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At some point, every business that uses measuring instruments must ask this question: How often should we calibrate? The answer to this question is never a simple matter of every six months or annually. Calibration schedules should be individualized and depend on such factors as the volume of equipment use, working conditions, accuracy, and manufacturer recommendations. A well-thought-out calibration schedule will help to ensure the accuracy of measurements, increase product quality, and reduce the possibility of errors in business processes. It is never a good idea to wait for something to go wrong before it is calibrated and Instrument calibration

Factors to Consider in Calibration Schedules

There is no ideal calibration schedule that would apply to all measuring instruments. Although the industry standard might be once a year, some devices need calibration more frequently, and others less often. How often a device should be calibrated depends on how much it is used and what degree of confidence is required in its measurements. Calibration schedules should be developed on the basis of each device’s use rather than an arbitrary schedule. Consider how much the device is used The more the instrument is used, the more often it should be calibrated. As a rule, the equipment that is used on a daily basis requires a calibration schedule that is more frequent than the tools that are used rarely. For instance, a device that is used in the production process requires more frequent calibration than a spare instrument that is used only occasionally.

Assess working conditions

Working conditions are also an important factor that affects calibration schedules. For instance, a device that is exposed to vibrations, transportation, dirt, or extreme temperatures and humidity will exhibit drift more often than an instrument that is used under normal room conditions. Working conditions influence instrument calibration schedules, particularly if the equipment is used in an environment that is not controlled. Follow the manufacturer’s recommendations Equipment manufacturers offer calibration schedules that are relevant to the specific batch of instruments. While the recommendations can be ignored, most producers know what their equipment is capable of. If instruments perform well, the calibration interval can be extended, and if they fail frequently, the interval can be reduced. It is vital not to rely on guesswork when it comes to the calibration of measuring

instruments

Review industry-specific rules Various industries have developed calibration control rules that are specific to them. For instance, manufacturing process equipment, airplanes, medical devices, pharmaceuticals, the food industry, and labs all have industry-specific rules about the calibration of measuring instruments. Additionally, certain organizations that have been authorized to certify calibration processes develop their own calibration rules. Such firms possess quality management system certificates that enable them to take responsibility for the calibration process. It is essential to remember that compliance with regulatory rules dictates calibration schedules in some industries. Industry-specific rules and regulations often dictate how often measuring instruments should be calibrated.

Review the calibration history

A calibration history helps to determine the calibration intervals that have worked successfully in the past. If, for instance, an instrument has always been accurate, the calibration schedule can stay the same, with minor adjustments. At the same time, if a device frequently exhibits drift, the calibration intervals should be shortened. It is important to rely on a device’s calibration history when developing a new calibration schedule. By doing so, businesses can avoid guesswork and unnecessary mistakes.

Calibrate after repair or any adjustment

Every measuring instrument must be calibrated after it undergoes repairs or any form of adjustment, such as hardware or software servicing. Recalibration is essential because any repair or adjustment can affect an instrument’s measurement accuracy. The calibration after servicing ensures that the results delivered by the device are not compromised in any way.

Calibrate after physical damage

A measuring instrument should always be calibrated after it has been physically damaged. Dropping an instrument, for instance, does not necessarily mean that it is visibly damaged, but its accuracy might have been affected. Calibration after physical damage helps to ensure that the results are reliable and accurate. A dropped instrument should never be used without calibration

Verify measurements between two succeeding calibrations It is a good practice to verify the measurement results when an instrument is used between two succeeding calibrations. In other words, routine checks of a device’s measurement accuracy should be performed to ensure that nothing is out of order. In this case, verification plays an important role in the calibration process because it helps to catch irregularities before the next calibration

Create a calibration management system

There are various calibration management systems that help to track calibration records. Most of them contain calibration records, which typically include the following information:

Equipment identification,

Dates and due dates for calibration, Calibration records, Service records, Equipment location, And who is responsible for the instrument. An organized calibration management system is an integral element in any calibration process. It ensures that the calibration records of equipment are available, up-to-date, and easy to navigate. Pull-Out Point A systematic approach to tracking calibration due dates is essential in every calibration process. Benefits of Maintaining the Right Calibration Schedule Measuring instruments with appropriate calibration schedules enable organizations to:

