Calibration Fundamentals

Calibration
Fundamentals
An
Introduction to
Metrology

Presented by
Jol Rameaux
Service & Support Unit
Agilent Technologies Europe

October 24, 2013
Calibration Fundamentals
1
October 24, 2013
2
Todays topics
Theres much more
beneath the surface !
Contents

Metrology definition
Measurements
confidence
What is calibration?
Cal comparison
Iceberg ahead !
How to calibrate
Calibration of Agilent
equipment
Errors and uncertainty
Summary
An
Introduction
to Metrology
The Importance of Measurement
Metrology is the science of measurement
October 24, 2013
3
British scientist Lord Kelvin (William Thomson
1824-1907) is quoted from his lecture to the
Institution of Civil Engineers, 3 May 1883...
"I often say that when you can measure what you are
speaking about and express it in numbers you know
something about it;
but when you cannot express it in numbers your
knowledge is a meagre and unsatisfactory kind"
You cannot manage what you cannot measure.
HP co-founder Bill Hewlett
Metrology : Wiki Definition

October 24, 2013
4
Metrology is the science of measurement.
Metrology includes all theoretical and practical aspects
of measurement.

Applied metrology concerns the application of measurement
science to manufacturing and other processes and their use in
society, ensuring the suitability of measurement instruments,
their calibration and quality control of measurements. Although
the emphasis is on the measurements themselves, traceability
of the calibration of the measurement devices is necessary to
ensure confidence in the measurements.

Metrologist : Perform metrology

The Need for Good Measurement

October 24, 2013
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We all make and use measurements
every day
How much fuel will I get?
What weight of fruit does the pie need?
Will this nut fit the bolt?
Does your mobile phone reliably connect to any network?
Which drug is most effective?
What is the time?
We have expectations
about the correctness of
these measurements
What are Specifications?
Define a products expected performance
October 24, 2013
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An example using a familiar product

Manufacturers view
Frequency: 900 MHz
Channel spacing: 200 kHz
Max power: 2 W
Rate/Modulation: 270 kbps/GMSK
Sensitivity: -97 dBm
etc.
Reason: Conforms with legal criteria
(safety, interference); compatible with
operators networks.
Consumers view

Reception quality
Reason: Can hear
clearly when driving
(*)
a
car, while in an elevator
or walking through an
underpass.

(*)
Via Bluetooth
hands-free, of course!
Why Measure?
October 24, 2013
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We take measurements to get information about the
manufactured or used product so that we can make
good decisions.
Measure the product
to see if it conforms
with specs or
requirements
We have a
good product
Yes
But how do we know our
measurement tools are
giving good results?
No
Does it
comply?
Measurement decisions
are made during:
Research
Product development
Production
Final testing
Operation
Measurement Confidence
October 24, 2013
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Measurements are made using a wide variety of
instruments, ranging from very simple to extremely
sophisticated.
We must have confidence that all those measuring
instruments are giving valid, useful data.
Because measured values are the basis of decisions.
That confidence is provided by an
effective program of calibration

Calibration Confidence
October 24, 2013
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Reference Equipment used during calibration should be
calibrated and should match or exceed accuracy expectation.
Procedures used during calibration should be clear, validated
and repeatable.
Measurement results should be given at minimum as a
Pass/Fail result and preferably with measurement data and
uncertainties associated
Existing Traceability toward reference standards
People should know what they are doing

Preference should be given to automated calibration as it
increases confidence in overall calibration procedure
So, what is calibration ? (1)

October 24, 2013
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A graphic illustration search Google Images for meal and see the variety
Are they all identical ?
So, what is calibration ? (2)
Definition
October 24, 2013
11
Operation that, under specified conditions, in a first step
establishes a relation between the quantity values with measurement
uncertainties provided by measurement standards and corresponding
indications with associated measurement uncertainties and, in a second
step, uses this information to establish a relation for obtaining a
measurement result from an indication.
From the ISO/IEC Guide 99 : 2007 -- International Vocabulary of Metrology
Or more simply...
The process of comparing a device with unknown performance to
measurement standards traceable to the SI units and with determined
uncertainties to enable obtaining thereafter useful measurement results
from the device.

