February 2026 Volume 8

OPERATIONS & MANAGEMENT

Troubleshooting Unreliable Measurement Systems A gage is deemed unacceptable when the combined variation of the repeatability and reproducibility errors are too large relative to either the total study variation or the specification range, making the measurement system unreliable for its intended purpose. The technical oversight of measurement systems includes finding and correcting (if possible) the root causes of nonconforming gages. While a full treatment of troubleshooting errant gage would consume many more articles, the following key steps will get you started: Step 1. Verify the Gage Setup Check calibration, resolution, and physical condition. Ensure the gage is appropriate for the feature being measured and free from wear, debris or damage. Step 2. Evaluate the Measurement Process Confirm that the measurement method is standardized and applied consistently. Review temperature, humidity, vibration and other environmental variables. Ensure parts are positioned Ensure measurements were taken in randomized order and that the study includes enough parts, operators, and trials. Poor study design can obscure true variation sources. Step 5. Analyze Sources of Variation High EV suggests that the gage needs to be recalibrated, repaired, or replaced. High AV indicates operator inconsistency. Step 6. Implement Improvements Improve gage design, upgrade instruments if needed, add fixturing to stabilize part alignment, or control the measurement environment to reduce external influences. Step 7. Reevaluate and Maintain Run a follow-up Gage R&R study to confirm improvements. Continue periodic evaluations to ensure the measurement system remains capable over time. Why Troubleshooting Gage R&R Matters An unreliable measurement system undermines the foundation of manufacturing quality. Decisions based on inaccurate data can lead to defects, increased costs, and reduced customer satisfaction. By systematically measuring and addressing the sources of error in your measurement systems, you can ensure they provide accurate and actionable data. Whether you’re a seasoned engineer or new to measurement system analysis, the principles outlined here provide a roadmap to success in Gage R&R analysis. consistently, using fixtures if needed. Step 3. Address Operator Variation Verify that operators are trained, follow the same procedure, and are not affected by fatigue or distraction. Differences in technique typically drive reproducibility issues. Step 4. Review Data Collection

Ray Harkins is the General Manager of FIA member, Lexington Technologies in Lexington, North Carolina. He earned his Master of Science from Rochester Institute of Technology and his Master of Business Administration from Youngstown State University. He has also taught over 120,000 students through his quality and manufacturing-related courses such as Gage R&R Simplified: Essential Tools for Quality Engineers and Root Cause Analysis and the 8D Corrective Action Process through the online learning platform, Udemy. He can be reached via LinkedIn at linkedin.com/in/ray-harkins or by email at the.mfg.acad@gmail.com.

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FIA MAGAZINE | FEBRUARY 2026 38