Increase the accuracy of measurements

Ensure product quality, Reduce production errors, Minimize instrument downtime, Prevent audit failures, Increase the level of customer satisfaction, Reduce waste and rework, Standardize processes, Improve equipment reliability, And make more informed business decisions. Common Mistakes to Avoid In the calibration process, it is easy for organizations to make mistakes that undermine the accuracy of measurements. Thus, it is always important to avoid such calibration mistakes as: Waiting for equipment to malfunction before it is calibrated, Not paying attention to the manufacturer’s recommendations, Using instruments that appear to be fine without calibration, Failing to keep track of calibration history, Using damaged equipment without calibration, Having the same calibration schedule for all measuring instruments regardless of their use. By avoiding calibration-related mistakes, organizations can increase the accuracy of measurements and minimize the possibility of errors in the production process. The accuracy of measurements is of paramount importance in any business operation. It must be ensured at all costs.

Final Notes

Every measurement taken in a manufacturing plant or test lab can have an impact on a business decision. Whether it sends a product to the warehouse or the reject bin, causes a machine to continue running or automatically shut down, or influences any other business-critical decision, it all comes down to the integrity of the measuring instruments. Measuring instruments have a tendency to drift over time, and calibration is a good opportunity to check for that drift and make it right. Skipping regular calibrations can have negative consequences on the business if not done correctly. In fact, out-of-spec measurements can cause numerous issues, ranging from low-quality products to expensive audits. Here are some reasons you should never skip calibration services

Increase in Measurement Errors The obvious consequence of skipping regular instrument calibrations is measurement errors. After all, if the measuring instrument isn’t calibrated, any measurement will be inaccurate. A slightly off measurement can cause widespread issues, particularly if the measurement is relied on for multiple business processes. Even worse, if the instrument was regularly calibrated before and the drift only recently occurred, the inaccuracies go unnoticed for an extended period. Measurement errors can occur in any stage of production, especially in the manufacturing process. These errors can be small or major and can lead to a variety of different issues. Pull-Out Point Small measurement errors can cause big production issues.

Lowered Product Quality The manufacturing process revolves around measurements. Without them, processes can’t be controlled or products created consistently. Therefore, any inconsistency in measurements will inevitably lead to inconsistencies in the products. Incorrect measurements with calipers, scales, pressure sensors, or any other measuring equipment means products are no longer fit for purpose or specification. Some products will be rejected, or if not detected early enough, may even make it to the customer with defects. Pull-Out Point Products are only as consistent as the measuring instruments used to make them.

More Rejections and Rework Products that are incorrectly measured run the risk of being unnecessarily rejected or, on the flip side, being incorrectly accepted with defects. Either way, inaccurate measurements lead to higher costs, whether it’s extra rework for incorrectly rejected items or lower yields for incorrectly accepted ones.

Failed Customer and Quality Audits For many businesses, an essential requirement for customers and partners is evidence that measuring equipment has been calibrated regularly. When an ISO auditor or customer representative visits the facility, the first thing they may do is check calibration records for important instruments. Therefore, not being able to provide the necessary documentation regarding instrument calibration can lead to audit failures. Pull-Out Point Auditors rely on the assurance of documented evidence.

Higher Downtime When it’s discovered too late that measuring equipment was inaccurate, extra downtime is needed to recalibrate the instruments, send them for repair or replacement, and even retest previously manufactured products if they were affected by the faulty measurements.

Increased Costs While skipping regular instrument calibration may seem like a good way to cut costs, the opposite is true. The costs related to skipped calibrations can be extremely expensive, including product recalls, material losses, customer complaints, instrument repair costs, emergency calibration, production downtime, overtime, and extra audits. Preventive instrument calibration is always a much safer and cheaper alternative to fixing measurement-related issues. Pull-Out Point Preventive calibration costs less than repair and loss.

Loss of Customer Confidence When customers receive lower-quality products than expected or when they detect issues or inconsistencies in what they purchase, it can lead to a loss of customer confidence. It can take forever to regain that trust, so skipping instrument calibration and consequent quality control slips can be devastating to customer relationships if not addressed.

