7 Need-to-Know Best Practices for Companies That Use Measuring Equipment

The value of any measuring equipment stems from precision, but such instruments become slightly inaccurate with time and use.

Neglecting measurement accuracy issues can result in grave design and fabrication errors, costly material waste, lengthy production delays, and significant financial losses.

Companies relying on measuring tools must adopt these seven best practices to avoid miscalculations.

1.     Value Operator Training

Any measuring equipment complying with industry standards can produce imprecise readings when misused. The most common rookie mistakes are as follows:

• Using tools for improper applications
• Failing to wear personal protective equipment
• Going over the tool’s range or magnitude limitation
• Measuring objects in unsuitable environments
• Handling delicate tools roughly
• Exposing sensitive equipment to extreme shock
• Exerting excessive force
• Skipping procedural steps
• Jotting down unsteady readings
• Forgetting to return instruments to their protective cases after use

User ignorance and incompetence can do more than create a false sense of measurement accuracy. They can also damage instruments prematurely and permanently, so management should adequately train staff to use measuring tools correctly and handle them with care.

Draft detailed procedures everyone can easily follow to take accurate measurements consistently. Since every instrument is unique, prepare a separate relevant training session for each. Schedule refresher training to correct detrimental behaviors and pragmatic techniques to overcome challenges.

Treat the user manual as the guide to measuring tool operation — as it should be — but encourage staff to think critically and be resourceful. Good operators play it by the book and feel confident in thinking outside the box in extraordinary situations.

Guides do not have an answer for everything, so let seasoned operators pass down their wisdom to their greener counterparts. For example, experienced operators can share proven techniques not found in user manuals for properly handling objects prone to deformation during measurement.

2.     Think About Interferences

An independent, climate-controlled work area is the ideal environment for taking measurements. However, only some companies have sufficient resources to build and design such perfect workspaces. Minimizing all possible interferences is a more realistic goal.

Spacious and clutter-free work areas are conducive to measurement taking and prevent accidents. Placing equipment on a stable surface helps mitigate vibrations. The work area should also be level unless the tool needs a particular position to operate and yield reliable results.

Instruments with electronic indicators are susceptible to signal interferences. Locate sources of radio waves that can affect readings on digital tools that show you their reading on a display — such as gauges, calipers and tape measures — to position equipment accordingly. Reduce the buildup of static charges with ionizing bars and antistatic clothing and mats. Equipment grounding is another preventive measure worth taking.

Loose, dirty and broken cables can cause continuity issues, so ensure all cords associated with measuring instruments are in good repair. Neatly lay them down — away from high-traffic areas, if possible — and secure them in conduits.

3.     Neutralize Environmental Disturbances

Temperature, humidity and air pressure are environmental factors that can negatively impact the performance of some measuring tools. Drafts can also cause measurement errors, so consider investing in an environmental control system to maintain the ideal indoor climate for measurement. Make the room as airtight as possible and position equipment away from air currents.

Let the measuring tool and what it is measuring acclimate to the environment. Doing so ensures the two are at the same temperature at the time of measurement, preventing thermal imbalance from tainting readings.

4.     Put a Premium on Cleaning

Contaminants such as dirt, debris, material residue and bodily secretions like sweat can affect measurement accuracy. The tiniest of particles can throw off readings in high-precision activities.

Only some industries must comply with stringent cleanliness requirements due to the sensitive nature of their business. Still, every enterprise should hold itself to higher standards to prevent miscalculations:

• Strictly abide by the equipment manufacturer’s cleaning instructions.
• Put on gloves, declutter workspaces routinely and control air pollutants to reduce the risk of physical contamination.
• Implement a strict spot-cleaning policy to create a culture of mindfulness and keep measuring tools spotless.
• Schedule regular cleaning since equipment in storage still accumulates dirt. This routine maintenance task also allows inspectors to discover and address signs of wear and tear early.

5.     Be Mindful of Storage

Dampness and wet air can corrode the metallic components of squares and calipers. Gages need a climate-controlled environment to stay accurate. It is impossible to store measuring instruments in a vacuum, but keeping them in a dry place is a helpful rule of thumb.

If the storage area is unconditioned, silica gel packets will help keep moisture levels in check. They absorb water in the air and release some when humidity drops to a certain point.

Sometimes, equipment positioning is as important as the storage location to prevent warping. For instance, levels must be horizontal when stored to keep their vials intact. Hanging or leaving protractors on a flat surface matters to protect their plastic parts from distortion.

Tools like gauges must be in protective cases when not in use to protect them from impact damage and dust buildup. Storing levels in pouches is wise to prevent accidental abrasion. Magnetic fields have a negative effect on micrometer accuracy, so keep them away from magnetic sources.

6.     Prioritize Regular Calibration

Measuring tools are like knives that dull over time. Using technicians to adjust measuring tools until they meet the acceptable accuracy ratio set by industry standards costs money, but this expense translates into savings.

Regular calibration prolongs equipment service lives by determining causes of accelerated wear and reducing the need for premature replacement. This maintenance task also prevents losses associated with inaccurate readings.

In sectors with no room for measurement error — such as food, medical and manufacturing — routinely calibrated instruments promise safety because they ensure machines work as intended, preventing injuries or worse. Regulatory bodies may also seek proof of calibration when doing certification assessments. Complementing maintenance logs with this document makes it easy to pass audits, continue operating legally and avoid production disruptions.

7.     Lubricate Parts Accordingly

Lubrication keeps separate components slippery, reducing friction when they touch one another during movement. Excessive friction results in faster wear and tear that causes parts to fail sooner than expected, while extreme resistance leads to equipment overheating and frequent unplanned maintenance sessions.

Lubricants can keep measuring equipment rust- and corrosion-free by shielding its metal components from water and oxygen, as well as discourage intense friction.

Take Measuring Equipment Handling and Maintenance Seriously

Precision is the yardstick for measuring equipment reliability. Losing this ability turns these assets into liabilities. Follow these pieces of advice to preserve their utility for as long as possible.