Out-of-Tolerance Condition
An out-of-tolerance condition occurs when a measuring instrument's error or performance exceeds the approved acceptance limit.
What this term means in maintenance
An out-of-tolerance condition occurs when a measuring instrument's error or performance exceeds the approved acceptance limit.
What happens when an instrument is out of tolerance
The organization may need to:
- Identify and remove the instrument from use
- Adjust or repair it
- Recalibrate it
- Assess previous measurements
- Identify affected product or process
- Record the nonconformance
- Define corrective action
Practical example
A pressure gauge is found reading 0.5 bar low outside the approved tolerance. The team reviews inspections and decisions made since the previous accepted calibration.
As-found and as-left results
As-found data shows the instrument condition before adjustment. As-left data shows the condition after correction.
Impact assessment
The review should consider the size and direction of error, measurement use, product limits, time since the previous accepted result, alternative evidence, and risk.
Common mistake
Adjusting the instrument and closing the calibration without reviewing the effect of earlier inaccurate measurements.
Related concepts
Related maintenance terms
Keep exploring connected CMMS, reliability, and maintenance planning terms.
Calibration
Calibration is the documented comparison of a measuring instrument against a known reference to determine its accuracy and confirm whether it remains suitable for use.
Nonconformance
A nonconformance is a failure to meet a specified requirement, procedure, standard, acceptance criterion, or approved maintenance control.
Corrective and Preventive Action
Corrective and Preventive Action, or CAPA, is a controlled process for correcting a problem, removing its causes, and preventing recurrence or similar future problems.
Glossary FAQs
- What does out of tolerance mean?
The instrument error or performance exceeds the approved acceptance limit.
- What should happen after an out-of-tolerance result?
Control the instrument, correct it, and assess the effect on previous measurements and decisions.
- Why are as-found results important?
They show the instrument condition before adjustment and support impact assessment.