This document discusses how calibration fits into the manufacturing process and ensuring quality. It notes that manufacturing goals include safety, quality and profitability. However, calibration has often become separated or "siloed" from manufacturing. This can impact quality if calibration is not properly integrated. The document advocates for a comprehensive measurement assurance program to link calibration to manufacturing goals through instrument suitability, guard bands on tolerances, and thorough non-conformance evaluations. This helps ensure calibration preserves good measurements and the manufacturing process meets its objectives.
HỌC TỐT TIẾNG ANH 11 THEO CHƯƠNG TRÌNH GLOBAL SUCCESS ĐÁP ÁN CHI TIẾT - CẢ NĂ...
Transcat's "Calibration's Role in the Manufacturing Jigsaw Puzzle" Presentation
1. Calibration s
Calibration’s Role
in the Manufacturing Jigsaw Puzzle
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Webinar hosted and presented by
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Better by Your Every Measure • 800.828.1470 • www.transcat.com
2. Agenda
The Big Picture: Manufacturing Goals
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Puzzle Pieces: Segregation of Departments/Functions
The Calibration Puzzle Piece
The Piece Appears to Fit . . . But Does It Really?
Getting the Pieces to Fit Properly
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Better by Your Every Measure • 800.828.1470 • www.transcat.com
3. The Big Picture: Manufacturing Goals
Making p
g products that are:
• In market demand
• Profitable
• Effective
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• Safe
Better by Your Every Measure • 800.828.1470 • www.transcat.com
4. Puzzle Pieces: Segregation of Depts/Functions
Some functions of the manufacturing p
g process are split apart
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into separate departments
Some functions or sub-functions/sub-assemblies are
outsourced
Better by Your Every Measure • 800.828.1470 • www.transcat.com
5. Puzzle Pieces: Segregation of Depts/Functions
Materials are purchased from multiple sources
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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
Better by Your Every Measure • 800.828.1470 • www.transcat.com
6. The Calibration Puzzle Piece(s)
How has Calibration been segregated from the
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manufacturing 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?
calibration silo’
Better by Your Every Measure • 800.828.1470 • www.transcat.com
7. The Piece Appears to Fit . . . But Does It Really?
Calibrations may be taking p
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. . . that doesn’t mean Measurement Assurance is in place!
• Example: Omega HH82A
• What similar risks do your current calibrations impose?
Better by Your Every Measure • 800.828.1470 • www.transcat.com
8. Getting the Pieces to Fit Properly
If a manufacturing business is interested in:
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• Maximizing Profits
• Product Safety & Quality . . .
Then they must have an active Measurement Assurance
program
Better by Your Every Measure • 800.828.1470 • www.transcat.com
9. Getting the Pieces to Fit Properly
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 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)
• OOT investigations performed properly
• Corrective action taken for OOT impacting product
Better by Your Every Measure • 800.828.1470 • www.transcat.com
10. Getting the Pieces to Fit Properly
Example: Temperature measurement
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• Mfg Engineer needs to measure solution used to treat product
• Process measurement is 350° ± 2° C
• Which instrument is suitable f this measurement?
for ?
LL: UL:
Process Process
348°C 350°C 352°C
Better by Your Every Measure • 800.828.1470 • www.transcat.com
11. Getting the Pieces to Fit Properly
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,
interval directly impacting previous process measurements
LL: UL:
Process Process
348°C 350°C 352°C
Better by Your Every Measure • 800.828.1470 • www.transcat.com
12. 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
Solution temperature is right at nominal: 350° C
°
LL: UL:
Process Process
348°C 350°C 352°C
Better by Your Every Measure • 800.828.1470 • www.transcat.com
13. Getting the Pieces to Fit Properly
Process measurement
• Instrument is on its last day of use before it will be recalibrated
• Instrument is used to measure solution temperature
• S
Solution temperature is right at nominal: 350° C
°
LL: UL:
Process Process
348°C 350°C 352°C
Better by Your Every Measure • 800.828.1470 • www.transcat.com
14. Getting the Pieces to Fit Properly
Temperature Instrument Calibration
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• Instrument is recalibrated (and subsequently was adjusted)
• As Found reading shows the instrument drifted to upper limit: 352° C
• This drift occurred over its calibration interval
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LL: UL:
UUT UUT
348°C 350°C 352°C
Better by Your Every Measure • 800.828.1470 • www.transcat.com
15. Getting the Pieces to Fit Properly
Temperature Instrument Calibration
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• 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?
