Daye Poly Technic College

Mechanics
Level IV
Learning guide No. 2

Unit of Competence: Calibrate Measuring Equipment

Module Title: Calibrating Measuring Equipment
TTLM Code: IND MCS4 02 0217
By: LabenaManza
AmanuelTaddesse
ErmiasTesfaye

October 2023
Lo1 Check equipment for correct operation
Introduction
Every year, there are a number of accidents from using work equipment,
includingmachinery. Many are serious and some are fatal. Manufacturing companies must
checkfor correct operation of equipment (components), for wear, loose connectionsequipment,
and believed it of great importance to provide maintenance program forequipment for their
correct operation. Check equipment for correct operation, for wear, loose connections depend on
the typeof equipment. Any equipment with moving parts must be checked at least twice a
year,static equipment at least once a year.Intervals for maintenance work and checks generally
depend on
 Location
 Kind of use
 Frequency of use
 Possible vandalism (damages)
The equipment must be checked for correct operation and safety, especially: Wooden parts
 Check that all bolts and screws are tight and retighten if necessary.
 Check for rot (decomposition) and, if necessary, smooth splinters.
 Recommendation: apply paraffin wax to the upper end grain areas once a year
 Check the ash wood rungs of the ladders for wear and tear, the remainingdiameter must
be at least 30 mm.Slide parts
 Check the slide surface for vandalism (damaged)
 Check blots and screws on the hut are tightSwing parts
 Make sure that the joints moves smoothly, apply grease if required
 Check welds of metal cross beam for cracks
 Check chain and connection to chain, the first chain link must be locked; checkwear on
contact surfaces between first and second chain link.
 Check bearings and chains for wear and tear
What is work equipment?
‘Work equipment’ is almost any equipment used by a worker while at work including: machines
such as circular saws, drilling machines, photocopiers, mowing machines, tractors, dumper
trucks and power presses; hand tools such as screwdrivers, knives,and hand saws; lifting
equipment such as lift trucks, elevating work platforms, vehicle hoists, lifting slings and bath
lifts; other equipment such as ladders.
Measuring Tools and equipment
To produce an article from sheet metal and/or metal plate you need different types of tools and
equipment. Even though for different assembly we use different types of tools and equipment the
following are those used for sheet metal and/or plate metal work

1. Measuring and marking out tool: - these are tools used for measuring and marking.
Steel rule: - the steel rule is frequently used in the work shop and on site for measuring
component of limited accuracy quickly. It is a popular and widely used measuring device.
Steel rules are may be rigid or flexible depending up on their thickness. The can measure
length from 150mm to 1m.

Flexible steel tapes:-they are used for measuring distances greater than 1m in length. It is
available in size ranging from the hand pocket size (3-5mm) up to and above 30m.

FigureStandards of measurement – the rule and steel tape. (a) The steelrule; (b) the steel tape
Scriber:-This is the basic marking out tool. It consists of handle with sharp point. The
pointed end is made from hardened steel so that it will stay sharp in use as shown in figure
Punches:- punches can be center and dot . They are used for making indentation in the
surface of the metal.
FigurePunches: (a) dot; (b) center punch Figure 3.2Scriber
2. Cutting and notching tools:-The following are tools used for cutting and notching
sheet metal/plate metal.
 Hand shear (snips)
 Bench shear
 Guillotine shear
Hand shears (snips). Snips can be straight, universal and pipe snipes. Universal snips have short
thick blade which will with stand the twisting of the snips when being used on the irregular
curved cuts. Straight snips have thin blades which are only strong vertical plane. They are
therefore only suitable for straight cuts and external cut when surplus west has to be removed.
Figure 2.3a shows some typical hand shears and figure 2.3b shows the cutting action of hand
shears.
 INTRODUCTION
A Sheet metal worker has to make various metal products from sheet metal. He uses hand tools
or machines to cut sheet metals, strips, rods, and etc, to make the product. Because of this, he
must know the different types of cutting tools and machines in sheet metal work.
CUTTING WITH SNIPS
Hand snips are used for cutting the layout from the sheet metal, are made in a number of sizes
and styles. Snips is used like a scissors to cut thin, soft metal. It should used only to cut 20 gage
or thinner metal.
Types of snips
a) General purpose snips: - are used for all routine cutting. The snips may be either
combination or straight blade snips. The combination blade is the most commonly used
by sheet metal workers for cutting straight and circular work. General purpose snips are
usually used on 26 gauge or lighter.
 Figure General purpose snip (Combination blade)

b) Bulldog snips: - are obtainable with either the straight or combination blade. These are
heavy-duty snips for cutting thicker metals. They are characterized by long handles with
comparatively short blades for better leverage. Bulldog snips are used for all general
cutting on thicker metals.

