Inspection and Testing

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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-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 suppliers 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.
• Resistance or DC Resistance
• Measured in ohms
• The opposition to current flow
• Report actual results EX gt 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
• 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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