LL: UL:
UUT UUT
348°C 350°C 352°C
Better by Your Every Measure • 800.828.1470 • www.transcat.com
16. Getting the Pieces to Fit Properly
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 values
LL: UL:
Process Process
x
348°C 350°C 352°C
Better by Your Every Measure • 800.828.1470 • www.transcat.com
17. Getting the Pieces to Fit Properly
OOT-NCR Evaluation
• So the process measurements taken on the day the instrument was
previously calibrated were not actually 350° C, they were 348° C
• The same applies to the process readings at the end of the cal cycle
LL: UL:
Process Process
x
348°C 350°C 352°C
Better by Your Every Measure • 800.828.1470 • www.transcat.com
18. Getting the Pieces to Fit Properly
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’!!
at risk !!
LL: UL:
Process Process
x
348°C 350°C 352°C
Better by Your Every Measure • 800.828.1470 • www.transcat.com
19. Getting the Pieces to Fit Properly
Instrument with better accuracy:
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• 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 tolerance
LL: LL: UL: UL:
Process UUT UUT Process
x
348°C 349°C 350°C 351°C 352°C
Better by Your Every Measure • 800.828.1470 • www.transcat.com
20. Getting the Pieces to Fit Properly
Instrument with better accuracy:
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• 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 tolerance
LL: LL: UL: UL:
Process UUT UUT Process
x
348°C 349.5°C 350°C 350.5°C 352°C
Better by Your Every Measure • 800.828.1470 • www.transcat.com
21. Getting the Pieces to Fit Properly
Instrument with better accuracy:
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• 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 concept
LL: LL: UL: UL:
Process UUT UUT Process
x
348°C 349.5°C 350°C 350.5°C 352°C
Better by Your Every Measure • 800.828.1470 • www.transcat.com
22. Getting the Pieces to Fit Properly
Instrument with better accuracy:
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• Traditionally, a 4:1 ratio is sufficient to reduce the probability that an
OOT will have an impact on the product/process
• For some measurements this cannot be achieved so risk is higher
measurements, achieved,
LL: LL: UL: UL:
Process UUT UUT Process
x
348°C 349.5°C 350°C 350.5°C 352°C
Better by Your Every Measure • 800.828.1470 • www.transcat.com
23. Getting the Pieces to Fit Properly
Instrument with better accuracy:
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• However, if one or more of the process measurements was at its
lower limit . . . risk still exists for this “In Tolerance” calibration
• Using the “As Found cal value all readings were higher by 0 5° C
As Found” value, 0.5°
LL: LL: UL: UL:
Process UUT UUT Process
347.5°C
x
348°C 349.5°C 350°C 350.5°C 352°C
Better by Your Every Measure • 800.828.1470 • www.transcat.com
24. Getting the Pieces to Fit Properly
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)
(IT-NCR
• Impact studies are expensive; consumes valuable resources
• Can cost thousands of dollars per evaluation event
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• 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!
Better by Your Every Measure • 800.828.1470 • www.transcat.com
25. Getting the Pieces to Fit Properly
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 Limits
LL: LAL: LL: UL: UAL: UL:
Process Process UUT UUT Process Process
347.5°C
x x
348°C 348.5°C 349.5°C 350°C 350.5°C 351.5°C 352°C
Better by Your Every Measure • 800.828.1470 • www.transcat.com
26. Getting the Pieces to Fit Properly
Guard Band result:
• Now if the instrument cal reveals a drift up to the maximum tolerance
there is no need to perform IT-NCR evaluation
• If instrument error is greater than this (i e it is OOT) then OOT NCR
(i.e. OOT), OOT-NCR
LL: LAL: LL: UL: UAL: UL:
Process Process UUT UUT Process Process
x
348°C 348.5°C 349.5°C 350°C 350.5°C 351.5°C 352°C
Better by Your Every Measure • 800.828.1470 • www.transcat.com
27. Getting the Pieces to Fit Properly
Summary:
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• Implement a good Measurement Assurance Program
• Understand and exercise good Suitability selection
• Guard Band the process tolerance limits to reduce costly NCR evals
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• Understand both the process and the calibration to ensure the intent
of preserving good measurements on the product is not lost
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• Be thorough in your NCR evaluations
• Get help if you’re in over your head!
Better by Your Every Measure • 800.828.1470 • www.transcat.com
28. Thank You for Joining Us!
Questions?
800.828.1470
www.transcat.com