Out of Tolerance: What Happens When Your Equipment Fails Calibration?
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Out of Tolerance: What Happens When Your Equipment Fails Calibration?
You send an instrument in for routine calibration expecting everything to check out but the results show it is out of tolerance. What does that actually mean, and what should you do next?
An out-of-tolerance result doesn’t necessarily mean your equipment is unusable. However, it does mean the instrument was found to be measuring outside its specified acceptable limits and should be addressed before it returns to regular use.
What Does “Out of Tolerance” Mean?
Every measurement instrument has specifications that define how accurately it should perform. During calibration, its readings are compared against a known reference standard.
If the results fall outside the instrument’s acceptable specifications, it is considered out of tolerance.
The difference may be small, but in applications where accuracy is critical, even minor measurement errors can affect quality, compliance, or operational decisions.
Why Does Equipment Fall Out of Tolerance?
Measurement instruments can drift over time for several reasons, including:
● Regular wear and frequent use
● Temperature, humidity, or other environmental conditions
● Shock, vibration, or accidental drops
● Improper storage or handling
● Aging internal components
This is one reason regular calibration is important. An instrument can appear to be working normally while its measurement accuracy has gradually changed.
What Should You Do Next?
When equipment is found out of tolerance, the next step depends on the instrument and the extent of the issue. It may require adjustment, repair, recalibration, or, in some cases, replacement.
It’s also important to consider how the instrument has been used since its previous successful calibration. If it was responsible for critical measurements, those results may need to be reviewed to determine whether the accuracy issue could have affected previous work.
Maintaining clear calibration records makes this process much easier.
Can You Reduce the Risk?
Calibration drift cannot always be prevented, but a proactive calibration program can help identify changes before they create larger problems.
Following appropriate calibration intervals, storing and handling equipment correctly, and responding to unusual or inconsistent readings can all help maintain measurement reliability.
Confidence in Your Measurements
An out-of-tolerance result isn’t simply a failed test. It’s valuable information that helps you identify a potential accuracy issue before continuing to rely on questionable measurements.
Kingsway Instruments provides NIST-traceable calibration services and the expertise to help customers understand their calibration results and determine the appropriate next step. If you’re unsure about the accuracy of your equipment, or it’s time for its next scheduled calibration, our team is here to help keep your measurements reliable.
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