Higher Risk Levels In many industries, measuring instruments are crucial for the safety of workers, the environment, and the general public. Pressure, temperature, gas, flow, and electrical measuring instruments are some of the common types of measuring equipment used to ensure that safe operating ranges are not exceeded. With that in mind, incorrect measurements pose much higher risks than just slightly off product measurements. Essentially, any measuring instrument that impacts the safety of people and equipment is much more sensitive to calibration-related issues. Pull-Out Point Proper measurements prevent dangerous situations.

Non-compliance With Regulations and Standards Many industries, such as pharmaceuticals, medical devices, aerospace, food, and research, are highly regulated and require calibration to be performed in accordance with specific regulations and standards. By skipping instrument calibration, companies can find themselves in more difficult situations during audits and inspections, including findings and citations.

Poor Decision-Making Every instrument measurement made in a facility can impact some level of a business decision. That can range from day-to-day decisions about equipment maintenance to strategic-level operations and maintenance scheduling. Any inaccuracies in measurements directly impact any business decisions made based on those measurements. Pull-Out Point Better decisions start with better measurement data.

Missed Equipment Issues Instrument calibration not only ensures accuracy but also detects early signs of equipment failure. By skipping regular calibration checks, potential issues with the equipment can go undetected until they are much more serious and expensive to fix.

If you have worked with measuring instruments, you have probably come across such terms as calibration, adjustment, and verification. They all describe technical processes related to the functioning of measuring instruments. Yet, they are not synonyms. Understanding the differences between these terms is essential because they serve different purposes. Getting them mixed up might lead to faulty records, poor audit results, and even incorrect conclusions about the state of a measuring instrument. Let us first define each term and highlight the conditions under which they are applied and Instrument calibration

Calibration

Calibration is a process where a measuring instrument is compared to a reference instrument with a known accuracy. By doing this, it becomes possible to establish if the instrument under calibration provides accurate measurements and to what extent it deviates. Calibration is always accompanied by technical documentation that contains calibration results – calibration certificates. One should remember, however, that calibration, as a rule, does not affect the indications of an instrument. To put it another way, while calibration can reveal an error, it cannot correct it. Example A digital thermometer was calibrated at a temperature of 100 degrees Celsius. As a result of the calibration, it was found that the thermometer indicates 99.7 degrees Celsius at the calibration point. The instrument was therefore calibrated. Calibration determines the degree of measurement accuracy; it cannot change the characteristics of an instrument

Adjustment

The technical term adjustment refers to changing an instrument so that its indication coincides with the required value. An adjustment is made when an instrument is found to be inaccurate based on calibration. In other words, if calibration revealed deviations beyond the allowable limits, the instrument can be adjusted to make it more accurate. After the adjustment, calibration of an instrument is performed again to check if the adjustment has been done correctly. Example A pressure gauge in a compressed air station was found to indicate a pressure 3 kPa higher than the reference instrument. Such discrepancy goes against the permissible limits of error. The gauge was adjusted; after that, a calibration was performed to check if there were any errors left. An adjustment corrects measurement errors after they have been revealed.

Verification

Verification is a process of proving that a measuring instrument meets the requirements for its use. Verification differs from calibration in that verification does not always determine the amount of deviation of an instrument. While calibration answers the question of how accurate the instrument is, verification answers the question of whether the instrument is accurate enough. In other words, verification focuses on the comparison of an instrument with specific technical requirements, while calibration determines the degree of accuracy of an instrument. Example Before using a weighing scale in a laboratory, it is necessary to verify that it is accurate enough for the upcoming tests. The verification process will show that either the scale is accurate or not. Verification ensures that an instrument complies with the required technical specifications.

Comparison of the Three Concepts

The table below compares the three concepts in terms of their goals, impact on an instrument, and provision of measurement data. The Interrelation of the Three Processes Usually, processes described by these three terms are interrelated. First of all, an instrument is subjected to calibration to determine its accuracy. Then, based on the calibration results, an adjustment is performed if the calibration revealed deviations beyond the permissible limits. Finally, another calibration or verification is performed to ensure that the adjustment was performed correctly. By doing these three actions in sequence, it becomes possible to determine the accuracy of the instrument, eliminate errors if any, and ensure the accuracy of the adjustment.