There is no detail on what should be done during calibration.
Calibration Provides Confidence
October 24, 2013
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Confidence that a devices past performance was valid and
that its future performance will continue to be good within
recommended calibration interval.
Unacceptable past performance may
necessitate customer alert and product recall.
Due to drift, measuring equipment needs to be
regularly calibrated to contain error to
acceptable limits.
Knowledge of the value of a calibrated
parameter becomes less certain as time
elapses since calibration.
Some products require annual optimisation
(adjustment) for high confidence of
compliance in future.

Time
P
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v
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Performance
drift
Calibration &
adjustment
Spec limit
Calibration &
adjustment
Verification, Calibration, Adjustment, Repair
October 24, 2013
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Specification
Limit of normal equipment operation, defined by original manufacturer

Verification
Test versus specifications. Result is Pass or Fail. Verification should include a data
report with failed points, if any, and possibly measurement uncertainty.

Adjustment
Mechanical or electrical tuning of equipment to bring it back within specifications.
Adjustment can be done in case of Failed verification or Passed verification (adjust
always equipment). Adjustment should include a as-received data report and a post-
adjusted data report.

Calibration
Verification + Adjustment combined (if needed)

Repair
If equipment fail verification and cannot be adjusted, then unit is faulty and should be
repaired. Adjustment is not a repair !

Calibration Performance
Real data comparison
MXG RF Digital Signal Generator

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Max
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820 POINTS TESTED
257 POINTS TESTED
Calibration Performance
Real data comparison
MXG RF Digital Signal Generator

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M
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1
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Max
Min
Max
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M
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Not measured (long or difficult tests)
Calibration -- The Iceberg Analogy

October 24, 2013
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The calibration certificate and
measurement data report
What the customer sees

Calibration -- The Iceberg Analogy
More to it than meets the eye
October 24, 2013
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The calibration certificate and
measurement data report
What the customer sees

What the customer doesnt see
Calibration procedure, software
Measurement adequacy
Traceability
Equipment recall system
Records
Labelling for identity & status
Interval management
Environment
Supplier evaluation
Technical competence
How to deliver Calibration? (1)

Calibration is verifying instrument specifications by measuring actual performance
using external lab standards [instruments] that in turn have better performance, and
are traceable to International Standard (NIST, NPL, PTB and NMIJ).

Agilent measures the actual
performance of every warranted
specification, for every installed
option, every time using same
procedure and including adjustments
You need :
- Systems/ETEs used as reference
- To follow OEM recommendations
- Appropriate Procedures
- Trained People
- Cal Laboratory
- To archive results

How to deliver Calibration ? (2)

October 24, 2013
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Use OEM Calibration Labs
Built your own cal lab
Bring Cal Lab on your site(s)
Mix of all above

How to deliver Calibration ? (3)

October 24, 2013
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TME Software Calibration Platform
Check ETEs (reference) needed
Check ETEs cal due date
Compute uncertainties as a function of
ETEs used

Define tests to be run as a function of configuration
(option, frequency, etc), test operator setup
Give Pass/Fail summary and data reports with points out
of specs
Print clean data report
Archive data and traceability
Validated by Agilent (operation, data points, uncertainties)

Calibration of Agilent Equipment?

October 24, 2013
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Automatic Calibration with commercialy available software
Reliable & Repeteable
Automatic configuration check and uncertainty measurement
Most new equipment
Automatic Calibration with proprietary software
Reliable & Repeteable
Automatic configuration check and uncertainty measurement
Older equipment
Manual Calibration
Rely on strickly following recommended test procedure
Highly operator dependant
Very old equipment, no computer interface
No-Calibration required
Accessories, cables, adapters
30 %
40 %
20 %
10 %
What Needs Calibrating?

October 24, 2013
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Any equipment used in incoming, final inspection, in-process or
quality control (SPC), product calibration/testing.
Equipment used to perform lengthy or costly machine set-up.
Items whose indications impact upon controlled conditions
(e.g. environment).
Any situation where the failure costs are too high (safety, one off
testing, etc).
Equipment used in R&D where design decisions are made.
Used during failure or returned material analysis, where critical
determinations could be affected (including repair troubleshooting).
Whenever someone acts upon an instrument's reading.
Equipment used for calibration (traceability) of any of the equipment
used in the above situations.
In general, all equipment who are used as reference for other items
Error & Uncertainty
October 24, 2013
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Error is the result of a measured
value minus the expected or
nominal value of the quantity. The
purpose of calibration is to
determine the magnitude of (and
possibly correct for) errors.

