In the world of quality control, every measured value is the foundation of a decision. And every decision can impact processes, safety, costs, and overall reliability. That’s why industrial metrology is not a formality — it’s a strategic lever for competitiveness.
In this article, we’ll analyze what went wrong in one of the most well-known space agencies in the world to bring the importance of metrology into everyday industrial reality. Because if a measurement error can cost millions at NASA for its space exploration missions, in any other company it can still compromise product quality, operational safety, and corporate reputation.
In 1998, NASA’s Mars Climate Orbiter was destroyed as it entered the Martian atmosphere. Its mission was to study Mars for one Martian year (687 days) and serve as a communications relay for other spacecraft. Needless to say, this mission was of immense value among NASA’s ongoing space programs.
The cause of the failure? A simple but fatal error: the incorrect conversion of measurement units, which compromised spaceflight navigation.
We had planned to approach the planet at an altitude of about 150 kilometers (93 miles). We thought we were doing that, but upon review of the last six to eight hours of data leading up to arrival, we saw indications that the actual approach altitude had been much lower. It appears that the actual altitude was about 60 kilometers (37 miles).
This happened because one engineering team used the Imperial system (pounds), while the other used the metric SI system (Newtons). The result? $100 million lost, years of work wasted, and a critical lesson in applied metrology.
Want to know more? Watch our breakdown of the NASA error on YouTube
But this case is not just about international space station. It reflects challenges faced in any industrial setting, where traceability and instrument calibration are mission-critical.
“Yes, but that’s an extreme case. That would never happen to us.”,
You may think so — but metrological errors happen more often than you’d expect, and they’re often subtle.
Back when this space mission launched, the International System of Units (SI) and derived quantities (like the Newton) were already widely established. Still, the reference system wasn’t properly applied — even by NASA — leading to serious financial consequences.
If even NASA can fall victim to such a “simple” mistake, it’s because these errors are often hidden in everyday details:
These are all examples of non-compliance with metrological traceability, which is fundamental for valid measurements. Each hardness test is influenced by these parameters, whether we’re talking about Rockwell hardness, one of the most commonly used methods in this field, or Vickers, Brinell, Shore, or IRHD.
Across all industrial sectors, metrology training is essential. It’s not enough to use a measurement tool — technicians must understand the metrological context in which the tool is used.
Key areas to focus on include:
Metrology evolves. New materials, updated standards, and digital measurement tools require continuous education.
From the lab to the production department, everyone should understand the importance of measurement — not just the specialists.
Analyzing actual errors, like NASA’s, helps internalize metrological principles and identify warning signs in your own operations.
ASTM, ISO, JIS, DIN, UNI — choosing the correct metrological standard is essential to ensure consistency across labs, production, and clients.
These standards are not interchangeable. In some cases — such as hardness testing for polymers and elastomers — even the final measurement results differ. For example, Shore AO hardness (ISO standard) and Shore E hardness (ASTM standard)).
This impacts critical factors such as:
Underestimating these aspects may lead to discrepancies between labs, customers, and certifications.
In industries like aerospace, medical, or automotive, error margins are minimal. A faulty measurement can compromise:
System performance
Product safety
Compliance with certifications
Even outside the space industry, rigorous metrology practices are the key to reliable results.
Companies and labs often use a standard out of habit or internal tradition. But choosing the right standard — based on application, regulations, and market requirements — is a strategic tool to prevent data conflicts and quality failures.
Here’s a practical checklist to support your quality assurance processes:
Verify metrological traceability of all instruments and reference standards.
Schedule periodic checks and daily verifications, in addition to annual calibrations.
Choose the right standard for your specific application and standardize its use across departments, suppliers, and customers.
Invest in metrological training: every euro spent on training saves you many more in potential errors.
In an increasingly regulated and precision-driven world, metrology is not a cost, but an investment in reliability, quality, and brand reputation.
On the occasion of World Metrology Day – May 20, take the opportunity to:
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