{"id":120018,"date":"2026-10-07T07:30:00","date_gmt":"2026-10-07T05:30:00","guid":{"rendered":"https:\/\/www.reichelt.com\/magazin\/?p=120018"},"modified":"2026-10-07T09:14:58","modified_gmt":"2026-10-07T07:14:58","slug":"redefining-calibration-when-digitalisation-drives-innovation","status":"publish","type":"post","link":"https:\/\/www.reichelt.com\/magazin\/en\/technical-papers\/redefining-calibration-when-digitalisation-drives-innovation\/","title":{"rendered":"Redefining calibration: When digitalisation drives innovation"},"content":{"rendered":"\n

Reliable measurements are the backbone of quality assurance in the electronics industry, but they are only as good as the calibration of the measuring instruments used. At the same time, quality assurance is in a state of change. Companies are facing increasing demands for security, compliance and transparency \u2014 while also feeling growing economic pressure. What’s more, in an increasingly automated and globally networked production environment, the pressure to ensure traceability according to international standards is mounting. Under these circumstances, the calibration of measuring instruments can become an important competitive factor.<\/p>\n\n\n\n

In the following article, Jan-Christoph Pakusa, Product Manager Power Supplies<\/a>\/Test & Measurement<\/a> at reichelt elektronik, explains the challenges companies are facing and the innovative approaches they can adopt in order to make processes, safer, future-proof and more efficient.<\/p>\n\n\n\n

Basic principles of calibration<\/h2>\n\n\n\n

First of all, it is important to draw a distinction between the terms calibration, adjustment and verification.<\/p>\n\n\n\n

\"Calibration,<\/figure>\n\n\n\n
    \n
  • Calibration: compare and document<\/strong>
    During calibration, the values of the measuring instrument are compared with the values of a reference instrument or a standard. Any deviations are documented as part of this comparison. These results are recorded in a calibration certificate, along with all details about the tested object, the references, the test setup and procedure itself as well as the ambient conditions during the test. The aim is to ensure that the measurement results are traceable to national and international calibration standards in order to guarantee comparability and traceability.
    <\/li>\n\n\n\n
  • Verification: regulated by law & carried out by the authorities<\/strong>
    Verification, which is a legally regulated procedure, is distinct from calibration. In Germany, it is carried out exclusively by public authorities called test laboratories. During verification, testing is carried out to check whether a measuring instrument meets the legal requirements set out by the German Measurement and Verification Act. Verification is primarily intended to protect the consumer and their health: In addition, carrying out verification is mandatory wherever measurement results are directly converted into monetary values, such as by retail scales or electricity meters.
    <\/li>\n\n\n\n
  • Adjustment \u2013 fine-tuning to a reference value
    <\/strong>The third term is adjustment. This consists of direct and precise adjustment to align with a known reference value. Depending on the device, this can be done using mechanical elements such as potentiometers, menu navigation or PC software. Since an adjustment changes the original device settings, a new calibration is always carried out \u2014 once before and once after the adjustment. Only by following this procedure can measurement results be documented comprehensively and measurement errors during calibration identified.<\/li>\n<\/ul>\n\n\n\n

    Various standards and rules define a comprehensive framework for these processes. ISO\/IEC 17025, which defines the requirements for testing and calibration laboratories, and ISO 9001, the international standard for quality management systems, are particularly relevant. Depending on the industry, additional regulations may be in force, such as the IPC and IEC standards in the electronics industry.<\/p>\n\n\n\n

    Key challenges for everyday calibration<\/h3>\n\n\n\n

    In practice, calibration presents a wide range of challenges, both at the technical and economic level, but also especially at the organisational level.<\/p>\n\n\n\n

    On the one hand, calibration involves a great deal of organisational and logistical effort. The scheduling and availability of the test equipment as well as its transportation to and from external service providers require precise and detailed coordination. Especially in highly automated production environments, any unavailable measuring equipment poses a risk of delays or quality gaps.<\/p>\n\n\n\n

