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Inspection and Testing

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Inspection and Testing 2

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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Inspection and Testing 3

Introduction (continued)

• Purchase order imposes inspection systems via EB2678 and Standard Clauses (60-5, 60-19, 60-58) for MIL-I-45208, 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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Inspection and Testing 6

• 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).

3 Basic Types of Inspection:

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• Final Inspection shall verify that the product is dimensionally acceptable, properly assembled, and the documentation is satisfactory in accordance with the purchase order.

3 Basic Types of Inspection:

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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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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

Electrical Testing

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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.

Electrical Testing

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Continuity

• Determines if there is an uninterrupted electrical connection between two points.

• Resistance or DC Resistance • Measured in ohms• The opposition to current flow• Report actual results EX: > 1 Ohm

Electrical Testing

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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:– 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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