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How can you properly calibrate and adjust equipment during maintenance?

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Calibration and adjustment are essential tasks for maintaining the accuracy, efficiency, and safety of equipment in manufacturing. They ensure that the equipment operates within the specified parameters and meets the quality standards of the products. However, calibration and adjustment can also be challenging and risky if not done properly. In this article, you will learn how to calibrate and adjust equipment during maintenance in a systematic and safe way.

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Dibyendu Mukherjee, CMRP

Manufacturing Engineering, Asset Care, Project Management, Technical Audit
Jason Premo

Acclaim Aerospace ?? Swiss Lathe Ultra Precision Machining ?? Aviation ?? Space??Defense ?? Pew Pews ?? Medical ??…
Hossein Moshiri

Producer of 99% caustic soda, Поставщик химикатов напрямую из Ирана

1 Plan ahead

Before you start calibrating and adjusting any equipment, you need to plan ahead and prepare the necessary tools, materials, and documentation. You should check the equipment manual, the maintenance schedule, and the calibration certificates to identify the calibration and adjustment requirements, methods, and frequency. You should also gather the appropriate instruments, such as gauges, meters, testers, and spanners, and ensure that they are calibrated and verified. Moreover, you should wear the proper personal protective equipment (PPE) and follow the safety rules and procedures of your workplace.

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Hossein Moshiri

Producer of 99% caustic soda, Поставщик химикатов напрямую из Ирана
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Overlooking Contract Details: Carefully review and negotiate the contract terms. Pay attention to cancellation policies, hidden fees, and other clauses that could impact your overall budget. Neglecting Flexibility: Be open to flexible dates or alternative arrangements. This can provide negotiating leverage and help secure better rates or additional perks. Failure to Consider Package Deals: Many venues offer package deals that include catering, audio-visual equipment, and other amenities. Negotiate comprehensive packages to streamline planning and potentially reduce costs.

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Suman Sarkar

AM and EMS professional in Bauxite mines,refinery and Smelter ( AP technology)
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Planning and Scheduling process is a great point. Which one will come first. Planning is dependent on time,urgency,materials availability, diagnosis and shortfalls. Scheduling is the most important aspect of planning process,which requires, involvement of the planner.He has the sole responsibility to scedule multiple task,in discussion with maintenance and production supervisors, MRPs, maintenance technicians and operators. It is to be noted Scheduling task has a great importance to do the effective planning and past experiences. Scheduling to be done 4 weeks in advance, so that maintener and Operation will not face any difficulties in a safe manner.

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2 Isolate and secure the equipment

The next step is to isolate and secure the equipment from the power source and other hazards. You should turn off the equipment and disconnect it from the electricity, gas, water, or other utilities. You should also lock out and tag out (LOTO) the equipment to prevent any accidental or unauthorized operation. Additionally, you should release any residual pressure, heat, or chemicals from the equipment and clear the area from any obstacles or debris.

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Dibyendu Mukherjee, CMRP

Manufacturing Engineering, Asset Care, Project Management, Technical Audit
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Planning and scheduling are key to the successfull equipment readiness. Certain areas to look into before scheduling - Asset Hierarchy Development, Asset Strategy Development, Maintenance Work Packaging – maintenance plans into logical blocks of work to be executed under work orders created in CMMS, Spare Parts Identification and Optimisation – and part kitting, Selection of manpower with required skill set. Not to forget, on the day of field work, safety (tool box talk, LOTO, training).

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3 Perform calibration and adjustment

Once the equipment is isolated and secured, you can perform the calibration and adjustment according to the equipment manual and the calibration standards. You should follow the steps and instructions carefully and use the instruments correctly. You should also record the calibration and adjustment data, such as the readings, settings, adjustments, and errors, in a logbook or a form. Furthermore, you should compare the data with the acceptable ranges and tolerances and verify that the equipment meets the specifications.

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4 Test the equipment

After you finish calibrating and adjusting the equipment, you need to test it to ensure that it works properly and safely. You should reconnect the equipment to the power source and other utilities and remove the LOTO devices. You should also perform a functional test, such as running a sample product or a test cycle, and check the output and performance of the equipment. Additionally, you should inspect the equipment for any leaks, damages, or defects and fix them if necessary.

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5 Document and report

The final step is to document and report the calibration and adjustment results and actions. You should update the calibration certificates and labels and attach them to the equipment. You should also file the logbook or the form and keep it for future reference. Moreover, you should report any issues, problems, or deviations to your supervisor or manager and seek their guidance or approval. By documenting and reporting, you can ensure the traceability and accountability of the calibration and adjustment process.

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6 Here’s what else to consider

This is a space to share examples, stories, or insights that don’t fit into any of the previous sections. What else would you like to add?

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Jason Premo

Acclaim Aerospace ?? Swiss Lathe Ultra Precision Machining ?? Aviation ?? Space??Defense ?? Pew Pews ?? Medical ?? Electronics ?? Chief Engineer & Machinist ?? STEM Ed Advocate ?? GA Tech Yellow Jacket
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Unfortunately too often tools and equipment only receive attention when something is wrong... or discovered during an audit, ugh! Instead think of borrowing some methods from Lean's 5S and visual factory. In each work area, create a simple magnet board chart with a list of equipment and tools, and their daily, weekly, monthly, yearly etc maintenance. Use color coded red, yellow, green magnets! Empower EVERYONE to use the magnets and boards during a daily 5S checklist to denote any needs or problems. Yellow could mean that a tool is approaching it's calibration date and that plans need to be made in advance (especially if you only have one) Red could mean fault codes or tool that had to be taken out service because it was dropped.

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How can you properly calibrate and adjust equipment during maintenance?

1

2

3

4

5

6

1 Plan ahead

2 Isolate and secure the equipment

3 Perform calibration and adjustment

4 Test the equipment

5 Document and report

6 Here’s what else to consider

Manufacturing

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How can you properly calibrate and adjust equipment during maintenance?

1

2

3

4

5

6

1 Plan ahead

2 Isolate and secure the equipment

3 Perform calibration and adjustment

4 Test the equipment

5 Document and report

6 Here’s what else to consider

Manufacturing

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