Figure. Bulldog snip (Combination blade)

c) Aviation snips: - have wide use for cutting curves, inside corners of 90o, and intricate
designs in sheet metal. They have a compound leverage that enables them to cut designs.
They are usually color coded in keeping with industry standards, green cuts right hand,
red cuts left hand, and yellow cuts straight.
 Figure. Aviation snips

d) Hawk bill snips: - have wide use to cut curves and scrolls. It is also used for cutting
internal openings. Haw, however, we do not often use them since the Aviation snips can
cut as intricate shapes and thicker metals.
e) Circular snips: - have blades that curve sideways. They are designed for cutting inside
circles and also for cutting metal, such as when trimming off a metal duct flush to a wall.
Like the hawk bill snips, the circular snips have largely been replaced by the aviation
snips. Many sheet metal workers, however, still are using the circular snips for trimming
off sheet metal flush with the wall.
General care of snips
 It is important that the blades of any of the snips be at right angles to the metal when
doing any cutting. Allowing the snips to turn to the side will result in a prying (odd)
action on the blades and will cause the snips to be sprung out of alignment.
 Open the snips as far as possible, and cut the metal to within 13mm of the end of the
blade. Open and repeat the cutting. Cutting is usually done on the right edge of the sheet.
 To cut in to corners or to cut notches the point of the blade.
 To cut an irregular shape or a curve, first rough cut within 3 mm of the line. This thin
edge of metal will curl out of the way so that you can get a smooth edge.
 To cut an internal opening, punch or drill a hole in the waste metal. Complete the cut
with hawk bill snips.
 Never cut nails, wires, rivets, and bars tin snips. The clearance on snips blades is only for
sheet metal.
 You must not put more pressure on the snips blades than they are designed for, or you
will spring the blades and make them useless.
 Make sure the blade is sharp and free of cracks or other defects. The hand snips can be
sharpened by taking them apart and filing the blades flat on the inside edge.
  To avoid binding of the sheet metal, when cutting, it is good practice to cut from the side
that will allow the narrowest portion of the metal to rise away from the bench.
 Resting the heel of the snips on the bench provides additional leverage. The trainee can
cut easily by pushing down on the upper handle, rather than having to squeeze both
handles together.
Who is responsible for work equipment?
 Employers and those who have control over work equipment (eg those hiring out work
equipment) have responsibilities for equipment provided for use at work.
What risks are there from using work equipment?
Many things can cause a risk, for example:
 Using the wrong equipment for the job, eg ladders instead of access towers for an extended
job at high level;
 Not fitting adequate guards on machines, leading to accidents caused by shearing, crushing,
trapping or cutting;
 Not fitting adequate controls, or the wrong type of controls, so that equipment cannot be
turned off quickly and safely, or starts accidentally;
 Not properly maintaining guards, safety devices, controls etc so that machines or equipment
become unsafe;
 Not providing the right information, instruction and training for those using the equipment;
 Not fitting roll-over protective structures (ROPS) and using seat belts on mobile work
equipment where there is a risk of roll over.
 Not maintaining work equipment or carrying out regular inspections and thorough
examinations;
 Not providing the personal protective equipment needed to use certain machines safely, eg
chainsaws, angle grinders.
What can I do to reduce the risks?
Use the right equipment for the job
 Many accidents happen because people have not chosen the right equipment for
the work to be done. Controlling the risk often means planning ahead and
ensuring that suitable equipment or machinery is available.
Make sure machinery is safe
 You should check the machinery is suitable for the work – think about how andwhere it will
be used.
 If you think that machinery you have bought is not safe DO NOT USE IT. Contact
the manufacturer or supplier to discuss your concerns
Hiring out work equipment
 If you hire out work equipment you are responsible for ensuring that the
equipment is safe to use at the point of hire. You should also make reasonable
attempts to find out what the equipment will be used for and provide advice on
how it should be used. The safe use of the equipment is the responsibility of the
person who hires it.
Guard dangerous parts of machines
 Controlling the risk often means guarding the parts of machines and equipment
that could cause injury.
Select the right controls
 Some risks can be reduced by careful selection and siting of the controls for
machinery and equipment, for example:
 Position ‘hold-to-run’ and/or two-hand controls at a safe distance from the danger
area;
 Make sure stop and start buttons are readily accessible;
 Ensure control switches are clearly marked to show what they do;
 Make sure operating controls are designed and placed to avoid accidental
operation, eg by shrouding start buttons and pedals;
 Interlocked or trapped key systems for guards may be necessary to prevent
operators and maintenance workers from entering the danger areas before the
machine has stopped;
 Where appropriate, have emergency stop controls within easy reach, particularly
on larger machines so they can be operated quickly in an emergency; ensure
that a machine can only be restarted following a stoppage by use of the start
control. It should not be possible to restart the machine simply by resetting a
device such as an interlock guard or trip bar.