The Need to Distinguish Between Them

Proper knowledge of the distinction between the three terms is essential for at least two reasons. First, using correct terms makes it easier to communicate with external parties such as customers, regulatory authorities, and auditors. Second, the correct application of terms ensures good auditing results. Knowing which action was taken and whether it was documented correctly allows one to provide more reliable evidence of the conformity of products during an audit. Moreover, understanding what action was taken allows one to evaluate the state of the measuring instrument more accurately. For example, if the instrument was calibrated, one can be sure that its characteristics were measured and documented. If the instrument was adjusted, one can assume that a calibration was performed beforehand and potential inaccuracies were eliminated. If the instrument was verified, one can conclude that it meets the required accuracy and therefore can be used with confidence. Common Myths About Calibration, Adjustment, and Verification Some myths about calibration, adjustment, and verification could be dispelled by examining the definitions and examples given above. Calibration corrects instrument characteristics This is not true because calibration only measures accuracy; it cannot change anything in an instrument. If calibration reveals errors, they must be eliminated by adjustment.

Verification is a replacement for calibration

Even though verification can be used to check if an instrument complies with requirements, it does not provide information about the extent of compliance. In other words, verification only tells you whether the instrument is accurate enough, but it does not tell you how accurate it is. Calibration, on the other hand, helps obtain quantitative characteristics of accuracy. Adjustment can be performed without calibration This is wrong because adjustment cannot be done without knowing the current characteristics of the instrument. Calibration provides this information.

When to Apply Calibration, Adjustment, and Verification Usually, calibration is performed periodically to determine how accurate the instrument is. Adjustment is performed only when an instrument is found to be inaccurate. Verification is performed more frequently, both before working with the instrument and after it has been transported or adjusted to determine whether it can be used.

Summary

Measurement is an aspect that most people do not think about, but it is present in most of the products and services people enjoy in their lives. Be it the medicines they take when they are sick or the cars they drive to work every day, several industries rely on measuring instruments to help them make the best products. A slight mistake in measurements can result in bad products, unsafe goods, failed inspections, production delays, and financial losses. Calibration helps most businesses ensure that their measurement instruments are working stably and accurately to help them achieve desired results. The industries that rely on regular calibration services most are listed below and Calibration certificate

Manufacturing Industry

Most manufacturers regularly calibrate measuring instruments, especially those involved in the production of goods that require very accurate measurements. The production processes always involve measuring tools such as measuring equipment, pressure gauges, torque, and measuring tapes. Inaccurate measurements during production may lead to poor-quality goods and may require expensive recalls in case the products do not pass inspections. Consistent measurements result in consistently high-quality goods

Pharmaceutical Industry

This industry strictly adheres to regular calibration because of the implications of their work. Medicines and other pharmaceuticals need to be produced under controlled conditions and accurate measurements to ensure they work efficiently and safely. Thus, the need for regular calibration of measuring instruments such as temperature, balances, pressure, humidity, and others. Pull-out point Without regular calibration of measuring instruments, pharmaceutical companies cannot guarantee safe and effective medicines. Healthcare and Medical Laboratories Various medical equipment needs to be regularly calibrated for accuracy because most of the equipment is used in testing and diagnosis, which requires very accurate measurements. This aspect of the medical field uses thermometers, blood pressure monitors, laboratory analysers, incubators, and weighing scales among other equipment. Regular calibration ensures the accuracy of measuring instruments in the medical field, ensuring that test results, diagnoses, and subsequent treatments are done correctly and safely. Similarly, medical laboratories conducting tests on different materials need to ensure they use accurate and reliable measuring instruments to help them get verifiable results.

Food and Beverage Industry

Most people do not consider the role of regular calibration of measuring instruments when it comes to production and safety of the foods and drinks they consume. The food and beverage industry relies on several measuring instruments such as temperature, weighing, analysers, and moisture tests to ensure that the products they produce are safe for human consumption. Regular calibration thus plays a vital role in ensuring that measurements used in testing, manufacturing, packing, and transporting food and beverage products are reliable and accurate.