Error is by how much we miss the
target (i.e. the red bulls-eye).
The dispersion (spread of shots)
represents repeatability a
component of uncertainty.
Shots at a target
another illustration of error
Outlier
Average
error
Negative
error
Positive
error
Expected
value
Measured
value
Measured
value
Error, Precision & Accuracy
October 24, 2013
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Accurate and precise
Precise but inaccurate Inaccurate and imprecise
Quite accurate but imprecise
Accurate = True
Precise = Repeatable
Note: In reality we need lots of
data to determine the distribution
(5 shots is not enough).
T
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Bad reference equipment
Bad methodoloy
Bad approach
State of the art
Concepts of Uncertainty
Example : How long is a piece of string?
October 24, 2013
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Contributors
Tape measure
Manufacturing tolerance
Bent or stretched
Temperature / humidity
Graduation resolution
String
Lying straight / flat
Under / Over-stretched
Temperature / humidity
Frayed ends

Method & Personnel
Lining-up string & tape
measure
Horizontal or vertical
Repeatability
Eye report on graduation
Concepts of Uncertainty
Sources of error & uncertainty
October 24, 2013
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Measuring equipment
Specifications inc. imported uncertainty
(traceability)
Readability
Properties of the thing being measured
Stability
Sensitivity to input change
Readability
Measurement method
Use of correctional data
Configuration
Data processing
Operator skill
Reaction time
Manual dexterity
Visual ability (meter parallax)

Environment
Temperature
Humidity
Altitude / Barometric pressure
EMI
Impedance effects
Mismatch
Loading (e.g. local / remote sensing)
Cables and connections
Torque
Materials
Cleanliness
Mechanical stress
Measurement non-repeatability
Due to properties of the test equipment and
unit-under-test and also the variable influences
of test environment and operator.
Mistakes !
Cant be accounted for but can be statistically
identified (outliers).

Uncertainty
Example : Power sensor cal factor
October 24, 2013
27
Er
s e
t e
Mi
Mt
Ms
Mi
Ks Ks Kb
(

A =
2
2
)) ( 1 (
)) ( 1 (
2
1
) (

Measurement equation
Uncertainty calculation for a device

October 24, 2013
28
One spreadsheet/calculation to be created for each measurement
setup and adjusted (uncertainty) for each measured point
-> Give uncertainty per measured point
-> Imply Pass/Fail criteria

Same analysis to be done for each measurement point
Same analysis to be done for each setup (alternate replacement)

Remember the MXG : 820 measurement points for 10 performance
setup ! Not including alternate ETEs analysis.

-> This analysis and validation is the pure role of the metrologist

Basic Model for Product Specification
Where does uncertainty fit in?
October 24, 2013
29
Mean
Production line
test limit
Production
process
distribution
(manufacturing
reproducibility)

Production
margin
Calibration
uncertainty
Delta environment
and drift
Specification
Guardband
Time
P
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v
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Performance
drift
Calibration &
adjustment
Spec limit
Calibration Intervals
October 24, 2013
30
May be expressed as a calendar
period, usually months or years
between calibrations.
Or might be an interval of usage time
such as 1000 hours of operation.
Or possibly the number of usage
operations, especially mechanical
items subject to degradation through
wear.
Although a manufacturer may
recommend an interval (the spec
implicitly has time dependency
owing to expected drift), the
equipment user is responsible for
assigning the appropriate
interval. Most of users follow
manufacturers recommended CI

Aim is to balance the cost of
calibration (how often and the
extent of the testing) with the
risk of bad measurement (cost
of product recall, safety, etc.)
Better do a complete calibration
every 3 years than a bad
calibration every year
Calibration Summary
What you need to remember
October 24, 2013
31
Only manufacturer can define specs and what need to be tested.
All calibration are not equivalent. Compare what is really done to
have a complete picture : function, number of points and accuracy.
Calibration certify past performance was correct and future
performance is expected to be good
Some calibrations can be done by yourselves, some cannot.
Agilent is ready to help, in performing on-Site calibration for
reduced down time and minimize risk in shipment
You can tune calibration interval. It is your decision, but you should
be able to justify in front of auditors.
Metrology is really a specific and full time job reserved to
specialists
Any question : joel_rameaux@agilent.com or contact Boris at IBIS
Calibration Summary