Make sure hand tools are safe
Many risks can be controlled by ensuring hand tools are properly used and maintained,
for example: hammers – avoid split, broken or loose shafts and worn or chipped heads.
Make sure the heads are properly secured to the shafts; files – these should have a
proper handle. Never use them as levers; chisels – the cutting edge should be
sharpened to the correct angle. Do not allow the head of cold chisels to spread to a
mushroom shape – grind off the sides regularly; screwdrivers – never use them as
chisels and never use hammers on them. Split handles are dangerous; spanners –
avoid splayed jaws. Scrap any which show signs of slipping. Have enough spanners of
the right size. Do not improvise by using pipes etc as extension handles.
Carry out maintenance work safely
 Many accidents occur during maintenance work. Controlling the risk means
following safe working practices, for example:
 Where possible, carry out maintenance with the power to the equipment off and
ideally disconnected or with the fuses or keys removed, particularly where
access to dangerous parts will be needed. If possible break all phases and lock
off equipment using lockable isolators and a padlock. If more than one person is
involved use a multi-hasp lock off system. Check the equipment won’t restart
before working on it;
 Maintain parts of equipment which could fall;
 Allow moving equipment to stop;
 Allow components which operate at high temperatures time to cool;
 Switch off the engine of mobile equipment, put the gearbox in neutral, apply the
brake and, where necessary, chock the wheels;
 To prevent fire and explosions, thoroughly clean vessels that have contained
flammable solids, liquids, gases or dusts and check them before hot work is
carried out. Even small amounts of flammable material can give off enough vapor
to create an explosive air mixture which could be ignited by a hand lamp or
cutting/welding torch;
 Where maintenance work has to be carried out at height, ensure that a safe and
secure means of access is provided that is suitable for the nature, duration and
frequency of the task.
 Instruct and train employees
 Make sure employees have the knowledge they need to use and maintain
equipment safely.
 Give them the information they need, eg manufacturer’s instructions, operating
manuals, training courses and check they understand them;
 Instruct them on how to avoid risks, eg check that the drive is not engaged before
starting the engine/machine;
 An inexperienced employee may need some instructions on how to use hand
tools safely;
 As well as instruction, appropriate training will often be necessary, particularly if
control of the risk depends on how an employee uses the work equipment;
 Only competent workers should operate work equipment;
 Never assume an employee can use work equipment safely, especially if they
have just started work, even if they have used similar equipment elsewhere.
 Training may be needed for existing staff as well as inexperienced staff or new
starters (do not forget temporary staff), particularly if they have to use powered
machinery. The greater the danger, the better the training needs to be. For some
high-risk work such as driving fork-lift trucks, using a chainsaw, and operating a
crane, training is usually carried out by specialist instructors.
 Remember, younger people can be quite skilful when moving and handling
powered equipment, but they may lack experience and judgment and require
additional supervision. The level of supervision needed will depend on how
mature they are and whether they can work safely without putting themselves or
others at risk.
Calibration is a
 Establishment the relation of an instrument’s accuracy to the international
standard.
 Comparison between measurements – one of known magnitude or correctness
made or set with one device and another measurement made in as similar a way
as possible with a second device. Proper calibration of an instrument allows
 people to have a safe working environment and produce valid data for future
reference.
Purpose of instrument calibration
Calibration refers to the act of evaluating and adjusting the precision and accuracy
ofmeasurement equipment. Instrument calibration is intended to eliminate or reduce
bias(unfairness) in an instrument's readings over a range for all continuous values.
WHY IS CALIBRATION REQUIRED?
But why can’t we just leave it alone as long as the instrument is operating properly and
continues to provide the indication we expect?
Instrument error can occur due to a variety of factors: drift, environment, electricalsupply,
process changes, etc. Since a calibration is performed by comparing or applyinga known signal
to the instrument under test, errors are detected by performing a calibration. An error is the
algebraic difference between the indication and the actualvalue of the measured variable.
Typical errors that occur include:
 Precision is the degree to which repeated measurements under unchanged
conditions show the same result
 Accuracy is the degree of closeness of measurements of a quantity to its actual
true value.
Accurate measurement means:
 Meeting the specifications of your product or process
 Ensuring traceability for your measurements
 Meeting the requirements of your quality and official recognition procedure
Calibration may be used for:
A new instrument :- We must make sure the instrument is providing accurateindication
After an instrument has been repaired or modified
When a specified time period has elapsed
When a specified usage (operating hours) has elapsed
After an event, for example
 After an instrument has had a shock, vibration, or has been exposed to
anadverse condition which potentially may have put it out of calibration
ordamage it
 Sudden changes in weather

