Transcat's "Calibration's Role in the Manufacturing Jigsaw Puzzle" Presentation

Calibration’s RoleCalibration s Rolein the Manufacturing Jigsaw Puzzleg g

Webinar hosted and presented byp y

Better by Your Every Measure • 800.828.1470 • www.transcat.com

AgendaAgenda

The Big Picture: Manufacturing Goalsg g Puzzle Pieces: Segregation of Departments/Functions The Calibration Puzzle Piece The Piece Appears to Fit . . . But Does It Really? Getting the Pieces to Fit Properlyg p y


The Big Picture: Manufacturing GoalsThe Big Picture: Manufacturing Goals

Making products that are:g p• In market demand• Profitable

ff• Effective• Safe


Puzzle Pieces: Segregation of Depts/FunctionsPuzzle Pieces: Segregation of Depts/Functions

Some functions of the manufacturing process are split apart g p p pinto separate departments Some functions or sub-functions/sub-assemblies are

outsourced


Puzzle Pieces: Segregation of Depts/FunctionsPuzzle Pieces: Segregation of Depts/Functions

Materials are purchased from multiple sourcesp p Sub-assemblies are made at local tool shops

• Some companies enforce quality of parts on the supplier• Some companies check a sample of supplier parts for quality


The Calibration Puzzle Piece(s)The Calibration Puzzle Piece(s)

How has Calibration been segregated from the g gmanufacturing process? What was the original point of calibration in manufacturing?

• Many manufacturers have lost the connection between calibration and the original goals of business

How has this ‘calibration silo’ affected manufacturing? How has this calibration silo affected manufacturing?


The Piece Appears to Fit But Does It Really?The Piece Appears to Fit . . . But Does It Really?

Calibrations may be taking place but . . .y g p . . . that doesn’t mean Measurement Assurance is in place!

• Example: Omega HH82A• What similar risks do your current calibrations impose?


Getting the Pieces to Fit ProperlyGetting the Pieces to Fit Properly

If a manufacturing business is interested in:g• Maximizing Profits• Product Safety & Quality . . .

Then they must have an active Measurement Assurance program



An active Measurement Assurance program consists of:An active Measurement Assurance program consists of:• Right tool for the job (i.e., suitability)• Regular calibration

– Calibrations that support the process where the instrument is used

– Calibrations that supply the correct tolerancesCalibrations that supply the correct tolerances– Calibrations that are valid (i.e., calibration measurement

uncertainties support the measurements made)• Using the instrument/tool correctly• Accounting for irregularities in the production measurement process

(i.e., Process measurement uncertainties)(i.e., Process measurement uncertainties)• OOT investigations performed properly• Corrective action taken for OOT impacting product



Example: Temperature measurementp p• Mfg Engineer needs to measure solution used to treat product• Process measurement is 350° ± 2° C

f ?• Which instrument is suitable for this measurement?LL:

ProcessUL:

Process

348°C 352°C350°C



Process measurement• An instrument with an accuracy equal to the process limits?• Not good because the instrument can drift the full amount over its cal

interval directly impacting previous process measurementsinterval, directly impacting previous process measurementsLL:

ProcessUL:

Process

348°C 352°C350°C


Getting the Pieces to Fit Properly

Process measurement


• Instrument has been calibrated today and adjusted to nominal• Instrument is used to measure solution temperature the same day

S ° C• Solution temperature is right at nominal: 350° CLL:

ProcessUL:

Process

348°C 352°C350°C



Process measurement


• Instrument is on its last day of use before it will be recalibrated• Instrument is used to measure solution temperature

S ° C• Solution temperature is right at nominal: 350° CLL:

ProcessUL:

Process

348°C 352°C350°C



Temperature Instrument Calibrationp• Instrument is recalibrated (and subsequently was adjusted)• As Found reading shows the instrument drifted to upper limit: 352° C

f• This drift occurred over its calibration intervalLL:

UUTUL: UUT

348°C 352°C350°C



Temperature Instrument Calibrationp• Did it move all at once or a little over time?• How does this impact the measurements of the process since the

last time the temperature instrument was calibrated?last time the temperature instrument was calibrated?LL:

UUTUL: UUT

348°C 352°C350°C



OOT-NCR Evaluation• It must be assumed this shift occurred immediately following the last

calibration because that is the only supporting evidence to show the last known good condition of its temperature valueslast known good condition of its temperature values

LL: Process

UL: Process

x

348°C 352°C350°C



OOT-NCR Evaluation• So the process measurements taken on the day the instrument was

previously calibrated were not actually 350° C, they were 348° CThe same applies to the process readings at the end of the cal cycle• The same applies to the process readings at the end of the cal cycle

LL: Process

UL: Process

x

348°C 352°C350°C



OOT-NCR Evaluation


• What if some process readings indicated the solution was at its lower limit: 348° C? This would be acceptable for the process test, but . . .The In Tolerance cal would not have flagged this situation as ‘at risk’!!• The In Tolerance cal would not have flagged this situation as at risk !!

