IMTE Calibration , Traceability & Least count

MEASUREMENT

Since measurement plays such a fundamental part in our

Service, it is important that the accuracy of the
measurement is fit for purpose, i.e. it fully meets the
requirements of the application. Every measurement is
inexact and therefore requires a statement of uncertainty to
quantify that inexactness. The uncertainty of a
measurement is the doubt that exists about the result of
any measurement.
Accuracy and Precision
Accuracy - degree to which a measured value agrees with the true
value of the quantity of interest
 A measurement procedure is accurate when it is absent of systematic
errors
 Systematic errors - positive or negative deviations from true value
that are consistent from one measurement to the next
Precision - degree of repeatability in the measurement process
 Good precision means that random errors in the measurement
procedure are minimized
 Systematic Errors
 The result of
1. A mis-calibrated device, or
2. A measuring technique which always makes the measured value larger
(or smaller) than the "true" value.
 Example: Using a steel ruler at liquid nitrogen temperature to measure
the length of a rod.
 The ruler will contract at low temperatures and therefore overestimate
the true length.
 Careful design of an experiment will allow us to eliminate or to correct
for systematic errors.
 What is Calibration?
• Calibration is the set of operations that establish, under specified
conditions, the relationship between values indicated by a measuring
instrument, a measuring system or values represented by a material
measure, and the corresponding known values of a measurand (the
parameter that is being measured)
• A wide variety of measuring equipment is used during manufacturing and
assembly. Every piece of measurement equipment needs to be calibrated.
A calibration is not valid indefinitely; it will expire and have to be repeated.
• All gauges must have a valid calibration before being used. If the gauge
does not have a valid calibration it must NOT be used. It is the
responsibility of the user to ensure the equipment is within calibration.
Calibration fulfils two objectives:
• It determines accuracy of the measured data
• It provides traceability to the measurement
 Calibrations are correct?
Determining and documenting the deviation of a
measuring instruments indication from the
conventional ‘true’ value.

Sure we can calibrate our instruments so that we

know they are accurate. But how do we know the
calibrations are correct? What value is ‘true’ and how
can we trust it?
 What is Traceability?

One way of ensuring that your measurements are accurate is by

tracing them back to national standards. This method of
guaranteeing a measurement's accuracy through an unbroken chain
of reference is called traceability.

Traceability is a method of ensuring that a measurement (even with

its uncertainties) is an accurate representation of what it is trying to
measure.
Traceability: The concept of establishing valid
calibration of a measuring standard or instrument by
step-by-step comparison with better standards up to
an accepted national or international standard.
 What is Uncertainty?
No measurement is ever guaranteed to
be perfect. Uncertainty of measurement
is the doubt that exists about the result
of any measurement. By quantifying the
possible spread of measurements, we
can say how confident we are about the
result.
 UNCERTAINITY
In order to express the uncertainty of a measurement, we need
to evaluate as accurately as possible the errors associated
with that particular measurement.
For example - we might say that a particular stick is 200
centimetres long, plus or minus 1 centimetre, at a 95%
confidence level. This is written:
200 cm ±1 cm at a level of confidence of 95%
This means we are 95% sure that the length of the stick is
between 199 centimetres and 201 centimetres.
 Difference between Uncertainty and Error
Don’t confuse the term Uncertainty and Error

Error is the difference between measured value and

the true value of the object being measured.

Uncertainty is the quantification of the doubt about

the Measurement result.
 Why is Measurement Traceability Important?

Measurement traceability is important because it gives you

confidence and assurance that your measurement results agree
with national or international standards within the statement of
uncertainty in measurement.
Without traceability, a laboratory can claim anything they want in
a test or calibration report. With traceability and the independent
verification of an accreditation or inspection body, you can
minimize the risk of falling victim to fraudulent information and
activities.
Measurement traceability can have a direct impact
on the uncertainty of your measurement results.
The traceability pyramid
The concept of traceability is
therefore usually represented by a
traceability pyramid. At the top of
the pyramid is the definition of
(say) the metre. Below it are all
the links in the traceability chain,
with the width of the pyramid
therefore becoming broader as
the uncertainty of measurement
increased. A basic rule of thumb
is that the fewer the links, the
less the uncertainty of
measurement.
 International metre

National and accredited metrology institutes

REFERENCE NORMAL

Gauge blocks

CALIBRATION EQUIPMENT
Gauge Straight- Dial gauge Setting
blocks ness mm calibration rings

