Transcript Inspection and Testing - General Dynamics Electric Boat

Inspection and
Testing
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Introduction
• All materials and services supplied to
Electric Boat must be inspected and tested
in accordance with Purchase Order
invoked specifications, drawings, standard
clauses, etc.
– Determine if supplier or government have
additional or more stringent requirements.
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Introduction (continued)
• Purchase order imposes inspection
systems via EB2678 and Standard
Clauses (60-5, 60-19, 60-58) for MIL-I45208, MIL-Q-9858, or ISO9000 series
– Accordingly, suppliers must establish and
maintain a compliant inspection system
– System must also address subtier suppliers
– Be aware of Supplemental Technical
Requirements (60-58 STRs) for ISO9000
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Introduction (continued)
• Inspection and Testing that result in OQE
must be performed by a supplier’s
organization independent of production,
i.e., the Quality Control Department.
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3 Basic Types of Inspection:
• Receiving Inspection verifies
acceptability of materials, services, and
associated documentation at receipt.
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3 Basic Types of Inspection:
• In-Process Inspection performed at
manufacturing stages deemed necessary
to verify:
– internal compliance with requirements as
production progresses, statistical process
control charting, non-accessible assembly,
etc.
– as required by the purchase order, drawing,
or specifications to be an EB or Government
Hold/Witness Point (SC37-8 series).
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3 Basic Types of Inspection:
• Final Inspection shall verify that the
product is dimensionally acceptable,
properly assembled, and the
documentation is satisfactory in
accordance with the purchase order.
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Requirements
• Inspection and Testing must be accomplished
using clear, complete, and current procedures
and instructions
• Inspection and Testing shall be performed in
appropriate environmental conditions with
respect to temperature, humidity, noise,
vibration, etc.
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Requirements (continued)
• Instruction needs to specify:
– Source of the inspection or test criteria
• drawing, specification, standard clause, etc.
– Gaging or tooling required to ensure proper
accuracy of measurements
– Provision for recording the actual results as
objective quality evidence for reference
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Requirements (continued)
• When required by a standard clause (10,
60, 76 series), drawing, or specification,
procedures shall be approved by Electric
Boat on a Vendor Procedure Approval
Request (VPAR), prior to performance of
the testing.
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Requirements (continued)
• Examples of Testing Procedures requiring
Electric Boat approval:
– NDT Procedures
– Noise Testing Procedures
– Shock Testing Procedures
– Vibration Procedures
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Requirements (continued)
• Examples of Testing Procedures requiring
Electric Boat approval (continued):
– Forging test specimen location drawings
– Production Procedures (when specified by the
Purchase Order or Procurement
Specification)
– Qualification and First Article Procedures
(when specified by the Purchase Order or
Procurement Specification)
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Electrical Testing
Dielectric Voltage Withstand Test
 Dielectric Voltage can be a Destructive test.
 Voltage Level and time should be considered.
• Example: Operating Voltage is 440VAC
• Test at 2 X 440 +1000VAC= 1880VAC
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Electrical Testing
Insulation Resistance
 An Insulation Resistance test is normally done with DC and is
usually performed at a lower voltage level such as five (500VDC)
hundred volts. An IR test measures the quality of the insulation
system and provides a measure in ohms or megohms. It is
sometimes used before a HiPot Test as both a predictor of a failure
condition and to provide a quantitative value of the insulation
system.
 Often performed before, during and after Hydro on Electrical Hull
Penetrators.
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Electrical Testing
Continuity
• Determines if there is an uninterrupted electrical
connection between two points.
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Resistance or DC Resistance
Measured in ohms
The opposition to current flow
Report actual results EX: > 1 Ohm
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Documentation
• Inspection and test results shall be documented,
preferably on a company form with letterhead.
• Inspection and test results must clearly indicate:
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the type and number of inspections or tests performed
the results of the inspection or test
the signature/date of personnel performing the test
additional requirements of the applicable SC76-9 series
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Documentation (continued)
• When required by the Purchase Order,
generally a Standard Clause, the
Inspection and Test Reports shall be
provided to Electric Boat.
• Inspection and Test Reports shall not
contain any qualifying statements, such as
“to the best of our knowledge”, “while in
our possession”, “approximately”, etc.
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Documentation (continued)
• All instruments, gages, and tools used to perform
official inspections and tests must be calibrated in
accordance with a documented calibration
program.
• Actual instruments, gages, and tools used to
perform official inspections and tests should be
identified and listed in the inspection or test report:
– provides additional objective quality evidence
– traceability if gage out of calibration
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Documentation (continued)
• Inspection Records and Test Reports shall
be traceable back to the product being
tested or inspected and the applicable
procedures or instruction being used.
• Corrections of errors on Inspection
Records or Test Reports shall be in
accordance with the requirements of
Electric Boat Specification 2678.
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Suggestion
• Initiate a method and procedure defining
type and accuracy of gages to be used
for dimensional inspection of particular
attribute tolerance ranges
– Gage for +/-.020” tolerance different than
+/-.0005” tolerance as is a 50psig test
different than a 500psig test
– 10% rule
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Suggestion
• To better ensure that the integrity and caliber
of the inspection system and the personnel
are being maintained:
– Implement an overcheck program that periodically
confirms inspector results
– Implement a refresher training and qualification
program for inspectors (similar to NDT, welding,
etc.)
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