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How can you validate liquid penetrant NDT equipment repeatability in Manufacturing Operations?

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Liquid penetrant non-destructive testing (NDT) is a widely used method to inspect surface defects in manufacturing operations. However, to ensure the reliability and accuracy of the results, you need to validate the repeatability of your liquid penetrant NDT equipment. This means verifying that the equipment can produce consistent and reproducible outcomes under the same conditions and parameters. In this article, you will learn how to validate liquid penetrant NDT equipment repeatability in manufacturing operations using a simple and practical approach.

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1 Define the scope

Before you start the validation process, you need to define the scope and objectives of your validation project. This includes identifying the equipment, materials, standards, procedures, and acceptance criteria that you will use for the validation. You also need to determine the number of samples, runs, and operators that you will involve in the validation. Depending on the complexity and criticality of your NDT application, you may need to consult with relevant stakeholders, such as customers, regulators, or industry bodies, to ensure that your validation meets their requirements and expectations.

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Brijendrasinh Vanar

Facilities Engineer at Amneal Pharmaceuticals
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Repeatability Testing: Perform repeatability testing by conducting multiple inspections on the same test specimen or part using the same equipment. This can involve testing the same area multiple times to check for consistent results. Statistical Analysis: Use statistical analysis techniques to analyze the data collected during repeatability testing. Calculate standard deviations and other relevant statistical measures to assess the consistency of the results. Documentation: Maintain thorough documentation of the repeatability testing process, including equipment settings, inspection parameters, and results. This documentation serves as a reference for future validations and audits.

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Albert A.

?Manufacturing Operations Management ??E2E Supply Chain Management ??Procurement Management ??Business Optimization & Strategy ??Manufacturing Capability Development ??Leadership ??ForbesBLK
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Repeatability Testing: Use the same equipment to conduct several inspections on the same test specimen or part in order to do repeatability testing. To ensure consistent findings, testing the same area more than once may be necessary. Examine the information gathered during repeatability testing using statistical analysis methods. To evaluate the consistency of the findings, compute standard deviations and other pertinent statistical measures Keep complete records of all equipment settings, inspection parameters, and outcomes related to the repeatability testing procedure. Future validations and audits can refer to this documentation.

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2 Prepare the samples

The next step is to prepare the samples that you will use for the validation. The samples should be representative of the actual parts or products that you inspect with liquid penetrant NDT. You should select samples that have known defects or flaws that are detectable by liquid penetrant NDT, such as cracks, porosity, or inclusions. You should also label and document the samples with their identification, location, size, and type of defects. You may need to use reference standards or calibration blocks to verify the accuracy and sensitivity of your equipment.

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Joshua Miller

Non-Destructive Testing, RT Level 1, FPI Level 3
(已编辑)
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Repeatability testing. Conducting MSA trials (Manufacturing Systems Analysis) maintaining the consistency in PT between inspectors has been a difficult task. With a kit of 50 hand-picked parts each time the parts were processed and inspected the Probability of Detection dropped. Regardless of cleaning techniques short of etching, defect indications continued to diminish, and residual evidence or contamination of previous evaluations was evident. All of these issues had an effect on our results.

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3 Perform the validation

The third step is to perform the validation using your liquid penetrant NDT equipment. You should follow the standard operating procedure (SOP) that you normally use for your NDT inspection. You should also ensure that you control and record the relevant variables and parameters that may affect the results, such as temperature, humidity, dwell time, pressure, lighting, and cleaning. You should perform multiple runs of the validation using the same or different operators and compare the results for consistency and reproducibility. You should also document and report any deviations or anomalies that may occur during the validation.

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Rajan Khurana

Visionary Manufacturing Executive | Global Operations Strategist | P&L & Operational Excellence Leader Overseeing multi-plant manufacturing units globally | Ensure scalable growth by deploying cutting-edge technologies
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It's crucial to maintain consistency and reliability in penetrant inspection processes for confidence in detecting defects. Magnaflux plays a key role by offering tested chemical consumables, enhancing reliability in fluorescent penetrant inspection (FPI) and dye penetrant testing for NDT professionals, engineers, and technicians.

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Albert A.

?Manufacturing Operations Management ??E2E Supply Chain Management ??Procurement Management ??Business Optimization & Strategy ??Manufacturing Capability Development ??Leadership ??ForbesBLK
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To have faith in the ability to find flaws, penetrant inspection procedures must be reliable and consistent. In order to improve the dependability of fluorescent penetrant inspection (FPI) and dye penetrant testing for NDT specialists, engineers, and technicians, Magnaflux plays a crucial role by providing tested chemical consumables.

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4 Analyze the results

The fourth step is to analyze the results of your validation using appropriate statistical methods and tools. You should calculate and evaluate the measures of repeatability, such as standard deviation, coefficient of variation, or confidence interval, for each sample, run, and operator. You should also compare the results with the acceptance criteria that you defined in the scope. You should identify and explain any sources of variation or error that may affect the repeatability of your equipment. You should also suggest and implement any corrective or preventive actions that may improve the repeatability of your equipment.

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Albert A.

?Manufacturing Operations Management ??E2E Supply Chain Management ??Procurement Management ??Business Optimization & Strategy ??Manufacturing Capability Development ??Leadership ??ForbesBLK
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This is the trickiest phase when there are several variables influencing the result. since each process step influences the one after it. Consequently, growing and the possible failures

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5 Document the validation

The final step is to document the validation process and results in a clear and concise report. The report should include all the information and data that you collected and analyzed during the validation. You should also include any relevant attachments, such as SOPs, standards, certificates, photographs, or charts. The report should summarize the main findings and conclusions of your validation and state whether your equipment met the repeatability criteria or not. You should also provide any recommendations or feedback that may help to optimize or enhance your liquid penetrant NDT equipment and inspection.

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6 Here’s what else to consider

This is a space to share examples, stories, or insights that don’t fit into any of the previous sections. What else would you like to add?

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How can you validate liquid penetrant NDT equipment repeatability in Manufacturing Operations?

1

2

3

4

5

6

1 Define the scope

2 Prepare the samples

3 Perform the validation

4 Analyze the results

5 Document the validation

6 Here’s what else to consider

Manufacturing Operations

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How can you validate liquid penetrant NDT equipment repeatability in Manufacturing Operations?

1

2

3

4

5

6

1 Define the scope

2 Prepare the samples

3 Perform the validation

4 Analyze the results

5 Document the validation

6 Here’s what else to consider

Manufacturing Operations

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