What Happens If Calibration Is Skipped in Manufacturing and Testing?
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.
Poor Reputation When it comes to building relationships with customers, product quality plays a massive role. Any decrease in quality due to inaccurate measurement instrumentation can cause reputation damage, which can be much more difficult to overcome than the initial cause of the issue. As mentioned throughout this list, high-quality products are the result of consistently accurate measurements, which in turn stem from regular instrument calibration. Pull-Out Point Good reputation is built on good products, which come from good, consistent measurements. Why Is It Important to Have Regular Calibration? Instrument calibration on a regular schedule helps prevent a wide range of issues that can occur due to measurement inaccuracies. It enables companies to keep measurements consistent, improve product quality, reduce product defects and unnecessary rework, stay compliant, avoid costly audits and downtime, improve employee safety, and much more. Ultimately, instrument calibration is a critical element of any quality management system that helps to produce products that customers are consistently happy with and Calibration procedures