Whenever observations appear questionable or instrument indications do not match the output of
substitute instruments as specified by a requirement, e.g., customer specification, instrument
manufacturer recommendation.
In general use, calibration is often regarded as including the process of adjusting the output or
indication on a measurement instrument to agree with value of the applied standard, within a
specified accuracy. For example, a thermometer could be calibratedso the error of indication or
the correction is determined, and adjusted so that it shows the true temperature in Celsius at
specific points on the scale. This is the perception of the instrument's end-user. However, very
few instruments can be adjusted to exactly match the standards they are compared to. For the
vast majority of calibrations, the calibration process is actually the comparison of an unknown to
a known and recording the results.
Purpose of a calibration
There are three main reasons for having instruments calibrated:
1. To ensure readings from an instrument are consistent (reliable) with othermeasurements.
2. To determine the accuracy of the instrument readings.
3. To establish the reliability of the instrument i.e. that it can be trusted.
A gauge blocks or slip gauges, Gauge blocks were invented in 1896 by Swedish machinist Carl
Edward Johansson. They are used as a reference for the calibration of measuring equipment used
in machine shops, such as micrometers, sine bars, calipers, and dial indicators (when used in an
inspection role). Gauge blocks are the main means of length standardization used by industry.
A gauge block is a block of metal or ceramic with two opposing faces ground precisely flat and
parallel, a precise distance apart. Standard grade blocks are made of a hardened steel alloy, while
calibration grade blocks are often made of tungsten carbide or chromium carbide because it is
harder and wears less.Gauge blocks come in sets of blocks with a range of standard lengths. In
use, the blocks are stacked to make up a desired length.
An important feature of gauge blocks is that they can be joined together with very little
dimensional uncertainty. The blocks are joined by a sliding process called wringing, which
causes their ultra flat surfaces to cling (stick) together. A small number of gauge blocks can be
used to create accurate lengths within a wide range. By using 3 blocks from a set of 30 blocks,
one may create any of the 1000 lengths from 3.000 to 3.999 mm in 0.001 mm steps.
In use, the blocks are removed from the set, cleaned of their protective coating(petroleum jelly or
oil) and wrung together to form a stack of the required dimension, with the minimum number of
blocks. Gauge blocks are calibrated to be accurate at 68 °F (20 °C) and should be kept at this
temperature when taking measurements.
Wringing is the process of sliding two blocks together so that their faces lightly bond.
Because of their ultra flat surfaces, when wrung, gauge blocks adhere to each other tightly.
The process of wringing involves four steps:
1. Wiping a clean gauge block across an oiled pad
2. Wiping any extra oil off the gauge block using a dry pad
 3. The block is then slid perpendicularly across the other block while applyingmoderate
pressure until they form a cruciform.
4. Finally, the block is rotated until it is in line with the other block.
After use the blocks are re-oiled or greased to protect against corrosion. The ability for agiven
gauge block to wring is called wringability; it is officially defined as "the ability of two surfaces
to adhere tightly to each other in the absence of external means."
Instrument calibration has to be repeated at prescribed intervals because the characteristics of
any instrument change over a period of time. Factors deciding :- the
 Usage rate
 Conditions of use
 Skill level of personnel
 Degree of accuracy expected
 Costs of calibration
Commercially availability of gauge block; The two basic futures which are universally used in
designating a set are
a. Indication of unit – whether inch or mm, letter E is used for inch units and letter M isused
for metric units.
b. Number of pieces in a set following the letter E or M
For example E 81 refers to a set whose blocks are in inch unit and are 81 in number.
Similarly M105 refers to a set whose blocks are in mm unit and are 105 in number. Most usually
sets available in inch unit are E81, E49, E41, E35, and E28.
The set of metric units are M112, M105, M87, M50, M33, and M27. A set 87, for example will
contain:
Lo2 Validate/calibrate precision measuring equipment
Calibration is the process of configuring an instrument to provide a result for a sample within an
acceptable range. This is a comparison between a known (standard) measurement and the
measurement given by your instrument. Standard precision should normally be ten times greater
than the precision of the measuring device that is being tested. Nevertheless, a precision rate of
3:1 is acceptable for most standard organizations.
There are two goals when calibrating measuring instruments:
1. Verification of the instrument’s precision;
2. Determination of the measurement’s traceability.