PRODUCTION MEASUREMENT EQUIPMENT

Micro- Vernier Dial Inside dial Inside
meters Calipers indicators indicators micrometers
Various accuracies - traceability triangle
Example of traceability chain for temperature measurement
 Traceability Chain
In this case, unit 1 has had its measuring
NPL instruments calibrated by laboratory A, whose
master standards have been calibrated by the
National Physical Laboratory of the country. Unit
LAB-A LAB-2 2, on the other hand, has had its measuring
Instruments calibrated at laboratory C, which has
had its standard calibrated from laboratory B.
Laboratory C’s standards have traceability to the
Unit 1 LAB-B NPL through laboratory B and laboratory 2. Thus,
both unit 1 and unit 2 have traceability to the
NABL. However, error in the measurement
LAB-C process leading to calibration of the measuring
instruments of unit 1 and unit 2 as a result of the
traceability factor would be different. While there
Unit-2 is no restriction on the number of steps that can
be taken in the traceability chain, uncertainty in
measurement becomes the limiting factor
 Fundamental Units- SI

Characteristic Fundamental unit Description

Length Metre(m) It is defined as the distance traveled by light in a

vacuum over a time interval of 1/299,792,458 of a
second.
Time Second(s) Second is defined as the duration of 9,192,631,770
periods of the radiation corresponding to the transition
between the two hyperfine levels of the ground state
of the cesium-133 atom
Mass Kilogram(Kg) It is defined by taking the fixed numerical value of
the Planck constant h to be 6.62607015×10−34 when
expressed in the unit J⋅s
Electric Current Ampere(A) The ampere (A) is a measure of the amount of electric
charge passing a point in an electric circuit per unit
time. 6.241×1018 electrons
 Fundamental Units- SI

Characteristic Fundamental Description

unit
Temperature Kelvin(K) The kelvin is the fraction 1/273.16 of the
thermodynamic temperature of the triple point of
water .
Light Candela(cd) candela is defined as the luminous intensity in a
given direction of a source that emits
monochromatic radiation of
frequency 540⋅1012540⋅1012 Hertz and that has a
radiant intensity in that direction of 1/683 watts per
steradian.
Amount of Mole(mol) It is defined as the amount of a substance that
Substances contains as many elementary entities as there are
atoms in 0.012 kg of carbon-12.
 Traceability Requirements as per ISO/IEC 17025

“5.6.1 General
All equipment used for tests and/or calibrations, including equipment for
subsidiary measurements (e.g. for environmental conditions) having a significant
effect on the accuracy or validity of the result of the test, calibration or sampling
shall be calibrated before being put into service. The laboratory shall have an
established programme and procedure for the calibration of its equipment.
NOTE : Such a programme should include a system for selecting, using,
calibrating, checking, controlling and maintaining measurement standards,
reference materials used as measurement standards, and measuring and test
equipment used to perform tests and calibrations.”
“5.6.2.1.1 For calibration laboratories, the programme for calibration of
equipment shall be designed and operated so as to ensure that
calibrations and measurements made by the laboratory are traceable to
the International System of Units (SI) (Système international d’unités).
 What is ILAC & IAF?

ILAC(International Laboratory Accreditation Cooperation)

is the international organisation for accreditation bodies operating in
accordance with ISO/IEC 17011 and involved in the accreditation of
conformity assessment bodies including calibration laboratories (using
ISO/IEC 17025), testing laboratories (using ISO/IEC 17025), medical
testing laboratories (using ISO 15189) and inspection bodies (using
ISO/IEC 17020).
The international arrangements are managed by ILAC in the fields of
calibration, testing, medical testing and inspection accreditation and
IAF (The International Accreditation Forum) in the fields of
management systems, products, services, personnel and other similar
programmes of conformity assessment. Both organizations, ILAC and
IAF, work together and coordinate their efforts to enhance the
accreditation and the conformity assessment worldwide.
 What does NABL stand for? What’s its use?
NABL stands for National Accreditation Board For Testing And
Calibration Laboratories. NABL has agreements with ILAC
(International Laboratory Accreditation Conference) and APLAC (Asia
Pacific Laboratory Accreditation Cooperation). These are especially
valuable for International recognition and mutual acceptance of test
results. In short accreditation has worldwide acceptance.
NABL is an autonomous body under the aegis of Department of
Science & Technology, Government of India, and is registered under
the Societies Act. It is only one of its kinds that assess laboratories
in India for quality and consistency in the results. The concept of
Laboratory Accreditation was developed to provide a means for third-
party certification of the competence of laboratories to perform
specific type(s) of testing.
 Misconception of Measurement Traceability

The ILAC P10 policy provides a great explanation of what

measurement traceability is not:
“The persistent misconception that metrological traceability may
be linked to a particular organization (e.g., “traceable to a
specific National Metrology Institute”) fosters continued
confusion with regard to its nature. Metrological traceability
pertains to reference quantity values of measurement standards
and results, not the organization providing the results.”

