A major biologics manufacturer sought to eliminate the inefficiencies of its decentralized instrument calibration program.
Historically, each department used a paper process to schedule and select vendors for calibration activities. As a result, the company had little control over the consistency of the calibration methodology, cost tracking, and overall scheduling.
Additionally, numerous non-critical assets were calibrated, leading to excessive downtime and unnecessary costs.
Design and implement a uniform, repeatable, and accurately documented calibration program. The success of the program would support sustainability, accountability, and regulatory compliance by effectively integrating the following elements:
- Proper identification of critical manufacturing assets
- Precise determination of calibration standards
- Standardizing calibration procedures
- Thoroughly documenting calibration activities
Learn how a major food processor improved work order planning, scheduling, MRO parts management, and the use of its CMMS by partnering with SEAM Group for Preventive Maintenance Optimization.
SEAM Group thoroughly analyzed existing processes, assets, and personnel roles. Upon review, the team established:
- An optimized master instrument list (MIL) which provided a criticality prioritized list of calibrated manufacturing assets
- Standardized work plan templates for in-house calibration technicians to have uniform instructions for the calibration of MIL assets
- A planner/scheduler role to centralize the coordination of calibration activities for in-house technicians, as well as external service providers
Implementing work plan templates for in-house calibration personnel proved to be particularly pivotal in the success of this partnership.
The standardization, documentation, and centralization of activities, the addition of the planner/scheduler role, and the use of SAP as the computerized calibration management system (CCMS) yielded measurable results for the customer.
- 50% of calibration activities can now be performed uniformly by in-house personnel
- 30% initial cost savings by standardizing work activities, relying on in-house personnel for calibration activities, and identifying assets
- Up to 5% year-over-year cost reduction is expected because of the calibration program redesign
- Increased internal customer satisfaction due to reduced downtime associated with calibration activities