Time-saving Paperless Calibrations

Wi-Fi or Off-line, Mobile Devices Provide the Complete Program Interface

Why Use ProCal Calibration Management Software over paper-based practices?

Companies who strive for continuous improvements need to implement ever better methods to manage practices. This need is especially relevant for those in the process industry where facilities typically utilize automated control systems, each which contain large numbers of fixed assets. Many of these assets are used to measure physical parameters and control production systems. ISO, FDA and other regulatory certifications require periodic testing of these devices to ensure consistency and accuracy of measurements. The need to document testing results for each and to easily retrieve historical information has led to migration from the use of paper and spreadsheets to calibration management software.

Streamlined Workflows with Automation

ProCal software provides many benefits. One of the most important is the ability to automate and streamline workflows. Features are designed to reduce the administrative and managerial load, improve the technician experience, eliminate human error and reduce operational costs. As a true asset management solution, ProCal can be configured for simple, single site or global, enterprise use.

Managed Work Flows

True paperless functionality requires more than just data collection. Procal software provides closed-loop workflows with advanced features for e-signature approvals, change control management, auto reminders, warnings, quality alerts, etc. Information is captured as actual data, not just “read only” files. Operational supervisors can use this data to make educated decisions to optimize calibration intervals, view departmental and employee productivity metrics, assess systems and device life-cycle reliability and more.

Can paperless calibrations be performed with off-line devices?

ProCal supports the use of off-line tablets and documenting process calibrators. Documenting calibrators are test standards that can source physical test parameters such as temperature or pressure and simultaneously read their correlating electronic signals during a calibration event. The calibrator automatically captures and stores as-found/as-left readings while presenting the technician an immediate pass/fail prompt at each designated test point. Subsequently, completed work can be uploaded into the master program for approvals, to create certificates and to store historical results.

Improved Efficiency

With increased automation comes increased efficiency. Less time will be spent writing things down using pen and paper. Fewer mistakes will be made because the program provides clear instructions for delegated tasks, performs all math functions and automatic data verification. As manual procedures are replaced with automated options, time needed to calibrate is shortened, productivity is improved, mistakes are lessened and operational costs are reduced.

Key Performance Indicators (KPIs) can be Tracked

As previously stated, ProCal calibration management software captures and manages information as data. This enables managers and engineers to track key performance indicators (KPIs). The system includes a variety of standard reports for the most commonly used KPIs. Special reports can be easily developed to client exact specifications. ProCal also enables information to be shared with other applications for even more advanced use of historical data.

Significant Cost Reduction

Calibration practices that utilize pen & paper, calculators and/or filing cabinets at any stage of operations are underperforming. This includes the use of paper-based work instructions, standard operating procedures, training documents, historical records, etc. If this describes your current methods, ProCal calibration management software will provide a significant return on investment.

Asset Optimization

Technicians typically capture as-found readings during a calibration event. They use this to determine in-tolerance status and whether adjustments are needed to pass or fail the device. Sometimes, a failed measurement might even because to initiate a product or quality assessment investigation. In a paper-based system, this is the extent of usefulness for this information. With ProCal data-driven calibration management software, this information can also be used to track asset reliability over time and provide an additional data point when making decisions for future asset selections.

Regulatory Compliance

SDLC (software development life cycle) is an important consideration for FDA and ISO regulated companies. These regulations demand that chosen software providers meet stringent guidelines within their internal development and pre-release testing practices. ProCal is a GAMP 4 rated application that supports a GAMP 5 level risk-based validation approach.

For those performing calibrations, there is no need for calculators anywhere in the calibration process. Workflow can be configured that clearly defines test routines, monitors data entry and provides an immediate visual prompt to indicate in-tolerance/out of tolerance conditions. Secured user sign-on and time/date stamped recording provides historical audit trail tracking of all activities.

Implementation and Support

Choose your calibration management software provider carefully. The credentials that they present are key to obtain optimum benefits for your investment. System features and functionality are important but other things to consider are:

  • Length of time in the business
  • Calibration domain expertise
  • Internal development and pre-release testing practices
  • Size of product user base
  • Scalability to long-term objectives
  • Deployment and system options
  • Vendor reputation
  • References and testimonials
  • On-boarding assistance
  • Post-sale support services
  • System integration expertise

Our company and products meet all of these criteria. For more than three decades, Prime Technologies has been providing quality calibration management solutions and services to regulated industries.

Paperless Case Study

Paperless CalibrationsIf you’re looking to streamline your record-keeping and reporting practices, electronic records management systems can help. A recent calibration management initiative at Schering-Plough underscores the point. Click here to read the study on “Prepare to Go Paperless” as written by the Editor in Chief of Pharmaceutical Online.

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Migration from Honeywell Loveland to ProCalV5

The migration consisted of 32,000 tags, 10,000 instrument loops, 1000 motors, 1000 relief valves, 19 years of calibration history and a customized test equipment data base. We were quite concerned about the 19 years of history and insuring that it remained intact.

We perform calibrations, motor and relief valve pm’s daily, the ProCalV5 engineers provided methodology and tools to make database validation possible, a daunting task with 19 years of history, and helped develop a plan to minimize database down time when switching to the new ProCalV5 database. The ProCal team worked tirelessly to find ways to mimic the functionality that we had built into the customized Loveland database. We were on a strict time table and the ProCal deployment initiative met the milestones which allowed us to stay on schedule. Prime Technologies provided two levels of training, administrator and technician training. The project was a total success. We have had two major outside audits since implementation, the ProCal database and reporting tool greatly contributed to the successful audit. Prime Technologies was extremely supportive before we purchased, during the implementation and now two years after go live. They are very responsive to our requests.

Walter Anderson

Instrument & Electrical Superintendent, PCS Nitrogen

Click here for a quote and web demonstration on ProCal Calibration Software