Calibration or Quality assurance - Endress+Hauser

Marco van Veen

Slide 1

03/29/2010

Calibration or Quality Assurance


Marco van Veen

Slide 2

03/29/2010

Follow the Signal – from Product to Vision

Yield

Value

CMMS : Computerized Maintenance Management

System

CMS : Calibration Management System

DCS : Distributed Control System

EMS : Energy Monitoring System

ERP : Enterprise Resource Planning

MES : Manufacturing Execution System

PAM : Plant Asset Management

PLC : Programmable Logic Controller

SCADA : Supervisory Control And Data Acquisition

SiS : Safety Instrumented System

User : Process Manager

System : MES, EMS (Energy)

Data : Not real time (hour/day)

Signal : 4-20mA, Fieldbus (digital)

Driver : Efficiency

Energy Management aM&T

Quality Value

User : Quality Assurance/Metrology

System : CMS (Calibration)

Data : Not real time (week/month)


Driver : Quality

Quality Management

Dia

gnost

ics

Val

ue

User : Maintenance

Systems : PAM, CMMS (Asset)

Data : Not real time (hour)

Signal : Status (digital)

Driver : Reliability, Availability

Asset and Life Cycle Mngt.

Logistical Value

User : Logistics

System : ERP (Material Management)

Data : Not real time (hour/day)


Driver : Delivery, Flexibility

Inventory ManagementTankVision

Safety Value

User : Safety

System : SiS (Safety)

Data : Real time (second)

Signal : 4-20mA, Fieldbus (SiS,

PROFIsafe)

Driver : Safety, Reliability

Safety Management

Process Value

User : Operator

System : DCS, PLC/SCADA

Data : Real time (second)


Driver : Process, Accuracy

Process Management


Marco van Veen

Slide 3

03/29/2010

Why is maintenance important?

Source: ARC Advisory Group

ARC “Best Maintenance Practices” survey


Marco van Veen

Slide 4

03/29/2010

Reasons for Calibration

What can be a reason for calibration?

Lining is deformed

Pollution/scaling on the lining

Electronics defect

Coil current is changed

Combination of factors

Process optimization

What could be the consequences when there is a

deviation discovered?

Production loss?

Environmental impact?

Personal impact?

Energy loss?

….

Legislation demands

- IFS 5.0

- HACCP

- …


Marco van Veen

Slide 5

03/29/2010

Example: Calibration at Tetra Pak

Therm Aseptic

UHT-treatment module

Temperature transmitter

indicates 140°C

Reality 142°C

5000 hours production per year

2°C temperature difference = 30kg steam per hour

30kg x 5000h x 0.08 €/kg = 12,000 € per year

Consequences

Picture to be

added

Indirect cost: 12,000 € per year

Calibration costs:

We thank TetraPak for providing this case study


Marco van Veen

Slide 6

03/29/2010

What do you do when…?

… deviation is found?

Adjusting the K-factor?

Replace instrument?

Inform Quality

….

How do you record this?

Who to manage this?

When is this done?

What is the history of the instrument?

…?


Marco van Veen

Slide 7

03/29/2010

Is your calibration information always up to date?

Calibration Certificates

Who performed the calibration

Calibration frequency / calibration plans

SOPs

Deviations on which instruments

Specification sheets

Product Status

Supplier specific information

Traceability

…


Marco van Veen

Slide 8

03/29/2010

How can I be Compliant?

Calibration

Management and

Notification

Traceable

Reference Standards

Defined Criticality

Classification

and Tolerance

Competent

Calibration

Personnel

Technically Valid

Calibration

Procedures

The cornerstones of valid plant instrument calibrations are:


Marco van Veen

Slide 9

03/29/2010

Calibration rigs are

traceable to

international standards

Calibration along the life cycle

Standard Operating

Procedures (SOP)

Standard

calibration

certificate

Master-SOP

Calibration

SOP

Calibration

Protocol

Cal.Plan

Calibration

Label

Logbook

Cal.Record

Calibration

Work

Traceable

equipment

Trained

Employees

Key Elements of

Calibration from

Owner Operator

viewpoint

Calibration Management

Software


Marco van Veen

Slide 10

03/29/2010

System Integration

W@M Life Cycle Management

“I need more information!”

PC= Product Center

SC= Service & Sales Center

CER

“We know more!”

Serial#

Work order /

Calibration

information

Endress+Hauser

Product center

• Serial number

• Order code

• Manuals

• Certificates

• Purchase info

Events:

• Production info

• Calibration info

• Repair info

Flow

Pressure

Level

Temperature

Analysis

Endress+Hauser

Sales center

• Maintenance reports

• Calibration reports

• Service reports

• Repair reports

• Inspection reports

within maintenance or

calibration contracts

Dynamic hyperlink / Web Services

Calibration Management System

Your application

Our information


Marco van Veen

Slide 11

03/29/2010

W@M

All data is stored in the W@M Life Cycle Management Portal

Data is dynamic and all actions taken in the future, (like

calibrations and repairs) are stored in the logbook

Additionally the product status per instrument is kept up-to-date


Marco van Veen

Slide 12

03/29/2010

Temperature measurements : RTD, TC, Infra Red

Conductivity measurements

pH measurements

Pressure measurements : Process, Differential

pressure

Flow measurements

Open channel flow measurements

Dataloggers, recorders and displays

On-site Calibration

Date calibrated:

Due da te:

Reference:

ISO9001:2000


Marco van Veen

Slide 13

03/29/2010

Workshop + Factory Calibrations

EA (European Cooperation for Accreditation)

Calibration laboratories

ISO17025 (EN45001)

Temperature

Flow

Pressure

• Flow

DN1 – DN2000, 0-1666 l/s

• Pressure

Relative, absolute and vacuum

• Temperature

RTD, TC and transmitters

• EMC/RFI

• System & Gauging


Marco van Veen

Slide 14

03/29/2010

Practice: Premiumcal calibration lab.

The most accurate, accredited production calibration

installation in the world!

Deviation on 1000 liter = 1 glas of Champagne (0.015%)

PremiumCal rigs are located in Reinach and Greenwood

Uncertainty +/- 0.015%

accredited according to ISO 17025

1-gram weight on

a 400-kg tank

during calibration


Marco van Veen

Slide 15

03/29/2010

High-tech installation (±0.015%)

Polished certified weights,

accuracy class F2 with 0.8 g/50

kg ±0.0016%

Class F2 weights : Normally

used for weight measurement of

precious metals

Load cells: OIML class C6

Installation is automatically

calibrated every two week.


Marco van Veen

Slide 16

03/29/2010

Calibration services to ensure product quality & safety

Take advantage of Endress+Hauser’s

calibration management solution:

CompuCal

“Fulfill regulatory requirements

and optimize quality efforts”

Benefits of calibration services:

Measurement reliability is proven and documented for audits

Process costs are reduced by ensuring optimal instrument performance

Calibration intervals are adapted to the application

Need to comply to… ?


Marco van Veen

Slide 17

03/29/2010

Example: Quality assurance

Installation availability and product quality is the common

concern of a QA department, Maintenance Management and

Plant Management.

Delivering a high quality end product is your “core-business”,

Maintenance and calibration of process-instrumentation is

(often) no “core-business”…

But maybe necessary due to assure quality


Marco van Veen

Slide 18

03/29/2010

Its not about how much a service provider can charge

More about how much can be saved

We have to balance necessary maintenance to cost

A good service provider should always

have this picture in mind


Marco van Veen

Slide 19

03/29/2010

Questions?

Calibration or Quality assurance - Endress+Hauser

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