AKADEMIA ZARZĄDZANIA TECHNICZNEGO

Edycja XI – STYCZEŃ 2025

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Biologics Manufacturer Completes Instrument Calibration Program Redesign with Key SAP Integration

A major biologics manufacturer sought to eliminate the inefficiencies of its decentralized instrument calibration program. 

Historically, each department used a paper process to schedule and select vendors for calibration activities. As a result, the company had little control over the consistency of the calibration methodology, cost tracking, and overall scheduling. 

Additionally, numerous non-critical assets were calibrated, leading to excessive downtime and unnecessary costs. 


Customer goals

Design and implement a uniform, repeatable, and accurately documented calibration program. The success of the program would support sustainability, accountability, and regulatory compliance by effectively integrating the following elements: 

  • Proper identification of critical manufacturing assets
  • Precise determination of calibration standards
  • Standardizing calibration procedures
  • Thoroughly documenting calibration activities
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Learn how a major food processor improved work order planning, scheduling, MRO parts management, and the use of its CMMS by partnering with SEAM Group for Preventive Maintenance Optimization. 

Read the case study >

Solution

SEAM Group thoroughly analyzed existing processes, assets, and personnel roles. Upon review, the team established:

  • An optimized master instrument list (MIL) which provided a criticality prioritized list of calibrated manufacturing assets
  • Standardized work plan templates for in-house calibration technicians to have uniform instructions for the calibration of MIL assets
  • A planner/scheduler role to centralize the coordination of calibration activities for in-house technicians, as well as external service providers 
 
Winning results

Implementing work plan templates for in-house calibration personnel proved to be particularly pivotal in the success of this partnership. 

The standardization, documentation, and centralization of activities, the addition of the planner/scheduler role, and the use of SAP as the computerized calibration management system (CCMS) yielded measurable results for the customer. 

  • 50% of calibration activities can now be performed uniformly by in-house personnel
  • 30% initial cost savings by standardizing work activities, relying on in-house personnel for calibration activities, and identifying assets
  • Up to 5% year-over-year cost reduction is expected because of the calibration program redesign
  • Increased internal customer satisfaction due to reduced downtime associated with calibration activities

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