Food safety is achievable only when reliable measurements are taken during all stages of production Aerospace Industry Most aerospace manufacturers ensure that all measuring devices used in the production process are regularly calibrated. The aerospace industry requires very accurate measurements that allow it to manufacture aircraft parts with higher accuracy. As such, regular calibration of dimensional measuring instruments is critical to ensure that tolerances are met.

Electronic Manufacturing

This industry produces some of the world’s most advanced electronic equipment. The production process requires the use of sophisticated measuring instruments such as oscillisopes, multimeters, signal generators, and power supplies among others. Electronic manufacturers perform regular calibration to ensure that the test equipment works reliably and meets accuracy expectations. Electronic manufacturers need regular calibration of test equipment because of the complexity and precision of electronic circuits.

Oil and Gas Industry

The oil and gas manufacturing companies conduct regular calibration of their measuring equipment to ensure accuracy and reliability of the devices. The industry has some of the highest accuracy requirements since the instruments are used in highly sensitive environments.

Chemical Industry

This industry conducts regular calibration of its measuring instruments to ensure that they operate reliably and consistently. The chemical manufacturing process requires highly accurate measurements, especially when it comes to temperature, pressure, flow of materials, and concentration levels. The industry conducts regular calibration to ensure that its production process is not interrupted, and the products produced have consistent quality.

Power Industry

The power sector deals with a wide range of measuring instruments used to monitor the production and transmission of energy. Power plants regularly conduct calibration of their measuring instruments to ensure they achieve maximum efficiency in meeting power generation targets. Some of the equipment that are calibrated regularly include temperature transmitters, electrical meters, pressure, and flow instruments among others. Reliable measurements enable companies to generate more electricity using existing power generation infrastructure.

Automotive Industry

This industry relies on measuring equipment to help it manufacture high-quality vehicles that are safe and efficient. The production process involves several measuring instruments including torque, measuring equipment, pressure gauges, force, and dimensional measuring devices. All these instruments need to be regularly calibrated to ensure that they help the manufacturer meet the accuracy requirements of the vehicle parts being produced.

Research and Development Companies

These companies conduct various tests and experiments to develop new products. As such, they need to regularly calibrate laboratory equipment such as balances, pipettes, analytical instruments, humidity, and temperature controllers to ensure they consistently get verifiable results.

Construction and Civil Engineering

Modern construction requires that engineers conduct accurate measurements when laying out worksites and constructing structures. This aspect of the construction process requires that survey equipment, lasers, concrete testing equipment, and other related tools are regularly calibrated. Similarly, the weighing scales and measuring instruments in construction sites also need to be regularly maintained to ensure accuracy of measurements during the building process. Small measurement mistakes during construction can lead to major structural problems at a later stage Key reasons why all industries need regular calibration Every industry has its own unique measuring instruments that are crucial for carrying out their respective activities. However, regardless of these differences, there are certain similarities that come with the need for regular calibration. These aspects of calibration are crucial and should not be overlooked because:

They help improve measurement accuracy and ensure that all production processes are reliable

They help organisations produce better quality goods and services

They help satisfy legal requirements by ensuring all measurements are done against set standards

They help improve customer confidence in the goods and services being offered by an organisation

They reduce the risks and losses associated with faulty measurements, thus minimising downtime

They help improve worker safety by ensuring the right measurements are taken at all times

They help with internal and external audits since measurements are verifiable and reliable

They help prolong the life of measuring instruments by ensuring they are regularly checked, serviced, and maintained

The results of a measurement define the basis of any quality-controlled organization. Many companies that deal with manufacturing processes, medical machinery, electronics, and other industries turn to calibration laboratories for ensuring that their products are high-quality and meet all the expectations. Therefore, instead of using an ordinary calibration laboratory, many businesses opt for an ISO/IEC 17025 calibration laboratory that has received international accreditation. An ISO/IEC 17025 calibration laboratory accreditation certifies a testing or calibration laboratory’s competence in carrying out measurements, which means there are qualified specialists, appropriate calibration process, and equipment that meets specific requirements. In other words, an ISO/IEC 17025 calibration laboratory is the preferred choice of any organization that wants to guarantee the reliability of its calibration processes. Why Reliable Calibration is Necessary A minor mistake in measurements can result in enormous losses, product recalls, numerous complaints, production downtime, failed audits, and other adverse outcomes. A reliable calibration laboratory prevents all these unwanted results by eliminating calibration errors and ensuring the precision and accuracy of measurements. Let’s take a closer look at ten calibration advantages of working with an ISO/IEC 17025 calibration laboratory.

