  • Measurement: Cylinder bore diameter
  • Specification: 86.00 ± 0.02 mm
  • Gage: Bore gage with digital indicator
  • Volume: 50,000 parts/month
Problem

Initial GRR study showed %GRR = 45%, making the measurement system unacceptable for production use. Customer was threatening to reject the measurement system.

Investigation Results
ComponentInitial %After Improvement
%EV (Repeatability)35%6%
%AV (Reproducibility)28%4%
%GRR Total45%7%
NDC28
Root Causes Identified
  1. High %EV: Bore gage calibration drift due to thermal expansion
  2. High %AV: Inconsistent gage insertion depth between operators
  3. Environmental: Temperature variation (±5°C) in measurement area
Solutions Implemented
  1. Temperature control: Installed HVAC system (±1°C)
  2. Calibration: Reduced calibration interval from monthly to weekly
  3. Fixturing: Added depth stop to ensure consistent insertion
  4. Training: Standardized measurement technique
Results & Lessons Learned
  • %GRR improved from 45% to 7% - now acceptable for production
  • Cost savings: $50K/year in reduced scrap and rework
  • Key lesson: Environmental control is critical for precision measurements
  • Sustainability: Implemented monthly GRR monitoring to maintain performance
Case 2: Transmission Gear Tooth Visual Inspection
Automotive OEM - Final Inspection
Background

Visual inspection of transmission gear teeth for surface defects (scratches, nicks, discoloration). This was an attribute GRR study with pass/fail decisions.

Initial Results
  • Overall Agreement: 72% (target: >90%)
  • Kappa Value: 0.35 (poor agreement)
  • False Reject Rate: 18% (too high)
  • False Accept Rate: 10% (unacceptable)
Study Parameters
  • Parts: 50 gears
  • Operators: 3 inspectors
  • Trials: 2 per operator
  • Categories: Pass/Fail
  • Reference: Expert panel consensus
Solutions & Results

Improvements Made:

  • Improved lighting (LED with adjustable intensity)
  • Added magnification (3X inspection scope)
  • Created visual defect standards with photos
  • Implemented structured training program

Final Results:

  • Overall Agreement: 94%
  • Kappa Value: 0.82
  • False Reject Rate: 4%
  • False Accept Rate: 2%

Medical Device Industry Case Studies

Case 3: Surgical Instrument Critical Dimensions
Medical Device Manufacturer - Class II Device
Background
  • Part: Surgical forceps
  • Measurement: Tip alignment (critical for function)
  • Specification: ±0.05 mm alignment tolerance
  • Gage: Vision measurement system
  • Regulatory: FDA 21 CFR Part 820 compliance required
Challenge: FDA requires %GRR ≤ 20% for critical safety characteristics. Initial study showed 28%.
Improvement Journey
Phase%GRRAction Taken
Initial28%Baseline study
Phase 122%Improved fixturing
Phase 218%Enhanced lighting
Final15%Operator training
Regulatory Success

Achieved FDA compliance with %GRR = 15%. The systematic approach and documentation were key to regulatory approval. Study results were included in the 510(k) submission.

Aerospace Industry Case Studies

Case 4: Turbine Blade Airfoil Profile
Aerospace Engine Manufacturer - Critical Flight Safety Component
Background

Coordinate Measuring Machine (CMM) measurement of turbine blade airfoil profile. Critical for engine performance and safety.

Unique Challenges
  • Complex geometry: 3D airfoil shape with tight tolerances
  • Material: Nickel superalloy (difficult to measure)
  • Tolerance: ±0.025 mm on critical dimensions
  • Requirement: AS9100 compliance, %GRR ≤ 10%
Final Results
  • %GRR: 8%
  • %EV: 5%
  • %AV: 6%
  • NDC: 7
  • Study time: 6 months
Key Success Factors
  • Temperature control: ±0.5°C in CMM room
  • Fixturing: Custom pneumatic fixture for consistent clamping
  • Programming: Optimized CMM measurement strategy
  • Training: Extensive operator certification program

Electronics Industry Case Studies

Case 5: PCB Solder Joint Inspection
Electronics Manufacturer - Automated Optical Inspection (AOI)
Background
  • Part: High-density PCB assemblies
  • Inspection: Solder joint quality (attribute data)
  • Method: AOI system + operator verification
  • Categories: Good, Insufficient, Excess, Bridge, Missing
  • Volume: 10,000 boards/day
Challenge

High false alarm rate from AOI system leading to:

  • Excessive operator verification time
  • Inconsistent operator decisions
  • Customer complaints about escaped defects
Solution: Human-Machine Collaboration

AOI System Optimization:

  • Refined inspection algorithms
  • Improved lighting and optics
  • Statistical process control on AOI performance

Operator Training Enhancement:

  • Created digital defect library
  • Implemented certification program
  • Added real-time feedback system

Result: Overall agreement improved from 78% to 96%, false alarm rate reduced by 60%

Key Lessons Learned Across Industries

Success Factors
  • Environmental control is critical for precision measurements
  • Operator training must be comprehensive and ongoing
  • Fixturing and setup standardization eliminates major variation sources
  • Regular monitoring maintains measurement system performance
  • Cross-functional teams accelerate problem-solving
  • Documentation is essential for regulatory compliance
Common Pitfalls
  • Rushing the study leads to poor data quality
  • Ignoring environmental factors causes unexplained variation
  • Inadequate operator training results in high reproducibility
  • Poor part selection doesn't represent true process variation
  • Single-point solutions often fail to address root causes
  • Lack of follow-up allows performance to degrade over time

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