October 24, 2013
32

Questions ?
Calibration Summary

October 24, 2013
33

Thanks for your attention !
Metrological [measurement] Traceability
Definition
October 24, 2013
34
Property of a measurement result whereby the result can be
related to a reference through a documented unbroken chain of
calibrations, each contributing to the measurement uncertainty.
From the ISO/IEC Guide 99 : 2007 -- International Vocabulary of Metrology

Or more simply as...
A series of calibrations of known accuracy that link
measurements to recognised standards through an
unbroken chain of comparisons.
The need for records is to link a product or service event to a
process, status or time.
If the process is measurement, detail about the
equipment, procedure, test conditions and personnel are
all relevant to demonstrating traceability.

Traceability
International System of Units (SI units)
October 24, 2013
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http://physics.nist.gov/cuu/Units/index.html
Every measurement
is linked to one or
more of just 7 base
units !

The kilogramme is the
only unit defined by a
prototype (a specific
physical item held at
BIPM in Paris, France).
Definitions (at NIST site)
Measurement Traceability
A representation of the national measurement system
October 24, 2013
36
NATIONAL
METROLOGY INSTITUTE
STANDARDS
LABORATORY
CAL FACILITY
MANUFACTURING
PRODUCT SPEC
Uncertainty is the potential inaccuracy.
The levels do not represent consistent values of uncertainty.
Test uncertainty ratio (TUR) is the ratio of the unit-under-test's
specification to the measurement uncertainty.
Spec = 15%
TUR 5:1
Unc = 3%
TUR 10:1
Unc = 0.3%
TUR 3:1
Unc = 0.1%
TUR 2.5:1
Unc =
0.04%
NATIONAL
REALISATION OF
SI DEFINITION
Unc =
0.008%
International
comparisons
via BIPM
International
comparisons
via regional
accreditation
organisation
Another
stds lab
Another
cal lab
And another
Another
production line
Another
factory
And another
Traceability Why Bother?
Summary
Common measurement references
are critical to the world-wide
exchange and acceptance of
products, services and technology.
The aim is to transfer these
references in a controlled manner
to the billions of individual
measurements made daily.
Traceable measurements ensure
uniformity of manufactured goods
and industrial processes.
It supports equity in trade,
compliance to regulatory laws and
standards.

If the calibration paper trail was
followed from the unit under test up
through the working, reference and
primary standards, it would
eventually end at the record of an
experiment made to establish the
quantity in terms of one or more of
the SI base units.
It is essential to science and the
development of technology.

October 24, 2013 37
Recommended Resources (Free)
Find out more
October 24, 2013
38
NPL Good Practice On-line Modules on:
Measurement
http://www.npl.co.uk/publications/good-practice-online-modules/measurement/
Uncertainty
http://www.npl.co.uk/publications/good-practice-online-modules/measurement-uncertainty/

NPL -- A Beginner's Guide to Uncertainty of Measurement
http://resource.npl.co.uk/cgi-bin/download.pl?area=npl_publications&path_name=/npl_web/pdf/mgpg11.pdf

UKAS M3003 -- The Expression of Uncertainty and Confidence in
Measurement
http://www.ukas.com/library/Technical-Information/Pubs-Technical-Articles/Pubs-List/M3003.pdf
In or Out-of-Spec?
October 24, 2013
39
But it doesnt define how.
Most accreditation bodies (all of Europes) stipulate ILAC-G8 which
requires conformity limits are set at spec minus uncertainty.
The US national implementation of 17025 is ANSI/NCSL-Z540.3 which
accepts a producer/consumer shared-risk approach:
The probability of false acceptance associated with any test point
labelled Pass shall not exceed 2 %.
Learn more at: http://www.agilent.com/metrology/ncsli2009_dobbert.shtml
Measured values
with plus and minus
uncertainty bars
Ideal
value
Specification
limit
A
B
C
D
E
ISO/IEC 17025 clause 5.10.4.2 :
When statements of compliance
[with a specification] are made, the
uncertainty of measurement shall be
taken into account.

A= Pass
B,C,D = Indeterminate
(Agilent treats D as Fail)
E= Fail
International Laboratory Accreditation Cooperation (ILAC) G8 : Guidelines on the Reporting of Compliance with Specification

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