Competent Calibration Technicians The first calibration advantage of an ISO/IEC 17025 calibration laboratory is connected to competent calibration technicians. First of all, this international standard ensures that lab technicians receive adequate training that allows them to carry out calibration tasks efficiently. Moreover, the calibration process in such laboratories is well-documented to guarantee that no employee can operate calibration procedures incorrectly. Pull-Out Point People do calibration, but competence ensures consistency.

Traceability to National or International Standards Hiring a calibration laboratory that has been accredited under ISO/IEC 17025 standard ensures that you work with experts that provide traceability of measurement results to international standards. In other words, an ISO/IEC 17025 calibration lab offers calibration services that ensure traceability via official references utilizing measurement data. Pull-Out Point Reliable measurements always start with traceability.

Properly Maintained Reference Standards A reliable calibration laboratory boasts reference standards that are properly maintained. The reference equipment is necessary because it defines the accuracy of a measured quantity. An ISO/IEC 17025 calibration lab features reference standards that are well-maintained and ensure the precision of calibration processes and measurement results.

Documented Calibration Procedures A calibration laboratory with documented procedures offers consistent and reliable measurement results because calibration technicians follow a particular set of instructions. Basically, calibration procedures ensure that everyone knows exactly what to do, which eliminates the possibility of using different calibration approaches. In other words, the uniformity of procedures helps achieve reliable calibration outcomes. Pull-Out Point Consistency is the key to reliable calibration.

Controlled Environment The environment where the calibration process takes place affects the accuracy and precision of measurement results. Thus, a reliable calibration lab provides a controlled environment that is free from any vibrations, pressure changes, temperature gradients, humidity, and other factors affecting measurement results. An ISO/IEC 17025 calibration laboratory meets all the requirements of a controlled environment as per ISO/IEC 17025 standard.

Evaluation of Measurement Uncertainty According to ISO/IEC 17025 standard, calibration laboratories should estimate and report measurement results considering the associated measurement uncertainty. In other words, reliable calibration laboratories evaluate and report the measurement deviation from an accepted reference value. Pull-Out Point Reliable calibration laboratories do not hide the measurement uncertainty.

Internal Laboratory Quality Control An ISO/IEC 17025 calibration laboratory has well-established internal laboratory quality control procedures that allow such facilities to monitor and control their calibration activities ensuring the precision of measurement results.

Participation in Proficiency Testing An ISO/IEC 17025 calibration laboratory often participates in proficiency testing that allows such a laboratory to compare its measurement results with those delivered by other calibration laboratories.

Calibration Documentation A reliable calibration laboratory can provide calibration documentation that confirms that calibration was performed correctly. Basically, calibration documentation assists in verifying calibration certificates, procedures, reference equipment, and other calibration-related data. Pull-Out Point A calibration certificate is your calibration control documentation.

Continuous Improvement An ISO/IEC 17025 calibration lab is dedicated to continuous improvement, which means that calibration laboratories work on the enhancement of calibration procedures constantly. In other words, continuous improvement defines the calibration process under ISO/IEC 17025 standard, which ensures that calibration activities meet the highest possible level. Why Do Businesses Choose ISO/IEC 17025 Calibration Laboratories? Many firms that require calibration services opt for ISO/IEC 17025 calibration laboratories because they offer reliable calibration services. An ISO/IEC 17025 calibration certificate proves that a calibration laboratory has been accredited under the international standard that ensures the accuracy and precision of measurements. Nonetheless, there are several additional reasons why organizations choose ISO/IEC 17025 calibration laboratories. Some of them are as follows:

Ensuring accurate measurements and compliance with regulations

Facilitating customer and ISO audits

Helping meet quality control and quality management system requirements

Lowering product liability insurance costs and inspection costs

Building confidence in inspection and measurement results

Ensuring consistent measurements

Improving the overall quality management system