INSTRUMENTATION TOOLS

Basics of Calibration
Calibration November22,2015

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CalibrationTheDefinition
Calibrationisthecomparsionofmeasurementdeviceoraninstrument(deviceundertest,DUT)
againstaknownwithequalorbetterstandard.Thestandardinameasurementisconsideredto
bemorecorrectofthetwoandonewouldcalibratethedeviceundertesttoknowfaritdeviates
fromthestandard.
Usual calibration usually done by commercial calibration laboratories uses a manufacturers
calibrationprocedureandisperformedwithareferencestandardmultipletimesmoreaccurate
typicallyatfourtimeswithaccuracyoftheDUT.
So,WhyDoWeNeedtoCalibrate?
Havinginstrumentsthatarecalibratedinsuresqualityoutputproducts.Outoftolerance(OOT)
instruments tend to give wrong readings resulting in unnecessary back jobs and process
failures.Badorlowqualityproductswouldpassasgoodonesresultinginwarrantycosts,and
good products as nonconformance to quality ones, resulting to unnecessary reworks. So
basically,calibrationisallaboutproducinghighqualitywhichisequalstomoney.
CalibrationTerms
Commoncalibrationterms
Out of Tolerance Conditions: If the results are outside of the instruments performance
specificationsitisconsideredanOOT(OutofTolerance)conditionandwillresultintheneedto
adjusttheinstrumentbackintospecification.
Optimization: Adjusting a measuring instrument to make it more accurate is NOT part of a
Typical calibration and is frequently referred to as Optimizing or Nominalizing an
instrument. (this is a common misconception) Only reputable and experienced calibration
providersshouldbetrustedtomakeadjustmentsoncriticaltestequipment.

AsFoundData:Thereadingoftheinstrumentbeforeitisadjusted.
delays.
As Left Data: The reading of the instrument after adjustment or Same As Found if no
adjustmentwasmade.
Without Data: Most calibration labs charge more to provide the certificate with data and will
offeraNoDataoption.InanycaseAsFounddatamustbeprovidedforanyOOTcondition.
LimitedCalibration:Sometimescertainfunctionsofaninstrumentmaynotbeneededbythe
user. It may be more cost effective to have a limited calibration performed (This can even
includeareducedaccuracycalibration).
TURTestUncertaintyRatio:Theratiooftheaccuracyoftheinstrumentundertestcompared
totheaccuracyofthereferencestandard.
ISO9000Calibration
ISO 9000 calibrations are crucial for many industries. The following is required for ISO 9000
CompliantCalibrations.
AnAccreditedCalibrationLabPerformingtheWork:Thecalibrationlaboratoryemployedto
performthecalibrationmustbeanISO9001:2000accreditedlaborbetheoriginalequipment
manufacture.
DocumentedCalibrationProcedures: Itiscriticalthatavalidcalibrationprocedurebeused
basedonthemanufacturesrecommendationsandcoveringallaspectsoftheinstrumentunder
test.
Trained Technicians: Proper Training must be documented for each discipline involved in
performingthecalibration.
TraceableAssets:Thecalibrationprovidermustbeabletodemonstrateanunbrokenchainof
traceabilitybacktoNIST.
ProperDocumentation: Allcriticalaspectsofthecalibrationmustbeproperlydocumentedfor
thecertificatetoberecognizedbyanISOauditor.
A Comprehensive Equipment List: For any manufacture to pass an ISO audit regarding
calibrationtheymustdemonstratethattheyhaveacomprehensiveequipmentlistwithcontrols
inplaceforadditions,subtractionsandcustodianshipofequipment.
CalibratedandNCRItemsProperlyIdentified:Theequipmentlistmustidentifyanyunitsthat
donotrequirecalibrationandcontrolsmustbeinplacetoensurethattheseunitsarenotused
inanapplicationthatwillrequirecalibration.
A Proper Recall System: A procedure should be established with time frames for recall
notification,anescalationprocedure,andprovisionsforduedateextension.