In practice, calibration also includes repairing the device if it is not calibrated.

A report is provided by a calibration specialist showing the error in measurements taken with
the measurement device before and after calibration.
Types of calibration
Instrument calibration can be done for different types of instruments, in every area of the
company. Some of the most frequently performed calibration services are:

 Pressure calibration;
 Temperature calibration;
 Flow calibration;
 Pipette calibration;
 Electrical calibration;
 Mechanical calibration.
The exact process used to calibrate equipment should vary according to the type of instrument,
how critical it is to the operation and the standards followed for calibration purposes.

Calibration devices, equipment

 Micrometer,
 Vernier caliper,
 Voltmeter,
 Oscilloscope,
 All types of comparators,
 Jigs and fixtures,
 Templates and
 Patterns etc.
 Micrometer,
 The micrometer is consists of a frame, a gauge button, a micrometer bolt, a force
measuring device and a locking device, shown in Figures 1, 2, 3, 4, 5, 6 and 7 respectively.
Equipment validation

Equipment validation provides wide-ranging and documented evidence

that the instrument is functioning precisely.
A validation process provides proof that the components critical to the precise functioning of the
equipment consistently meet predefined specifications and operational attributes.

This process involves identifying and quantifying each element related to the result produced
during analytic measurement. Validation is a guarantee that any internal malfunction in the
equipment will not negatively affect the quality of the result.

The validation process is guided by the validation protocol:

The validation protocol is a written plan expressing the validation method. The main
characteristics considered are the testing parameters, the product’s attributes, production
equipment and decisive stages that define the scope of acceptable test results.

Why do I need to validate equipment?

Equipment validation is the trademark of the warranty. It attests to the precise functioning of an
instrument within the range prescribed for the operating conditions and environment, while also
strictly adhering to the correct operating specifications.

For instance, failure to comply with regulatory requirements can make a company’s instruments
ineligible for use in the sector. This can result in significant losses for the company, further
reinforcing the need for validation.

The difference between calibrating and validating equipment

Equipment calibration concerns assessment of the precision of the results provided by a

piece of equipment, measuring variation in relation to the standard defined. Equipment is
adjusted according to the precision of its performance, in line with acceptable standards or
specifications.

Validation of equipment is a documented guarantee that each component of the equipment is

compliant with the manufacturer’s specifications. This is obtained by verifying performance in
relation to traceable standards of control. This provides absolute assurance of analytical
measurements and guarantees that the equipment’s precision, reliability and perfection are not
compromised in any way. Nevertheless, to maintain the precision of an instrument that is being
used, it must be calibrated.
Operations management
The design, execution, and control of operations that convert resources into desired goods and
services, and implement a company's business strategy
On the surface, companies from industry sectors such as mining, construction, manufacturing,
and service would appear to be very different. Certainly, the physical activities involved and the
resulting products are different. At a conceptual level, however, each of these companies can be
viewed as a complex system trying to utilize its resources to maximize its performance.
The ability of managers and workers to control and monitor the operations within such a system
has a great impact on its performance.
This Learning outcome addresses three issues related to controlling and monitoring operations In
such a system: architectures to organize those operations, artificial intelligence techniques for
scheduling those operations, and commercial software to implement monitoring and control.
The principal application focus of this Learning outcome is manufacturing, but the ideas can be
applied to a wide range of complex systems
Failure modes classification
Classification adapted from ISO 15243:2004
https://www.academia.edu/52251277/
Design_and_Fabrication_of_Wheelchair_into_Foldable_Bed