Think about that next time you read a traceability statement that
declares “traceable to NABL.
Example- Traceability reporting
What are the things to be checked in Calibration
certificate
• Calibration certificate number, issue date
• Unique ID of the measuring instrument
• Master gauge used and its traceability
• Calibration according to documented procedures
• Unbroken chain of calibrations traceable to National
Standard
• measurement uncertainty
• Validity
• Performed by trained and competent resources
Calibration by Accredited Lab
• Calibration certificate number,
issue date
• Unique ID of the measuring
instrument,make,model,range
• Master gauge used and its
traceability
• Calibration according to
documented procedures
• Unbroken chain of calibrations
traceable to National Standard
• measurement uncertainty
• Validity
• Performed by trained and
competent resources
Calibration by Unaccredited
Lab
• Calibration certificate number,
issue date
• Unique ID of the measuring
instrument, make, model, range
• Master gauge used and its
traceability
• Calibration according to
documented procedures
• Unbroken chain of calibrations
traceable to National Standard
• measurement uncertainty
• Validity
• Performed by trained and
competent resources
 Recalibration

Calibration of a measuring instrument ensures that the value displayed by the

instrument is both accurate and repeatable with respect to a traceable
standard. However, once calibrated, it cannot be assumed that the instrument
would continue to give accurate and repeatable results for all time to come.
Thus, recalibration of the instrument is necessary to estimate its deviation
from a reference value or standard and to ensure that the deviation is
acceptable for the measurement over time.
The purpose of a periodic calibration is:
• To estimate the reference standard’s or measuring instrument’s deviation
from a reference value and the measurement uncertainty associated with that
deviation;
• To reassure that the measurement uncertainty can continue to be achieved
with the reference standard or measuring instrument.
 Periodicity of calibration

• Recommendation of the instrument manufacturer;

• How frequently and severely the instrument is expected to be used.
• The influence of the environment.
• Maximum allowable variation of the measurand.
• The uncertainty of measurement required.
• Written procedure of Manufacturing unit which is using the
instrument
External calibrations – Not accredited
Using an accredited calibration laboratory is highly
recommended. It is not compulsory to use an accredited
laboratory, but if you use a non-accredited laboratory you
must ensure (audit) yourself that the laboratory is
traceable to National standard.

If we are witnessing the tests in an unaccredited

laboratory/manufacturer facility which is not accredited
then we should make audit as per the below check list to
ensure that lab IMTEs are traceable to National
standards.
 Least Count

The smallest value that can be measured by the measuring

instrument is called its least count. Measured values are good only
up to this value. The least count error is the error associated with the
resolution of the instrument.
Least Count
Least Count Error
The least count error is that When a measurement falls between two divisions,
then the approximate measurement made by the observer. when the instrument
shows a mean position between the two divisions then the observer has to take the mean position
as the approximate measurement.

In above, the measurement of the object, it is shown between two division lines, so then the observer
needs to take the approximation for the measurement.

The object length would be 19.5 millimeters in the above case.

 Instrument Limit of Error, ILE
 Be generally taken to be the least count or some fraction (1/2,
1/5, 1/10) of the least count.
 Which to choose, the least count or half the least count, or
something else.
 No hard and fast rules are possible, instead you must be guided
by common sense.
 If the space between the scale divisions is large, you may be
comfortable in estimating to 1/5 or 1/10 of the least count.
 If the scale divisions are closer together, you may only be able to
estimate to the nearest 1/2 of the least count, and
 if the scale divisions are very close you may only be able to
estimate to the least count.
 Rule for selection of Measuring Instrument

• Simply stated the “Rule of Ten” or “one to ten” is that the

discrimination (resolution) of the measuring instrument should
divide the tolerance of the characteristic to be measured into
ten parts.
• In other words, the gage or measuring instrument should be 10
times as accurate as the characteristic to be measured. Many
believe that this only applies to the instruments used to
calibrate a gage or measuring instrument when in reality it
applies to the choice of instrument for any measuring activity.
• The whole idea here is to choose an instrument that is capable
of detecting the amount of variation present in a given
characteristic.
 Selection of Measuring Instrument

