Business Challenge | As a global business decision, all our client’s sites were migrating to a new Computerized Calibration Management System (CCMS). The NEXA team initially conducted an Exploratory Phase Evaluation (EPE) to identify areas for improvement, and discovered the following:
- Product Critical classifications were higher than industry best practices.
- Calibration intervals were assigned based on classifications, not based on science, data, or historical performance.
- Critical failure rate results were high.
- Quality Manual Compliance check analysis showed multiple variances against global policy requirements.
- The client did not have full ownership of the CCMS, which resulted in additional costs to create reports, conduct audits, and provide support.
It should be noted that the NEXA team was recommended by our client’s animal health facility located in Elkhorn, NE, after successfully executing their CCMS migration in 2022.
Project Challenges | The NEXA team faced several challenges throughout the project, as follows:
- At the start of the project, our schedule was modified as a result of the site's precautions related to the avian flu threat. The NEXA team promptly adjusted to this change and seamlessly initiated the project on a revised timeline, reducing it from 12 months to 9 months for three client sites. As we had a strong bench of available resources, we were able to meet this new challenge, and successfully delivered the project within the requested timeframe.
- Our team introduced a new risk analysis method to the client, collaborating closely with their staff to educate them on effective science-based data analysis techniques. We emphasized the importance of adhering to industry standards and showcased the benefits of working efficiently.
- By utilizing historic data to identify patterns and establishing realistic frequencies, the client's company was able to reduce unnecessary time spent on investigations and avoid over-calibrating instruments. Once the stakeholders fully understood our data analysis approach, they embraced and adopted our methodology.
- In addition, we faced the challenge of assisting the client's technicians in adapting to the transition from a contracted CCMS to owning their own system. To address this, we provided hands-on training to ensure their comfort and confidence in utilizing the new system.
- The NEXA team performed an assessment of the current calibration system, resulting in the identification of a new system by the global team, and developed a 12-month migration plan for three sites. We also placed a NEXA Calibration Engineer onsite for one month at the start of each migration to conduct equipment walk-downs and gather information. To ensure consistency, the walk-down file was reconciled with the client's CMMS system.
- The team then initiated the CRA and CIA process, followed by a reverse traceability analysis for over 5,000 instruments and equipment. Failures and tolerances were verified through calculated risk-based analysis. Correct frequencies, cycles, and tolerances were reported and changes were made based on client consent, resulting in a reduction of criticalities in over 700 calibrated assets.
NEXA offers tailored Enterprise Asset Management solutions delivered through our 6 service tracks. Connect with us to discuss your next project or email us at salesteam@nexaeam.com.
