What Do You Do When Expertise Alone Isn’t Enough? Metquay’s Winning Formula for Calibration Management

A Lesson from History

Let’s rewind to October 30, 1935. The Boeing Model 299, a state-of-the-art airplane, was set to redefine military aviation as it roared down the runway at Wright Air Field in Dayton, Ohio. The onlookers were sure they were witnessing the future. But as the aircraft climbed to just 300 feet, it stalled, veered off course, and crashed in a tragic explosion. The culprit? Pilot error. The sheer complexity of the new aircraft overwhelmed the pilot, which caused him to forget a crucial step: releasing a control lock.

Instead of spelling disaster and the end of Boeing itself, this event led to an innovation that would save lives and revolutionize industries far beyond aviation: the checklist. A straightforward list of steps transformed what was once “too much airplane for one man to fly” into a critical asset for the Allied forces during World War II.

This story, detailed in Atul Gawande’s Checklist Manifesto, is a striking example of how simple tools can prevent failures even in the most complex environments. This theme - one of failure prevention - recurs throughout Gawande’s book, and it’s a lesson that resonates strongly with us at Metquay Inc. Our mission is to deliver the highest quality and reliability to the world of calibration management software, so checklists are central to our way of doing business.

Why Expertise Isn’t Always Enough

Even the most experienced professionals can make mistakes, especially when tasks are complex and repetitive. Legendary rock band Van Halen famously included a clause in their contracts requiring all brown M&Ms to be removed from their backstage bowl. While it sounds like nothing more than a quirky demand, it was a canary in the coal mine. Van Halen was a pioneer in the scale of their productions, so their contracts were very complex to make sure all the requirements were met. If every letter of the contract weren’t followed, disastrous, and even life-threatening errors, like stage or floor collapse, could result.

If the brown M&M were still present, this alerted the band to the fact that their contract had not been carefully read and followed and that it could be unsafe to continue with the show.

Creating and Using Checklists in Calibration Labs

Checklists provide a kind of cognitive net. They’re designed to catch flaws in memory and attention. For your checklists to be effective, they should meet certain criteria:

A checklist should:

1. only include minimum necessary steps

2. be explicit

3. offer the possibility of verification

4. instill a discipline of higher performance

   
   

For example, when preparing a batch of instruments for a client, a checklist ensures that every instrument is calibrated to the correct specifications, all data is accurately recorded, and client requirements are met.

Final Review Checklist for Calibration Lab

Instrument Verification:

[ ] All instruments are properly labeled with identification numbers.
[ ] Calibration is completed for all instruments scheduled.
[ ] Instruments are returned to their correct storage locations.

Calibration Data Review:

[ ] All measurement data is accurately recorded.
[ ] Calibration results meet the required tolerances and standards.[ ] Any discrepancies or anomalies noted during the calibration process are reviewed.

Documentation and Reporting:

[ ] All calibration certificates are completed and signed.
[ ] Calibration certificates include necessary details: instrument ID, date, technician name, and measurement uncertainties.
[ ] Calibration data is uploaded to the central database/system.

Environmental Condition Logs:

[ ] Environmental logs (e.g., temperature, humidity) show conditions were within acceptable ranges during calibration.
[ ] Any deviations from standard environmental conditions are documented.

Equipment Check:

[ ] All calibration equipment is cleaned and returned to its proper storage.
[ ] Equipment requiring maintenance or recalibration is identified and scheduled for service.

Client-Specific Requirements:

[ ] Client-specific calibration instructions are followed.
[ ] Client-required documentation and reports are prepared and ready for delivery.

Final Sign-Off:

[ ] Signatures from all responsible technicians and the quality manager are obtained.
[ ] Final review completion is documented in the lab’s record-keeping system.

Customer Communication:

[ ] A summary report for the client is prepared.
[ ] The client has been informed of the completion and any required findings.
[ ] Delivery or pickup of calibrated instruments is scheduled.

How Metquay Implements Checklists

Checklists have been a part of the Metquay company culture since our inception. They have made it possible to defend anyone - even the most experienced among us - against failure. Checklists are a measurable and inexpensive tool that has resulted in a substantial reduction in errors. 

Here’s how we integrate checklists into our software development workflows:

• Code Reviews: Before deployment, every piece of code is checked for security vulnerabilities and adherence to industry standards.

• Testing: Each software module undergoes thorough testing to ensure it works seamlessly with other components.

• Client Communication: We ensure all client requirements are fully understood and implemented.

  
  

This is an example of a checklist that’s similar to what we use:

Software Testing Checklist

Pre-Testing Preparation:

[ ] All test environments are correctly configured.
[ ] All required test data is prepared and available.
[ ] The test plan and test cases are approved by stakeholders.

Unit Testing:

[ ] Individual components or modules are tested for expected behavior.
[ ] Each function returns the correct output for valid inputs.
[ ] Error handling mechanisms are functioning correctly.

Integration Testing:

[ ] All integrated modules communicate and work together correctly.[ ] Data flow between modules and systems is tested.
[ ] Third-party APIs or services are integrated properly.

System Testing:

[ ] End-to-end testing of the entire system ensures all components work together.
[ ] The system meets all specified requirements.
[ ] The system is tested under typical and peak load conditions.

User Interface (UI) Testing:

[ ] The UI is consistent with design specifications.
[ ] All user interactions, including buttons, forms, and navigation, are tested.
[ ] The UI is responsive and functions correctly across different devices and screen sizes.

Performance Testing:

[ ] Load testing assesses the system's behavior under expected user load.
[ ] Stress testing evaluates system performance under extreme conditions.
[ ] Scalability is tested to ensure the system can handle increased load over time.

Security Testing:

[ ] Vulnerabilities in authentication and authorization mechanisms are checked.
[ ] Potential security risks such as SQL injection and cross-site scripting (XSS) are tested.
[ ] Sensitive data is encrypted and protected according to industry standards.

Regression Testing:

[ ] Previous test cases are re-run to ensure that new changes have yet to introduce new bugs.
[ ] All fixed bugs remain resolved.
[ ] Existing functionality is still working as expected after updates.

User Acceptance Testing (UAT):

[ ] End users have tested the system and provided feedback.
[ ] The system meets user requirements and expectations.
[ ] Final approval from stakeholders for deployment is obtained.

Bug Tracking and Reporting:

[ ] All identified bugs and issues are documented in a tracking system.
[ ] Each bug is assigned a severity level and priority.
[ ] The status of bug fixes is tracked, and retests are conducted as necessary.

Post-Testing Review:

[ ] All test results are reviewed, and all critical issues are resolved.
[ ] A summary report of the testing process, including key findings and recommendations, is prepared.
[ ] Sign-off from all relevant parties is obtained before proceeding to deployment.

Deployment Readiness:

[ ] All deployment scripts and configurations have been tested.
[ ] Rollback procedures are in place in case of deployment issues.
[ ] The deployment is scheduled, and all stakeholders are notified of the timeline.

The Cultural Shift

Failure during the test flight of the Boeing Model 299 created a cultural shift at Boeing in the way that they viewed test flying, which shows us that the true power of checklists is in the cultural shift they encourage. At Metquay, we foster a culture where discipline, attention to detail, and continuous improvement are valued. Checklists play a huge role in helping us to meet those cultural ideals, which allows us to deliver better results for our clients.

If you would like to know more about digital transformation possibilities of your calibration business, feel free to ping us at consulting@metquay.com. We are here to help you.