LL: Process

UL: Process

x

348°C 352°C350°C



Instrument with better accuracy:y• What if an instrument was selected with an accuracy twice as good?• If it drifted to its limit, process readings would only be off half of the

process toleranceprocess toleranceLL:

ProcessUL:

ProcessLL:

UUTUL: UUT

x

348°C 352°C350°C349°C 351°C



Instrument with better accuracy:y• What if an instrument was selected with an accuracy 4X as good?• If it drifted to its limit, process readings would only be off one quarter

of the process toleranceof the process toleranceLL:

ProcessUL:

ProcessLL:

UUTUL: UUT

x

348°C 352°C350°C349.5°C 350.5°C



Instrument with better accuracy:y• How far can we take this? 10X better? 100X better?• There are limits of technology and/or it eventually becomes cost

prohibitive to go too far with this conceptprohibitive to go too far with this conceptLL:

ProcessUL:

ProcessLL:

UUTUL: UUT

x

348°C 352°C350°C349.5°C 350.5°C



Instrument with better accuracy:y• Traditionally, a 4:1 ratio is sufficient to reduce the probability that an

OOT will have an impact on the product/processFor some measurements this cannot be achieved so risk is higher• For some measurements, this cannot be achieved, so risk is higher

LL: Process

UL: Process

LL: UUT

UL: UUT

x

348°C 352°C350°C349.5°C 350.5°C



Instrument with better accuracy:


y• However, if one or more of the process measurements was at its

lower limit . . . risk still exists for this “In Tolerance” calibrationUsing the “As Found” cal value all readings were higher by 0 5° C• Using the As Found cal value, all readings were higher by 0.5° C

LL: Process

UL: Process

LL: UUT

UL: UUT

x347.5°C

348°C 352°C350°C349.5°C 350.5°C



Lesson Learned:• Even In Tolerance results can impact your process measurements!• All cal data must be reviewed against process measurements to

understand the impact to the product (IT NCR evaluation)understand the impact to the product (IT-NCR evaluation)• Impact studies are expensive; consumes valuable resources• Can cost thousands of dollars per evaluation eventp• Parts or product likely have already been released/shipped• Could require product recall• If not released, could require rework• This risk can be reduced• Guard Band the process limits!• Guard Band the process limits!



What is Guard Band?• Determine realistic tolerance limits for the process measurement• Reduce these limits by the tolerance of the instrument used in the

process to arrive at Lower/Upper Acceptance Limitsprocess to arrive at Lower/Upper Acceptance LimitsLL:

ProcessUL:

ProcessLL:

UUTUL: UUT

LAL: Process

UAL: Process

x347.5°C

x

350°C348°C 352°C349.5°C 350.5°C348.5°C 351.5°C



Guard Band result:• Now if the instrument cal reveals a drift up to the maximum tolerance

there is no need to perform IT-NCR evaluationIf instrument error is greater than this (i e it is OOT) then OOT NCR• If instrument error is greater than this (i.e. it is OOT), then OOT-NCR

LL: Process

UL: Process

LL: UUT

UL: UUT

LAL: Process

UAL: Process

x

348°C 352°C350°C349.5°C 350.5°C348.5°C 351.5°C



Summary:y• Implement a good Measurement Assurance Program• Understand and exercise good Suitability selection

G C• Guard Band the process tolerance limits to reduce costly NCR evals• Understand both the process and the calibration to ensure the intent

of preserving good measurements on the product is not lostp g g p• Be thorough in your NCR evaluations• Get help if you’re in over your head!


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Transcat's "Calibration's Role in the Manufacturing Jigsaw Puzzle" Presentation

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Transcript of Transcat's "Calibration's Role in the Manufacturing Jigsaw Puzzle" Presentation