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Why a Repeatable Gauge Can Still Read High or Low

Compare the average reading with a reference

Repeatability describes the spread of readings made under the same conditions. To estimate bias, compare their average with the assigned value of an appropriate calibrated reference. In a hypothetical packaging inspection, a gauge reads 2.00 mm in ten checks of a reference assigned a thickness of 2.05 mm. The observed bias is −0.05 mm under those conditions, although the displayed readings have no visible spread.

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Check the working setup

Use a reference appropriate to the measurement geometry and range. Record the reference uncertainty and the gauge resolution, setup, contact force and temperature. A check on a rigid reference can reveal an offset in the gauge. Measuring a thin molded wall may also introduce deformation or positioning effects, so verify the working setup separately.

The offset at one reference size can guide an investigation of zero setting, contact wear or temperature. Applying a correction to production readings requires evidence that it applies to the relevant range and method.

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