EquipmentCustodianship: responsibilities for ensuring the equipment is returned to the cal

labshouldbeassignedanddelegated.
An OOT Investigation Log: Any instrument found out of tolerance requires that an
investigation be performed to determine the impact on manufacturing. Records and reports
needtobemaintained.
ISO/IEC17025Calibration
ISO/IEC 17025 Calibration: As a general rule 17025 calibrations are required by anyone
supplying the automotive industry and it has also been voluntarily adopted by numerous
companiesinFDAregulatedindustries.
ISO/IEC 17025 is an international standard that assesses the technical competency of
calibration laboratories. ISO/IEC 17025 covers every aspect of laboratory management,
rangingfromtestingproficiencytorecordkeepingandreports.Itgoesseveralstepsbeyonda
ISO9001:2000certification.
A17025calibrationisapremiumoptionthatprovidesadditionalinformationaboutthequality
of each measurement made during the calibration process by individually stating the
uncertaintycalculationofeachtestpoint.
WhenDoWeNeedToCalibrate?
HowCalibrationIntervalsareDetermined
Calibration intervals are to be determined by the instrument owner based on manufacture
recommendations.Commercialcalibrationlaboratoriescansuggestintervalsbutinmostcases
theyarenotfamiliarwiththedetailsoftheinstrumentsapplication.
The OEM intervals are typically based on parameters like mean drift rates for the various
components within the instrument. However, when determining calibration intervals as an
instrument owner several other factors should be taken into consideration such as: the
requiredaccuracyvs.theinstrumentsaccuracy,theimpactanOOTwillhaveontheprocess,
andtheperformancehistoryoftheparticularinstrumentinyourapplication.
HowtoImplementorImproveaCalibrationProgram
Any successful calibration program must begin with an accurate recall list of your test,
measurementanddiagnosticequipment.
Therecalllistshouldcontainauniqueidentifierwhichcanbeusedtotracktheinstrument,the
location, and the instruments custodian (Often asset management software, barcoding
systems,andphysicalinventoriesareusedtohelpestablishaccuraterecalllists).
It is important when assembling a recall list that modules, plugins, and small handheld tools
are not overlooked. Also, you may have several homemade measuring devices (e.g. Test
Fixtures) which will also need to be captured on your equipment list for a reliable calibration

program.
The next step is to identify all of the instruments on your recall list which may not require
calibration due to redundancies in your testing process (A commercial calibration laboratory
shouldbeabletoaidyouinidentifyingtheseinstruments).
After creating an accurate recall list procedures must be established for adding new
instruments, removing old or disposed instruments, or making changes in instrument
custodianship. Recall reports should be run with sufficient time for both the end user and the
serviceprovidertohavetheunitcalibratedwithaminimalimpactonproduction.
A late report identifying any units about to expire or already expired will ensure 100%
conformity.Afullservicecalibrationlaboratorywillsupplytheserecallreportsandwillprovide
specialescalationreportingwhenequipmentisnotreturnedforservice.
(Some calibration labs offer the choice of webbased equipment management systems that
allowtheircustomertoperformrecallreports,latereportsandkeepelectronicversionsoftheir
calibrationcertificates.)
AvoidingProductionDelays
Obtaintimelyequipmentcalibrationswithoutshuttingdownalinefordays.
Lookforacalibrationserviceproviderthatcanperformonsite(orinplace)calibrationsatyour
facility. Often when your volume is more than 20 calibrations, scheduling onsite calibration
savestimeandlowerscost.
Make sure you find a onesource calibration provider that has sufficient capabilities to
calibratenearlyallofyourequipmentduringtheonsite,reducingthedelaysandtheexpenseof
usinganadditionalsubcontractor.
OtheroptionsforreducingdowntimeincludemobileCalibrationlabservices,scheduleddepot
calibrations, calibrations during shutdowns, scheduled pickup and delivery, and weekend or
nightshiftcalibrations.
ShouldWeCalibrateOurselves?
Most companies discover they cannot effectively perform their own calibrations for many
reasons.Themostfrequentissueswithinternalcalibrationsare:
Cost of standards: Often, the cost of the assets with the required accuracy to perform the
calibrationisprohibitive(Itcouldtakeyearsofcalibrationstopayforonestandard).
Developing Procedures: Many manufactures procedures are not readily available.
Sometimestheyrequireresearchanddevelopment.Thiscancosthundredsofhoursoflabor.
ProductivityofTechnicians:Oftenanoncommercialcalibrationlaboratorysproductivityper
employeeisonlyafractionofwhatcanbeobtainedthroughanexternalcommercialcalibration
laboratorywhospecializesinautomation,efficientproceduresandexperiencedmanagement.
Cost of Management: Managing the employees, assets, maintenance and processes of a
calibrationlabcanbeburdensomeonexistingmanagementstaff.

Notacorecompetency:Theoverallmanagementburdenoftheoperationdistractsfromthe
corecompetencyofthecompany.
AlsoRead:WhatisCalibration?

POSTED BY S BHARADWAJ REDDY