    In addition, there is an obligation to be traceable to international standards and to comply with increasingly stringent regulatory requirements. This leads to hierarchically structured calibration processes that combine various areas of responsibility, a variety of technologies and differing test specifications. The coordination of these multi-layered structures is complex and error-prone and can also have a direct impact on product safety and the reliability of declarations of conformity.<\/p>\n\n\n\n

    This is compounded by the fact that companies are often faced with bottlenecks caused by external calibration service providers and their own specialist staff. Long throughput times, a lack of skilled staff and limited flexibility of calibration laboratories can lead to delays that result in high costs for the production environment.<\/p>\n\n\n\n

    Another problem area is digital integration and documentation. Many companies still work with paper-based or isolated systems, which makes it difficult to ensure complete traceability. A lack of interfaces between production and quality assurance systems impedes efficient processes and poses a risk during audits. In addition, incomplete or incorrect documentation can affect legal compliance and product safety.<\/p>\n\n\n\n

    Value for money also remains a long-term challenge for many companies. Growing economic pressures often force companies to weigh up which calibrations are actually needed and which can be delayed. However, making savings in the wrong place can have serious consequences.<\/p>\n\n\n\n

    \"Precision
    Automated testing processes support efficient and comprehensive quality assurance in modern electronics manufacturing.<\/figcaption><\/figure>\n\n\n\n

    From hurdle to solution: Innovation opportunities in calibration<\/h3>\n\n\n\n

    However, calibrations can not only be viewed as a necessary obligation, but also as an opportunity \u2014 especially in the area of digitalisation and automation. This is because processes can be accelerated significantly if, for example, time-consuming routine tasks such as data acquisition can be automated.<\/p>\n\n\n\n

    Digital traceability<\/strong> can be particularly significant. It is important to distinguish it from the term measurement traceability: Measurement traceability is understood as technical proof of measurement accuracy, while traceability is the complete documentation of production and delivery processes. Instead of scattered documents or manual inputs, digital systems implementing digital traceability enable measuring instruments, calibration data and standards to be permanently linked together. This also ensures compliance with traceability requirements according to international standards. By using digital management systems, the entire calibration history is automatically documented and linked to relevant standards such as ISO\/IEC 17025 or ISO 9001. This facilitates both internal quality inspections and external audits, and creates more transparency.<\/p>\n\n\n\n

    Cloud solutions<\/strong> that manage calibration data efficiently and strengthen audit compliance can also be a key component. Central data storage and standardised access rights allow companies to prove at all times that their test equipment is fully monitored. In addition, cloud systems typically provide higher data security than many local solutions. With data encryption during transfer and storage as well as regular backups, they usually have a multi-level security concept and guarantee access from any location.<\/p>\n\n\n\n

    In addition to more efficient processes, solutions that are implemented directly on the measuring instrument are becoming increasingly commonplace: <\/em>Self-calibration<\/strong> and remote calibration<\/strong> allow certain calibrations to be carried out during operation and without time-consuming transportation to external service providers. This reduces downtimes and increases flexibility, especially in highly automated production environments.<\/p>\n\n\n\n

    Predictive maintenance<\/strong> can be an especially strategic advantage. It is based on sensor data, AI and statistical analyses, making it possible to plan ahead and anticipate when calibration is actually necessary. This can reduce expenditure, for example by avoiding unnecessary testing.<\/p>\n\n\n\n

    Quality, safety and compliance<\/h2>\n\n\n\n

    While the calibration of measuring instruments is a technical necessity that involves a lot of organisational effort and regulatory requirements, it also offers great potential. Especially when it comes to concepts like the Smart Factory and Industry 4.0, it is clear that calibration plays a key role in intelligent, networked systems. Digital traceability, cloud systems and predictive calibration strategies using predictive maintenance make processes not only more efficient, but also more resilient and transparent. Calibration can therefore become a strategic instrument of quality that can get your company prepared for the future.<\/p>\n\n\n\n

    Images: Adobe Stock<\/p>\n","protected":false},"excerpt":{"rendered":"

    Reliable measurements are the backbone of quality assurance in the electronics industry, but they are only as good as the calibration of the measuring instruments used. At the same time, quality assurance is in a state of change. Companies are facing increasing demands for security, compliance and transparency \u2014 while also feeling growing economic pressure. 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