The selection of measuring instruments depends on the measurement

to be performed. Generally, three characteristics are considered;
these are:
• The range and magnitude of the parameter to be measured and the
accuracy of the measurement (the instrument should have the range
to cover effectively the range of the parameter).
• The resolution of the measuring instrument should be smaller than
the minimum unit of measurement of the parameter.
• Lastly, and most importantly, the accuracy or uncertainty of the
measuring instrument should comply with the accuracy requirement of
the parameter to be measured.
 Selection of Measuring Instrument
For example, if a process temperature of 100°C is being measured, the range of
the temperature indicator should be such that it can measure not only 100°C, but
also temperatures above and below that value. Suppose the following
thermometers are available:
(a) 0-99°C (b) 0-199°C (c) 0-99.9°C (d) 0-199.9°C

From the range specification it is clear that the thermometers at (a) and (b) have
a resolution of 1°C, while those at (c) and (d) have a resolution of 0.1°C. For
measurement of the above parameter, i.e. 100°C, the thermometers at (a) and
(c) above are not suitable, since these do not have the required range. The
choice is therefore between (b) and (d). This would again depend on the
tolerance specified for the task. If the tolerance is ± 1°C, then the thermometer at
(d) above should be selected. If, on the other hand, the parameter to be
measured is 100º ± 10ºC, then the thermometer with a range of 0-199°C would
be sufficient for the measurement.
 Selection of Measuring Instrument
The third important criterion for the selection of a measuring instrument
is the accuracy of measurement. The following table indicates the
accuracy:

The selected thermometer, when calibrated, should exhibit an accuracy

that complies with the desired accuracy of measurement as
demonstrated above. Alternatively, if the supplier of the thermometer
provides a valid calibration certificate, the selection is easier. From the
above explanation, it is clear that unless the parameter to be measured
is adequately defined, it is not possible to make a proper selection of
the measuring instrument.
Selection of Measuring Instrument
 Factors for selection of measuring equipment
Metrological Task

Output data

Organisation
Additional Conditions
• Measurement • Measurement • Standards •Existing
object place • Legislation measuring
• Inspection • Environment instruments
• Regulations
characteristic influences •Staff
• Guidelines •Metrological
• Inspection scope • Measuring • Safety infrastructure
• Results time(Cycle time) requirement
documentation • Level of • Customer
automation requirement
• Internal
Instruction
 Instruments selection for power measurement
• Power accuracy
• Every measuring device has some degree of uncertainty, which is why
accuracy is normally expressed as a range. Within this range, engineers
consider power accuracy as the primary indicator of uncertainty for basic
measurement
• Measurement range
• Another potentially confusing factor on many datasheets is measurement
range. It is important because the specified accuracy of a power-
measurement device varies depending on where the measurement is
within the range.
• Industry standards
• product design and testing will need to comply with some relevant industry
standards such as IEEE, CE, IEC, and MIL-STD standards
Use of the wrong instrument for power-related measurements can
cause product design evaluation to fail applicable industry
compliance tests.
 Selection of Measuring Instrument
Equipment selection

Equipment LENGTH Step Height Wall Thickness Outside Diameter Inside Diameter Hole Depth
S M L S M L S M L S M L S M L S M L
Micro meter External X X X X X
Micrometer internal X X X
Caliper X X X X X X X X X
Depth gauge X X
Height Gauge X X X X
Bore Cauges
Micrometer X X
Indicator X X
Spider gauge X
Air Gauge X X
Counter sink gauge X X
Thickness Gauges
Snap Gauge X X X X X X
Ultasonic X
Beam Comparators
Bowers X X X
Omigaguge X X X
Indicators
Lever X
Plunger X
Go & No Go gauges
Plug gauges X X
Slip gauges X X
Snap gauges X X
Visual Comparators
Radius
Thread
Surface textures
Comparator
Portable Probe
Profile Projector

Coordinate measurement machine X X X X X X X X X X X X X

 Selection of Measuring Instrument
Equipment Selection

Equipment Hole diameter Radius Thread Pitch Runout Finish Profile Roundness
S M L S M L S M L S M L
Micro meter External
Micrometer internal
Caliper
Depth gauge
Height Gauge
Bore Cauges
Micrometer X X
Indicator X X
Spider gauge X
Air Gauge X X
Counter sink gauge
Thickness Gauges
Snap Gauge
Ultasonic
Beam Comparators
Bowers
Omigaguge
Indicators
Lever
Plunger
Go & No Go gauges
Plug gauges X X X
Slip gauges X
Snap gauges
Visual Comparators
Radius X X
Thread X X
Surface textures
Comparator X X X
Prortable Probe X X
Profile Projector X X

Coordinate measurement machine X X X X X X

Measuring Method
Thank You!