In light of a gage R&R that will fail (will post the results when complete) on a $4K that someone in my company decided to purchase without the input of Quality, what has been the worst Gage R&R results you have seen from a gage?
I worked at a place that was similar except, it was a forge shop and they didn't install proper vibration dampeners. You could watch the X and Y moving, in real time, as much as .002" and management was ok with it... until the customers started rejecting parts.
At my last shop, we had to do an R&R on telescoping gages on a through hole that was made with a hot pierce punch. I want to say that the results were in the 50-60% range every time. Management said we had to do it annually. Every year it would fail, we would create a corrective action, the result was that it was not even a reliable way of measuring said feature, and we would do it all again next year.
How many decimal points out are the measured and calculated results to? I've seen some fairly bad results become acceptable if more decimal points are used in the calculations. Truncating the results can result in an artificially tight control limit in the calculations.
