Design and Analysis of the Slider Shear Test System Using Nested GR&amp;R Measurement System

doi:10.4186/ej.2023.27.3.11

Study

Final ProductionRecentStrong effect

Optimized Slider Shear Test System Achieves Sub-10% Measurement Error for Enhanced Product Quality Assurance

A redesigned slider shear test system, validated through finite element analysis and nested Gage Repeatability & Reproducibility (GR&R) studies, significantly reduces measurement error to below 10%, leading to more accurate product quality assessment.

Engineering Journal · 2023

01

Key Findings

01The redesigned slider shear test system was validated by FEM to produce the correct shear failure mode.
02The new system achieved a nested GR&R of less than 10%, indicating it is an adequate measurement system.
03Decreasing measurement error was shown through simulation to significantly reduce the over-reject rate.

02

Application

Design takeaway

Invest in and validate measurement systems with robust methods like GR&R to ensure that product quality assessments are based on accurate data, not testing artifacts.

How to apply

Before implementing a new quality control test, conduct a GR&R study to quantify its measurement error. Use simulation tools to predict the impact of measurement error on quality metrics.

Project actions

01When designing a testing apparatus, consider not just its function but also its measurement accuracy.
02Use statistical tools like GR&R to validate the reliability of your measurement methods.

03

Method & Evidence

AimHow can a redesigned slider shear test system minimize measurement error and ensure accurate failure modes for head gimbal assemblies?

MethodExperimental and Simulation-based Analysis

ProcedureA new slider shear test system was designed using a Six Sigma framework. Its structural integrity and ability to produce correct failure modes were confirmed via finite element method (FEM) simulations. The measurement system's accuracy was then evaluated using a nested Gage Repeatability & Reproducibility (GR&R) study. Simulation results were used to correlate measurement error reduction with over-rejection rates.

ContextManufacturing and quality control of electronic component assemblies, specifically head gimbal assemblies.

Variables

IV["Design of the slider shear test system"]

DV["Measurement error (GR&R)","Failure mode"]

CV["Material properties of the slider and suspension","Environmental conditions during testing"]

04

Strengths & Limitations

Strengths

+Application of a structured methodology (Six Sigma).
+Validation through both simulation (FEM) and experimental measurement (GR&R).

Limitations

The study's reliance on simulation means real-world performance might differ. The specific materials and environmental conditions of the test were not fully detailed.

Reliability & validity

The study addresses reliability through the GR&R analysis, which quantifies the consistency of the measurement system. Validity is addressed by using FEM to ensure the test elicits the correct failure mode, suggesting the test is measuring what it intends to measure.

Think critically

How might the 'correct failure mode' identified in this study be influenced by the specific materials and manufacturing processes of the head gimbal assembly, and how could this affect the generalizability of the findings?

05

Design Principles

"Measurement system accuracy is a prerequisite for reliable quality control and process capability assessment."

Accurate testing is crucial for ensuring the reliability and performance of critical components like head gimbal assemblies. By minimizing measurement error, designers and manufacturers can gain a clearer understanding of actual product quality, leading to more informed decisions about process improvements and material selection.

06

What This Means for Your Design

This research shows that a better-designed test machine for checking how strong the glue is on computer parts can give much more accurate results, with less than 10% error, which helps companies know if their parts are truly good or bad.

How to use in your project

1.Reference this study when discussing the importance of measurement system analysis and the impact of testing errors on design validation.

07

Add to My Project

08

Quick Cite

(2023). Design and Analysis of the Slider Shear Test System Using Nested GR&R Measurement System. Engineering Journal. https://doi.org/10.4186/ej.2023.27.3.11 Retrieved from https://designdex.org/study/341b1287-3964-4556-a0ca-b337a9cd9d31/optimized-slider-shear-test-system-achieves-sub-10-measurement-error-for-enhanced-product-quality-assurance

Paragraph starter

The accuracy of a testing system is paramount for reliable product quality assessment. Research by Pumkrachang et al. (2023) highlights that a redesigned slider shear test system, validated through finite element analysis and achieving a nested GR&R below 10%, significantly reduces measurement error. This reduction is critical for accurately reflecting real product quality and avoiding over-rejection rates, underscoring the need for robust measurement system validation in design projects.

09

Source

Engineering Journal

Design and Analysis of the Slider Shear Test System Using Nested GR&R Measurement System

journal · 2023

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Questions about this research

What does the research say about optimized slider shear test system achieves sub-10% measurement error for enhanced product quality assurance?: Invest in and validate measurement systems with robust methods like GR&R to ensure that product quality assessments are based on accurate data, not testing artifacts. Evidence: Engineering Journal (2023).
Why does "Optimized Slider Shear Test System Achieves Sub-10% Measurement Error for Enhanced Product Quality Assurance" matter for design?: Accurate testing is crucial for ensuring the reliability and performance of critical components like head gimbal assemblies. By minimizing measurement error, designers and manufacturers can gain a clearer understanding of actual product quality, leading to more informed decisions about process improvements and material selection.
How can designers apply this research?: Invest in and validate measurement systems with robust methods like GR&R to ensure that product quality assessments are based on accurate data, not testing artifacts.
What were the main findings?: The redesigned slider shear test system was validated by FEM to produce the correct shear failure mode.. The new system achieved a nested GR&R of less than 10%, indicating it is an adequate measurement system.. Decreasing measurement error was shown through simulation to significantly reduce the over-reject rate.
What research method was used?: Experimental and Simulation-based Analysis.
How strong is the evidence?: Evidence strength is rated Strong effect, based on a 2023 journal from Engineering Journal.
What should I do differently in my next project?: Before implementing a new quality control test, conduct a GR&R study to quantify its measurement error. Use simulation tools to predict the impact of measurement error on quality metrics.
What are the limitations?: The study relies on simulations for some aspects of validation, and the specific materials and manufacturing processes of the head gimbal assembly were not detailed.
Is there evidence that test system affects design outcomes?: The new test system accurately reflects the intended failure mode and has a low measurement error, which is essential for reliable quality assessment and reducing unnecessary rejections. Accurate testing is crucial for ensuring the reliability and performance of critical components like head gimbal assemblies. By minim Source: Engineering Journal (2023).
Where does this measurement error research apply?: Manufacturing and quality control of electronic component assemblies, specifically head gimbal assemblies. It sits within final production research on designdex.org.