THE CHALLENGE – A regulatory compliance audit determined that existing calibration practices and documentation required extensive improvements. In-house experience with instrument calibrations and quality systems was inadequate to develop an effective strategy to improve procedures and practices.
THE SOLUTION – ITS facilitated the purchase of ProCalV5 calibration software to provide the foundation infrastructure to electronically construct an asset database, develop Standard Operating Procedures and device calibration strategies and establish appropriate approval practices and responsibilities for work to be performed.
ITS technicians surveyed all existing facility systems and devices. Built master asset records and established all required hierarchical associations. The techs established record approval policies and recommended work schedules for specific devices. They also performed initial calibrations on all equipment and systems, completed work records for final approval and to establish historical records for each device. ITS then trained Unilever personnel on software, new SOPs and calibration practices and developed a list of recommend test standards for future calibrations to be internally performed.
THE IMPACT – Internal calibration practices were substantially improved. Subsequent compliance audits revealed no major and very few minor observations relating to instrument calibrations. With more reliable and dependable instrument readings, production lines were able to make more product in shorter periods resulting in an almost immediate return on initial investment.